Related Manuals for Johnson PL4
Summary of Contents for Johnson PL4
- Page 1 2005 4 Stroke 40/50 HORSEPOWER WARNING Read this Operator Guide thoroughly. It contains important safety information. When operating your boat, always have this Operator Guide onboard.
- Page 2 An Operator’s Readiness Test has been prepared on the last page of this Guide. Be safe! All passengers should be familiar with the proper operation of your boat and Johnson outboard. Be certain they fully understand and respect the controls and operation. Each operator is responsible for the safety of all passengers and other boaters.
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Page 3: Table Of Contents
SAFETY — THE RIGHT PLACE TO GET STARTED ....................2 PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ..............4 BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ....................5 BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ................... -
Page 4: General Information
1-800-336-BOAT. For equipment. It will acquaint the operator and pas- additional information about boating safety and reg- sengers with the Evinrude/Johnson outboard and ulations call: U.S. Coast Guard Boating Safety Hot- its controls, operation, maintenance and boating line 1-800-368-5647. - Page 5 For more information, see your Evinrude/ and operating conditions, and other boats. Johnson Dealer for a copy of Introduction to Avoid exhaust fumes from your engine or oth- High Performance Boating, P/N 335763. er boats, provide proper ventilation, shut off your engine when not needed, and be aware SAFETY MEASURES —...
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Page 6: Product References, Illustrations And Specifications
Certain features of systems discussed in this Guide from your selling Dealer. For the name and location might not be found on all models in all marketing ar- of the nearest Evinrude/Johnson Dealer in the Unit- eas. ed States and Canada visit www.evinrude.com or www.johnson.com. -
Page 7: Brp Us Inc. Limited Warranty For 2005 Johnson 4-Stroke Outboard Engines Sold In The United States And Canada
This warranty coverage is available only on Johnson 4-stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred ("Dealer"), and then only after the BRP US Inc. specified pre-delivery inspection process has been com- pleted and documented by the purchaser and Dealer. - Page 8 4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect. Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op- portunity to repair the defect.
- Page 9 7. LIMITATIONS OF LIABILITY ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN- TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA- TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY. ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expense for transporting Product to and from Dealer, removal of Product from a boat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering or...
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Page 10: Brp Us Inc. Limited Warranty For 2005 Johnson 4-Stroke Outboard Engines Sold Outside The United States And Canada
For a copy of the Limited Warranty, see your BRP US Inc. distributor/dealer authorized to distribute Johnson 4-Stroke products in the country in which the sale occurs. If further assistance is required, please contact BRP US Inc. Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier Recreational Products Inc. -
Page 11: California Emission Control Warranty Statement
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT Your Johnson 4-stroke outboard has a special environmental label required by the California Air Resourc- es Board. The label has one, two, three, or four stars. A hangtag, provided with your outboard, describes the meaning of the star rating system. - Page 12 Johnson 4-stroke outboards are still applicable to these models with the necessary modifications. Select emission control parts of your Johnson 4-stroke outboard are warranted from the date of purchase by the first retail consumer or the date the product is first put to use, whichever occurs first, for a period of: 4 years, or for 250 hours of use, whichever occurs first.
- Page 13 For any questions regarding your warranty rights and responsibilities or for the name and location of the nearest authorized BRP US Inc. dealer, contact BRP US Inc. Customer Support Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com. General Information -...
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Page 14: Features
FEATURES 000131 Item Description Item Description Fuel Line Filter Battery Cable Emission Test Port Power Trim & Tilt Reservoir Trim Limiter Rod Fuel Connector Anti-ventilation Plate 30 Amp Fuse and Spare Fuses Propeller Starter Motor Pinion Lubricant Drain/Fill Plug Steering Connector Water Intakes Installation Hardware Lubricant Level Plug... - Page 15 000132 Item Description Item Description 15 Amp Fuse and Spare Fuses Water Pump Indicator Electric Fuel Pump Engine Cover Latch Trailering Tilt Switch Dipstick Tilt Support Crankcase Oil Filter Power Trim & Tilt: Manual Release Oil Fill Cap Trim Tab/Anode Lifting Eye ECI Label Remote Control...
