Johnson 2 Stroke 40 HORSEPOWER Operator'S Manual Download Page 10 | Manualshive

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- General Information

BOMBARDIER MOTOR CORPORATION OF AMERICA

LIMITED WARRANTY FOR 2005

JOHNSON

2-STROKE OUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADA

For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distrib-
utor/dealer authorized to distribute

Johnson

2-stroke products in the country in which the sale occurs.

If further assistance is required, please contact Bombardier Motor Corporation of America Customer Sup-
port Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Product
was registered for warranty.

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Summary of Contents for 2 Stroke 40 HORSEPOWER

Page 1: ...R RL 2 Stroke 40 HORSEPOWER WARNING Read this Operator Guide thoroughly It contains important safety information When operating your boat always have this Operator Guide onboard 2005 ...

Page 2: ...son outboard can be significant We strongly believe the rewards for following our recommendations will be worthwhile Remember that YOU are the key to safety Good safety practices not only protect you but also protect the people around you Having fun is what it s all about and with your cooperation the pertinent information in this Guide can en sure a safe and enjoyable experience Enjoy the great o...

Page 3: ...TIONS 12 EMERGENCY STOP SWITCH 13 FUEL AND OIL 14 FUEL 14 OIL 14 ADDITIVES 15 FUEL OIL RATIO 15 MIXING FUEL AND OIL 15 FUEL SYSTEMS 16 BREAK IN 10 HOURS 16 ENGINE STARTING 17 BEFORE START UP 17 ENGINE STOPPING 19 SHIFTING AND SPEED CONTROL 20 EMERGENCY STARTING 20 FUEL ECONOMY 21 OPERATION 22 MANUAL TRIM 22 TRAILERING 24 TILTING 24 TILT SUPPORT 25 MOTOR ANGLE ADJUSTMENT 25 PROPELLER SELECTION 26 M...

Page 4: ...ANGER Indicates an imminently hazardous situa tion which if not avoided WILL result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided CAN result in severe injury or death CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate personal injury or property dam age It also may be used to alert against u...

Page 5: ...s adhere to the fueling procedure contained in this Operator s Guide and those given to you by the fueling station Always verify fuel level before use and during the ride Apply the principle of 1 3 fuel to des tination 1 3 back and 1 3 reserve fuel supply Do not carry spare fuel or flammable liquids in any storage or engine compartments Do not operate your boat if you are under the influence of dr...

Page 6: ...ern bracket or swivel bracket Record your outboard s Model Number ___________________________ Serial Number ___________________________ Purchase Date ___________________________ Ignition Key Number ______________________ Stolen Outboards North America Report your outboard as stolen to Customer and Dealer Support Services 250 Sea Horse Drive Waukegan IL 60085 U S A Give the outboard s model and ser...

Page 7: ... only on Johnson 2 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 BMCA specified pre delivery inspection process has been completed and documented by the purchaser and Dealer Warranty coverage only becomes available upon proper registration of Product by Dealer or o...

Page 8: ...ts and replacement of fuses zinc anodes thermostats timing belts starter motor bushings trim motor brushes filters propellers propel ler bushings and spark plugs Damage caused by improper or lack of installation maintenance winterization and or storage failure to follow the procedures and recommendations in the Operator s Guide Damage resulting from removal of parts improper repairs service mainte...

Page 9: ...PECIFIC RIGHTS AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE No distributor Dealer or any other person is authorized to make any affirmation representation or war ranty regarding Product other than those contained in this limited warranty and if made shall not be en forceable against BMCA BMCA reserves the right to modify this warranty at any t...

Page 10: ...ty see your Bombardier Motor Corporation of America BMCA distrib utor dealer authorized to distribute Johnson 2 stroke products in the country in which the sale occurs If further assistance is required please contact Bombardier Motor Corporation of America Customer Sup port Services 250 Sea Horse Drive Waukegan Illinois 60085 or the affiliate of BMCA where the Product was registered for warranty ...

Page 11: ...General Information 9 NOTES ...

Page 12: ...hrottle 3 Tilt Run Lever 12 Idle Speed Adjustment Knob 4 Angle Adjusting Rod 13 Stop Button Emergency Stop Switch 5 Anticorrosion Anode 14 Primer Knob 6 Lubricant Drain Fill Plug 15 Shift Lever 7 Lubricant Level Plug 16 Starter Handle 8 Stern Brackets 17 Manual Starter Housing 9 Clamp Screws 18 Fuel Tank 2 2 Not supplied in all marketing areas 5 6 7 8 5 9 3 4 2 1 17 16 15 29 14 13 12 11 10 000101 ...

