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Summary of Contents for Johnson R4
- 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 LIMITED WARRANTY FOR 2006 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ....................5 BRP LIMITED WARRANTY FOR 2006 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 selling Dealer. For the name and location of the might not be found on all models in all marketing ar- nearest Evinrude/Johnson Dealer in the United eas. States and Canada log on to www.evinrude.com or www.johnson.com. -
Page 7: Brp Limited Warranty For 2006 Johnson 4-Stroke Outboard Engines Sold In The United States And Canada
Bombardier Recreational Products Inc. ("BRP") warrants its 2006 Johnson ® 4-stroke outboard engines sold by authorized Johnson dealers in the fifty United States and Canada ("Product") from defects in ma- terial or workmanship for the period and under the conditions described below. 2. WARRANTY COVERAGE PERIOD... - 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 Limited Warranty For 2006 Johnson 4-Stroke Outboard Engines Sold Outside The United States And Canada
For a copy of the Limited Warranty, see your Bombardier Recreational Products Inc. (“BRP”) 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 Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BRP where the Product was registered for warranty. -
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 California, that are originally sold in California to a California resident, or subsequently warranty-regis- tered to a California resident. The BRP U.S. and Canada limited warranty conditions for Johnson 4-stroke outboards are still applicable to these models with the necessary modifications.
- Page 13 For any questions regarding your warranty rights and responsibilities or for the name and location of the nearest authorized BRP dealer, contact BRP Customer Support Services, 250 Sea Horse Drive, Waukeg- an, IL 60085, 1-847-689-7090 or visit www.johnson.com. General Information -...
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Page 14: Features
FEATURES Item Description Item Description Motor Cover Clamp Screw Crankcase Oil Drain Screw (Port side) Clamp Bracket Anti-Corrosion Anode Anti-Corrosion Anode Starter Handle Lubricant Level Plug Shift Lever Water Intake Throttle Grip Lubricant Drain/Fill Plug Throttle Tension Screw Water Pump Indicator - General Information... - Page 15 Item Description Item Description Starter Button (Electric Start Models) Fuel Connector Choke Knob (Rope Start Models) Emergency Stop Switch/Stop Button Low Oil Pressure Light Fuel Tank General Information -...
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Page 16: Engine Specifications
EM (Engine Modification) System: per 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 Capacity 67.6 fl. oz. (2 liters) Filter See Your Dealer... -
Page 17: Emergency Stop Switch
EMERGENCY STOP SWITCH WARNING SIGNAL If equipped, the emergency stop switch is on the If, during operation, your engine begins vibrating tiller handle. Use of the emergency stop feature is noticeably and will not exceed 2000 RPM (fast idle), highly recommended on all boats. the low oil pressure warning might have been acti- vated. -
Page 18: 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 19: Oil
It allows for extended oil change intervals and If your motor is equipped with a quick-dis- is best for high load applications. Evinrude/Johnson connect fuel hose, disconnect the fuel hose ultra 4-Stroke synthetic blend oil delivers ultra vis-... -
Page 20: Break-In (10 Hours)
Find and correct the first time. It is recommended you add Evinrude/ cause, or see your Dealer before you continue. Johnson 4-Stroke outboard oil. Refer to Changing • Verify shift function by shifting into gear and ob- the Oil for acceptable substitute lubricants. -
Page 21: 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 22 Move the tilt lock lever to the LOCK position. IMPORTANT: You may need to use the choke when restarting a warm engine. If your engine does not start quickly when warm, follow the procedure for cold starting. BEFORE cranking your engine, connect the battery as instructed in Battery.
- Page 23 Electric Start Models IMPORTANT: If motor is operated without a bat- tery, DO NOT connect any electrical equipment to Start-up motor’s charging system as electrical damage Align the arrow mark on the throttle grip with the could result. START position. While seated, press start button to START motor.