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Page 16: Engine Specifications
SAE J1930 Fuel Requirements 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil Crankcase – Oil Evinrude/Johnson Ultra ™ 4-Stroke synthetic blend oil – Refer to Fuel and Oil Capacity 2.3 qts. (2.2 Liters) Filter See your Dealer... -
Page 17: Remote Control
Evinrude/Johnson outboards. Evinrude/ 2. Trim/tilt switch (where equipped) Johnson controls deliver the cable stroke your out- 3. Fast idle button board needs for positive shift and throttle control, and they incorporate such safety and convenience 4. Throttle friction control features as: 5. - Page 18 Emergency Stop/Key Switch WARNING A combination emergency stop switch and key switch is a feature of Evinrude/Johnson prewired remote controls and all Evinrude/Johnson control Avoid knocking or pulling the clip off the wiring kits. Use of the emergency stop feature is stop switch during normal boating.
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Page 19: Engine Monitoring
ENGINE MONITORING IMPORTANT: Your outboard must be equipped with the SystemCheck (or equivalent) engine mon- itor. Operating your outboard without the System- Check (or equivalent) engine monitor will void your warranty for failures related to the functions moni- tored on your engine. When you turn the key switch ON, the System- Check engine monitor horn performs a self-test by sounding a 1/2-second beep. -
Page 20: Fuel And Oil
FUEL AND OIL FUEL Minimum Octane Inside the U.S. 87 (R+M)/2 AKI WARNING Outside the U.S. 90 RON Gasoline is extremely flammable and highly Your outboard has been designed to operate using explosive under certain conditions. Follow the above fuels; however, be aware of the follow- the instructions in this section explicitly. -
Page 21: Oil
It allows for extended oil change intervals and connect fuel hose, disconnect the fuel hose is best for high load applications. Evinrude/Johnson from the motor and from the fuel tank when Ultra 4-Stroke synthetic blend oil delivers ultra vis-... -
Page 22: Break-In (10 Hours)
With easy planing boats, use full throttle to quickly first time. It is recommended you add Evinrude/ accelerate boat onto plane. Immediately reduce Johnson 4-Stroke outboard oil. Refer to Changing throttle to one-half as soon as the boat is on plane. the Oil for acceptable substitute lubricants. -
Page 23: Engine Starting
ENGINE STARTING Connect the fuel hose to the fuel connector. DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death. -
Page 24: Engine Stopping
IMPORTANT: The engine will start and run without After Engine Starts the clip connected to the key switch. However, we DO NOT turn the key switch to START while the en- strongly recommend that the operator use the clip gine is running. Damage to the starter system could and lanyard anytime the engine is running. -
Page 25: Shifting And Speed Control
SHIFTING AND SPEED CONTROL IMPORTANT: When shifting from FORWARD to REVERSE or from REVERSE to FORWARD, pause at NEUTRAL until the engine is at idle speed IMPORTANT: Carefully check the function of all and the boat has slowed. control and engine systems before leaving the dock. -
Page 26: Emergency Starting
EMERGENCY STARTING Move the control handle to NEUTRAL, then remove engine cover. WARNING When using Emergency Starting proce- dures, the start-in-neutral-only feature is inoperative. Make sure shift lever is in NEU- TRAL position to prevent sudden boat movement when engine starts. DO NOT use jumper cables and a booster battery to start engine. -
Page 27: Fuel Economy
Tie knot in each end of the emergency starter cord. FUEL ECONOMY Thread the small bar from the tools kit halfway through one knot so it forms a handle. Hook the oth- The economy throttle range can save fuel, depend- er knot in the notch on the flywheel and wind the ing on boat load and hull design. -
Page 28: Operation
OPERATION While positioned within the tilt range, DO NOT run the engine faster than idle speed. If idling a tilted DANGER engine, keep its water intakes submerged at all times. DO NOT run the engine indoors or without The power tilt is often used to tilt the engine for adequate ventilation or permit exhaust clearance when beaching, mooring, or launching. - Page 29 Manual Release Tilting To operate the power tilt, push and hold the trim/tilt switch in the bow-up or bow-down position. The en- WARNING gine will tilt up or down until the switch is released or the engine reaches the end of its travel. Keep everyone clear of a tilted engine when backing out the manual release screw.