Page 13: ...Emergency Restart Clip Storage 29 Engine Cover Latch 22 Tilt Support Bracket 30 Spark Plugs 23 Steering Friction Adjustment Screw 31 Water Pressure Tap 24 Model and Serial Number Plate 32 Lifting Eye 25 Water Intakes 33 Fuel Pump Filter 26 Propeller 2 34 Emergency Start Cord 26 27 25 24 23 22 21 20 33 32 31 30 29 000102 28 19 34 ...

Page 14: ... to Fuel and Oil Fuel Oil 50 1 Ignition Features S L O W Speed Limiting Overheat Warning Spark Plug 2 Torque Refer to ECI Label 18 to 21 ft lbs 24 to 28 N m AC Lighting 3 3 Available as optional kit 60 watts AC 12 volts Gearcase Lubricant Capacity Evinrude Johnson Ultra HPF gearcase lubricant 16 4 fl oz 485 ml Propeller 4 4 Not supplied in all marketing areas 12 1 4 x 15 in 311 x 381 mm Fuel Tank ...

Page 15: ...oping it DO NOT cut or retie the lanyard 1 Emergency stop switch 2 Clip An extra clip is provided another person can in sert it in the stop switch and start the motor in an emergency 1 Extra clip 1 2 WARNING Avoid knocking or pulling the clip off the stop switch during normal boating The resulting unexpected loss of forward motion can throw occupants forward caus ing injury Your emergency stop swi...

Page 16: ... detergency than minimum TC W3 require ments Evinrude Johnson brand oils are formulated to give best engine performance while controlling piston and combustion chamber deposits providing supe rior lubrication and ensuring maximum spark plug life If Evinrude Johnson XD25 Formula outboard oil is not available you must use an NMMA certified TC W3 oil such as Evinrude Johnson direct injection oil or E...

Page 17: ...tion After break in the engine must be operated at a 50 1 2 oil fuel oil ratio High Performance During high performance operation you must use a 25 1 4 oil fuel oil ratio in your fuel tank MIXING FUEL AND OIL Use the following chart and these guidelines to mix oil with the engine s fuel Portable Tank Above and below 32 F 0 C add one gallon of fu el Pour in required amount of oil Add remaining fu e...

Page 18: ...quipment Launch the boat and start the engine according to the procedures in Engine Starting Verify water pump operation often Look for a steady stream of water from the water pump indi cator If the stream of water stops shut off the en gine to prevent damage Find and correct the cause or see your Dealer before you continue Verify shift function by shifting into gear and ob serving that the boat m...

Page 19: ...e cover is a machinery guard DO NOT operate your outboard with the cover off unless you are performing maintenance and then be careful to keep hands hair and clothing clear of all moving parts Contact with moving parts could cause injury DANGER Contact with a rotating propeller is likely to result in serious injury or death Assure the engine and prop area is clear of people and objects before star...

Page 20: ...Speed Control Twist the throttle grip to START 1 START IMPORTANT Avoid engine damage DO NOT run engine above START in NEUTRAL Start up Cold Engine Pull primer knob through its full stroke twice and re turn to the warm up color line showing position If the motor does not start after a few rope pulls prime again 1 Primer knob 2 1 1 1 WARNING Always shift to NEUTRAL before starting the engine to prev...

Page 21: ...ng If a steady stream of water from the water pump indica tor is not visible stop the engine Refer to Engine Overheating 1 Push primer in to RUN no color line showing when motor is sufficiently warmed up 2 Allow the engine to idle in NEUTRAL for about five minutes to warm up before shifting IMPORTANT To avoid engine damage after start up do not exceed one quarter throttle less than 2000 RPM in NEU...

Page 22: ...Y STARTING If the starter cord breaks or the starter fails your en gine can be started using a piece of the starter cord or a 1 4 in 6 mm cord about 4 ft 1 2 m long WARNING Do not operate motor in REVERSE with the tilt run lever in TILT Motor may tilt out of the water resulting in loss of control 3 2 1 WARNING When using Emergency Starting proce dures the start in neutral only feature is inoperati...