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Page 24: Engine Stopping
SHIFTING AND SPEED CONTROL After Engine Starts - All Models Gradually, push the choke in after the engine is warm. IMPORTANT: Carefully check the function of all control and engine systems before leaving the Check the water pump indicator. A steady stream of dock. -
Page 25: Emergency Starting
EMERGENCY STARTING Remove the cable from the manual starter. 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 injuries from unexpected boat movement when engine starts. The engine cover is a machinery guard. -
Page 26: Operation
OPERATION TILTING AND TILT SUPPORT DANGER IMPORTANT: Use the tilt grip to tilt your motor. Do not use the tiller handle to raise or lower the motor. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. -
Page 27: Shallow-Water Drive
Grasp tilt grip on engine cover and tilt motor to the Grasp tilt grip on engine cover and raise motor full tilt position. slightly. Pull down the tilt lever to engage tilt support. Pull up the tilt lever to disengage tilt support. 1. -
Page 28: Mooring
FLUSHING Engage Move tilt/run lever to the TILT position. 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 29: Low Oil Pressure Warning
4) Place the shift lever in NEUTRAL with the 3) Start the water — keep pressure between 20 propeller removed. to 40 psi (140 to 300 kPa). Flush the engine for five minutes. 5) Start the water — keep pressure between 20 to 40 psi (140 to 300 kPa). -
Page 30: Over-Revolution Limiting System
OVER-REVOLUTION LIMITING SYSTEM If the engine overheats, the S.L.O.W. (Speed Limit- ing Overheat Warning) protection system will im- mediately limit the engine speed to 2000 RPM. If This system is activated when engine speed ex- the engine was running faster than 2000 RPM ceeds maximum recommended speed for more when the S.L.O.W. -
Page 31: Trailering
TRAILERING The engine’s shock absorption system does not work while operating in reverse. If you back into an object, either in the water or while trailering, your Trailer your boat with the motor in a vertical posi- boat and engine can be seriously damaged. tion. -
Page 32: Carrying And Transporting
CARRYING AND TRANSPORTING Drain the crankcase oil from the engine. Refer to Crankcase Oil. After removing the engine from the boat, position it If you will be laying the engine down, minimize the upright until the cooling system stops draining. potential for fuel spillage by letting it run “out of gas”... -
Page 33: Special Operating Conditions
After operating your outboard, rinse it with fresh wa- el, and oiling systems must be inspected for signs ter and wipe it dry. Apply Evinrude/Johnson anti- of water intrusion. Your Dealer should perform this corrosion spray to any surface subject to corrosion, service. -
Page 34: Maintenance
Maintenance, replacement, or repair of the EPA Emission Regulations emission control devices and systems may be All new 2002 and more recent Johnson outboards performed by any marine SI (spark ignition) en- manufactured by BRP are certified to the EPA as gine repair establishments or individual. -
Page 35: 10-Hour Inspection
Stop the engine and drain the crankcase while the motor. Temperature and humidity changes while engine is warm. Refill it with Evinrude/Johnson ultra your outboard motor is not in use can cause corro- 4-Stroke synthetic blend oil. Refer to Crankcase sion of internal engine parts when they are not pro- Oil. -
Page 36: Pre-Season Service
Failure to check for fuel leakage could allow cedures. a leak to go undetected, resulting in fire or Examine all loosened or removed hardware and explosion. any steering, throttle, and shift systems. Replace damaged or missing parts with Evinrude/Johnson Genuine Parts or equivalent. - Maintenance... -
Page 37: Crankcase Oil
It is recommended you add Evinrude/ If Evinrude/Johnson ultra 4-Stroke synthetic blend Johnson 4-Stroke outboard oil. Refer to Changing oil is temporarily unavailable, you may use the Oil for acceptable substitute lubricants. -
Page 38: Adjustments
ADJUSTMENTS 3) Hold a suitable container under the oil drain screw. Remove the screw and drain the re- servior. Before you reinstall the screw, re- Throttle Friction place the gasket with a new one. Reinstall the screw and tighten it securely. Adjust until a slight drag is felt when accelerating or decelerating only. -
Page 39: Lubrication
LUBRICATION 5) Securely tighten both plugs. Gearcase Replace gearcase lubricant after first 10 hours of operation. Check level and condition of lubricant af- ter next 50 hours of operation. Add lubricant if nec- essary. Thereafter, check level and condition of lubricant every 50 hours. -
Page 40: Breather And Fuel Line
BREATHER AND FUEL LINE Lubrication Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom- Inspect the breather and fuel line for leaks, cracks, mended lubricant. swelling, or other damage. If the breather and fuel line are damaged in any way, they must be re- placed. -
Page 41: Spark Plugs
SPARK PLUGS PROPELLER WARNING WARNING The ignition system presents a serious To avoid accidental starting of engine while shock hazard. The primary circuit operates changing propellers, twist and remove all in excess of 250 volts; the secondary circuit spark plug leads. operates in excess of 25,000 volts. -
Page 42: Anticorrosion Anodes
BONDING WIRES Repair If your propeller hits a solid object, the impact is par- Bonding wires are used to electrically connect the tially absorbed by the rubber bushing in the hub to engine components so they exist in a common help prevent damage to the engine. -
Page 43: Battery
BATTERY Each outboard needs one battery that is: 12-volt, heavy-duty, designated "marine" Vented/refillable or maintenance-free 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 44: 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. • Battery Selector Switch OFF. Engine will not start •... - Page 45 NOTES Maintenance -...
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Page 46: 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 47 (1) Also recommended at 10-Hour Inspection (2) Emission-related component (3) Do not use light duty penetrating lubricants (4) Replace every 100 hours or annually if Evinrude/Johnson ultra 4-Stroke synthetic blend oil is not used Dealer Performed Service Operator Performed Service Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1”...
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Page 48: Installation
INSTALLATION Use this procedure to determine whether or not the boat’s transom height is correct for the engine’s WARNING shaft length: Set the motor on the boat’s transom and adjust the Your engine must not exceed the maximum angle so the anti-ventilation plate is parallel with the horsepower indicated on the boat’s capacity boat bottom. -
Page 49: Installing The Engine
DO NOT use tools to tighten clamp screws. Check clamp screws regularly. WARNING When replacing bolts, screws, and other fasteners, use Evinrude/Johnson Genuine Parts or parts of equivalent strength and material. 1. Clamp screws 2. Accessory transom plate Bolt your engine to the boat’s transom using 12 mm... - Page 50 - Installation...
- Page 51 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 will be in a position to contact you if correction to your outboard becomes necessary.
- Page 52 Bombardier Recreational Products - Installation...
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Page 53: Confirmation Of Receipt
The Dealer named on this document has instructed me on the operation, maintenance, safety features and warranty policy, all of which I understand and agree to be bound with. I am also satisfied with the predelivery set-up and inspection of my Evinrude/Johnson Outboard. I have also received a copy of the Operator’s Guide. - Page 54 - Installation...
- Page 55 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.
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