- Page 30 Bow-Up Bow-Down BOW-UP position will give the best fuel economy BOW-DOWN position will give the best accelera- and highest top speed. tion onto plane and the best towing power for skiing. The bow-down position is normally used for accel- erating from a standing start or from idle speed. Operating Conditions: In the bow-up position, your boat may tend to pull to Operating Conditions:...
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Page 31: Propeller Selection
PROPELLER SELECTION See your Dealer for a flushing device designed to fit your engine. Follow manufacturer’s instructions for installing and using it. To select the correct propeller for your boating ap- plication, your boat and motor MUST be water test- IMPORTANT: Before flushing the engine on a ed. -
Page 32: Engine Overheating
Outboard — Running ENGINE OVERHEATING IMPORTANT: Do not run your engine — even for a WARNING brief start-up — without supplying water to it. Refer to Flushing. Prevent injury from contact with rotating While boating, the engine’s water intakes must stay propeller;... - Page 33 IF cleaning the screens and indicator does not re- Low Oil Pressure Warning store the water pump indicator’s steady discharge, Should the oil pressure drop to a dangerously low SHUT OFF the engine and do not attempt to oper- level, the SystemCheck engine monitor will sound ate it.
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Page 34: Trailering
TRAILERING Engage the tilt support lever if you intend to leave the motor tilted for a period of time: • Tilt the motor UP using the trailering tilt switch. • Flip the tilt support lever down. WARNING Keep everyone clear of stern area when raising or lowering the outboard. -
Page 35: Impact Damage
IMPACT DAMAGE If you hit any object, stop immediately and examine the engine for loosening of attaching hardware and clamp screws, if equipped. Inspect for damage to Your engine has a shock absorption system de- swivel and stern brackets, steering components, signed to help withstand damage from impact with and components in the area of impact. -
Page 36: Special Operating Conditions
After operating your outboard, rinse it with fresh wa- NEUTRAL. ter and wipe it dry. Apply Evinrude/Johnson anti- If it is necessary to return to harbor with one engine corrosion spray to any surface subject to corrosion, not running, you should not attempt to operate the but avoid the anticorrosion anode(s). -
Page 37: Maintenance
Maintenance, replacement or repair of the emis- EPA Emission Regulations sion control devices and systems may be per- All new 2002 and more recent Johnson outboards formed by any marine SI (spark ignition) engine manufactured by BRP US Inc. are certified to the repair establishments or individual. -
Page 38: 10-Hour Inspection
Stop the engine and drain the crankcase while the tected. Fuel remaining in your fuel tank and in the engine is warm. Refill it with Evinrude/Johnson Ul- engine will oxidize and weather which can result in tra 4-Stroke synthetic blend oil. Replace the oil fil- loss of octane and can cause gum deposits in the ter. - Page 39 Replace damaged or missing parts with Evinrude/ Johnson Genuine Parts , or equivalent. Battery — Remove it, clean it, check its condition and water level, then charge it. Store it in a place that’s cool and dry, out of direct sunlight.
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Page 40: Pre-Season Service
Examine all loosened or removed hardware and any steering, throttle, and shift systems. Replace damaged or missing parts with Evinrude/Johnson Genuine Parts or equivalent. Refer to Engine Monitoring and review your en- gine’s warning system self-test routine. During your... -
Page 41: Battery
BATTERY Each outboard needs one battery that is: • 12-volt, heavy-duty, designated "marine"; • Vented/refillable or maintenance-free; and • Rated according to the minimum requirements in Engine Specifications. Deep-cycle batteries are suitable IF they meet or exceed the minimum CCA requirements. Ask your Dealer about your outboard’s require- ments before installing longer battery cables, a bat- tery switch or a battery insulator. -
Page 42: Crankcase Oil And Filter
You must add oil to the crankcase before starting the engine for the first time. It is recommended you add Evinrude/ Johnson 4-Stroke outboard oil. Refer to Changing the Oil for acceptable substitute lubricants. BEFORE filling the crankcase for the first time, be sure it is empty by checking the dipstick. - Page 43 After the first 10 hours of operation, replace the 5) Replace the oil fill cap and clean any spilled break-in lubricant with Evinrude/Johnson Ultra 4- oil off the engine and your skin. Stroke synthetic blend oil. Refer to 10-Hour In- 6) Reinstall the upper cover.