Page 23: ... handle bracket screws Hook the knot of your emergency start cord into the notch on the flywheel Wind the cord clockwise in the flywheel ridge 1 Knot 2 NEUTRAL While seated pull hard on emergency starting cord to start motor After the motor starts run it at less than 2000 RPM in NEUTRAL for two minutes then reduce speed to an idle Do not attempt to replace engine cover while en gine is running If ...

Page 24: ...speed is determined by the oper ator s use of the Touch Trim feature The effect of the maximum bow up and bow down positions will be relatively the same for most appli cations however the bow position that is best for your operating conditions could be at any trim set ting between the maximum bow up and bow down positions The boat will be properly trimmed when the trim an gle is adjusted to provid...

Page 25: ... position 1 Bow down 2 Minimum trim You can now resume operation in a manner suit able for the new trim position Operating Conditions In the bow down position minimum trim the boat may tend to turn to the right If this condition exists it should be compensated for with the operator s steering or the trim tab should be adjusted if this is your most commonly used trim position Refer to Adjustments W...

Page 26: ... and boat s transom TILTING IMPORTANT Use the tilt grip to tilt your motor not the steering handle Move tilt run lever to TILT position 1 TILT position 2 RUN position Grasp tilt grip on engine cover and tilt or lower mo tor to any position desired 1 Tilt grip Move tilt run lever to RUN to lock motor in the se lected position 1 RUN position 2 TILT position Leave the tilt run lever in RUN when launc...

Page 27: ...n Lower motor to normal operating position Move tilt run lever to RUN position MOTOR ANGLE ADJUSTMENT Motor should be perpendicular to the water when the boat is underway at full speed This adjustment can only be determined by water testing the boat Set angle adjustment for your normal load Place motor in full tilt position Refer to Tilt Sup port Remove one of the locknuts from angle adjusting rod...

Page 28: ...ngine in vertical position in a well ventilated area with good drainage 2 Install flushing device and garden hose 3 Place the shift lever in NEUTRAL with the propeller removed 4 Start the water keep pressure between 20 to 40 psi 140 to 300 kPa 1 Flushing device 2 Water pump indicator 5 Start the engine run it at idle only and flush it for at least five minutes Check the water pump indicator A stea...

Page 29: ...e S L O W protection system the en gine must be shut OFF and the cooling temperature restored IF the S L O W protection system activates and the stream from the water pump indicator becomes in termittent or stops reduce speed to idle and Shift to NEUTRAL SHUT OFF the engine Tilt the motor up Clean the intake screens of any blockage Clean the water pump indicator of any blockage Lower the motor and...

Page 30: ...boat and engine can be seriously damaged 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 swivel and stern brackets steering components and components in the area of impact Also exam ine the boat for structural damage Tighten any loosened hardware If the collision occurred in the water proceed slowl...

Page 31: ...e s Periodically wash the entire boat and outboard with soapy water and apply a coat of automotive wax Leave the engine cover in place when washing the outboard High Altitude If you boat at altitudes above 3000 ft 900 m your engine might benefit from a lower pitched propeller different carburetor calibration or both See your Dealer IMPORTANT To avoid permanent powerhead damage be sure that an engi...

Page 32: ...k and in the engine will oxidize and weather which can result in loss of octane and can cause gum deposits in the fuel system Your warranty does not cover engine failure caused by these conditions We strongly rec ommend that you have your Dealer prepare your outboard for the off season To do the off season storage preparations yourself gather the supplies and perform the following steps 2 4 fuel c...

Page 33: ... pro cedures 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 With the propeller removed check the gearcase for leakage If leakage is evident the gearcase seals should be replaced See your Dealer Anticorrosion anodes Check condition Refer to Anticorrosion Anodes Install the propel...

Page 34: ...as set on your new motor be fore it left the factory After the first 10 hours of ser vice check to see that it is still correct A slight drag should be felt when turning the motor If adjustment is necessary turn the adjustment screw Clockwise to increase friction or Counterclockwise to decrease friction 1 Steering friction adjustment screw Trim Tab A propeller will generate steering torque when th...

Page 35: ...ltra HPF gearcase lube If not available Hi Vis or other marine gearcase lube can be used however long term durability may be affected with continued use See your Dealer IMPORTANT The recommended gear lubricants include special additives for marine applications Do not use automotive gear lubricants 2 stroke or 4 stroke engine oil or any other oil or grease for gearcase applications With motor in no...