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Page 44: Adjustments
ADJUSTMENTS tab). Install plate, P/N 5031618, with screws saved, to prevent overheating and engine damage. Trim Tab WARNING Improper trim tab adjustment can cause dif- ficult steering. The trim tab is also an anti-corrosion anode. Disintegration of the anode can effect boat handling and performance. -
Page 45: Lubrication
5) Securely tighten both plugs. move filler cap and check fluid level. If necessary, add enough Evinrude/Johnson Power Trim/Tilt and Power Steering Fluid to bring the fluid level even with the bottom of the fill cap hole when the unit is at full tilt. -
Page 46: Water Pressure
Refer to Engine Maintenance and Inspection Schedule for in- spection and service frequency. An authorized Evinrude/Johnson Dealer should service the fuel filter. 1. Swivel bracket, tilt support IMPORTANT: A restricted fuel delivery system will not allow the engine fuel pump to deliver sufficient fuel under all conditions. -
Page 47: Fuses
FUSES SPARK PLUGS IMPORTANT: Always carry spare fuses. Use the spare fuse holder to hold an extra fuse. WARNING The fuse is located in the fuse holder. Refer to En- gine Specifications. The ignition system presents a serious shock hazard. The primary circuit operates in excess of 250 volts;... -
Page 48: Propeller
PROPELLER WARNING When servicing the propeller, always shift the outboard to NEUTRAL position, turn the key switch OFF and disconnect battery pos- itive (+) cable so the engine cannot be started accidentally. IMPORTANT: Apply Triple-Guard grease to the en- tire propeller shaft before installing the propeller. At least annually, remove the propeller and check for 1. -
Page 49: Anticorrosion Anodes
ANTICORROSION ANODES Your motor is equipped with one or more anodes that protect it from galvanic corrosion. Refer to Fea- tures for anode location. Disintegration of the an- ode is normal and indicates it is working. Check each anode periodically. Replace anodes smaller than 2/3 their original size. -
Page 50: Trouble Check Chart
TROUBLE CHECK CHART IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer. SYMPTOM POSSIBLE CAUSE Starter motor will not operate • Shift handle not in NEUTRAL. • Battery and electrical connections loose or corroded. • Fuse blown. Refer to Fuses. •... - Page 51 NOTES Maintenance -...
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Page 52: Engine Maintenance And Inspection Schedule
ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following maintenance chart provides guidelines for engine maintenance and in- spection scheduled to be performed by you and/or by an authorized Dealer. The schedule should be ad- justed according to operating conditions and use. - Page 53 Every 1000 hours (1) Also recommended at 10-Hour Inspection (2) Emission-related component (3) Replace every 100 hours or annually if Evinrude/Johnson Ultra 4-Stroke synthetic blend oil is not used (4) Do not use light duty penetrating lubricants Dealer Performed Service Operator Performed Service Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1”...
- Page 54 BRP US Inc. - Maintenance...
- Page 55 CHANGE OF ADDRESS / CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since BRP US Inc.
- Page 56 B R P U S I n c . E v i n r u d e J o h n s o n D e a l e r S u p p o r t S e r v i c e s 2 5 0 S e a h o r s e D r i v e W a u k e g a n , I L 6 0 0 8 5 - Maintenance...
- Page 57 BRP US Inc. Maintenance -...
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Page 58: Confirmation Of Receipt
Operator’s Guide Confirmation of Receipt Your Dealer Name: Address: Upon delivery of your new Evinrude / Johnson Outboard, complete and sign the form hereunder. Your deal- er will take receipt of the form for their records. Receipt Name: Address: Owner of Model No:... - Page 59 Readiness Test and a Final Word to the Owner/Operator The Operator’s Readiness Test..1. Did you read this Guide from front cover to rear cover? 2. Are you ready to take responsibility for the safe operation of your boat and motor? 3.
- Page 60 *5035761*...
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