Page 36: ...uency and recom mended lubricant 1 Swivel bracket and tilt support 1 Tilt tube 2 Steering handle fittings 3 Upper tilt cylinder rod 4 Clamp screws 1 Control shaft bushings control lever bearings carburetor linkage roller cam follower 1 Throttle cable bushings 2 Spark advance linkage 1 1 4 4 3 2 1 1 1 1 1 2 ...

Page 37: ...as follows If portable tank is used disconnect the fuel hose from the motor before servicing the filter Loosen screw and remove the cover Do not lose O rings 1 Cover 2 Filter 3 O rings Wash filter with clean solvent blow dry Reinstall filter keeping lip of filter screen toward fuel pump body Install large O ring in its groove in the cover and the small O ring around center post of pump body Replac...

Page 38: ...e propeller shaft before installing the propeller At least annually remove the propeller and check for debris Clean the shaft and regrease it before rein stalling a propeller Installation Slide thrust washer onto shaft with shoulder facing aft Slide propeller onto shaft engaging the splines and seating it on the thrust washer Slide spacer onto the shaft and engage the propel ler shaft splines Wedg...

Page 39: ...are propeller Keep your propeller in good condition Use a file to smooth slight damage to blade edges See your Dealer for repair of serious damage 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 an...

Page 40: ...Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contaminated with water or dirt Carburetor mixture out of adjustment Fuel oil mixture incorrect Engine loses power Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel filter obstructed Fuel system contaminated with water or dirt Water intakes obstructed and cooling system not operat...

Page 41: ...very 30 in Saltwater Upper tilt cylinder rod lubricate 1 7 Every 60 days Every 30 in Saltwater Steering handle fittings lubricate 1 7 Every 60 days Every 30 in Saltwater Clamp screws lubricate 1 7 Every 60 days Every 30 in Saltwater Swivel bracket tilt support bracket inspect and lubricate 1 7 Every 60 days Every 30 in Saltwater Throttle and shift linkage inspect and lubricate 1 7 Every 60 days Ev...

Page 42: ... of lube 5 D Fuel filter s replace D Propeller shaft splines inspect and lubricate 6 D Spark plugs replace 2 D Decarbonize 8 D Driveshaft splines inspect and lubricate 7 D Water pump inspect and replace D 1 Also recommended at 10 Hour Inspection 2 Emission related component D Dealer Performed Service O Operator Performed Service 4 Evinrude Johnson anti corrosion spray or Evinrude Johnson 6 in 1 mu...

Page 43: ...acity plate Such overpowering can cause loss of control Contact your Dealer or the boat s manufacturer if your boat lacks a capacity plate Boats designed for remote steered engines might be overpowered by a tiller steered engine of the maximum rated horsepower Ask your Dealer or boat manufacturer if you are unsure about your boat s suitability Incorrectly matched boat and engine tran som heights c...

Page 44: ...ler Propeller ventilation slip page often occurs resulting in poor boat perfor mance On a specialty hull non planing hull or on a boat with a curved transom these guidelines might not apply See your Dealer for special installation infor mation Installing the Engine IMPORTANT Follow all directions carefully The engine s warranty will not cover product damage or failure that results from incorrect e...

Page 45: ...nd apply caulk on and around bolts between stern brackets and transom to keep water out of the drilled holes Retighten clamp screws Install the large washers and two of the locknuts on the bottom bolts Install the small washers and the other two locknuts on the top bolts Tighten all nuts securely 1 Clamp screws 2 Small washers 3 Large washers After 30 minutes of operation retighten clamp screws by...

Page 46: ...onal kit IMPORTANT Alternating current is generated and MUST NOT be connected directly to a battery For battery charging install a battery charging kit See your Dealer Various combinations of light bulbs can be used Use 12 volt bulbs of wattage sizes indicated on the diagram Follow the illustration for proper installation of wires Make a 3 8 in 10 mm vertical cut through the cen ter of the AC ligh...

Page 47: ...contact you if correction to your outboard becomes necessary Outside the U S and Canada this card should be sent to the Bombardier Recreational Products division where the outboard was registered Please contact your Dealer or Distributor Change of address Change of ownership Model number Serial Number Old address Previous owner Last name First name M I Address City State Zip code Country Phone num...

Page 48: ...46 Maintenance Bombardier Motor Corporation of America ...

Page 49: ...Maintenance 47 Bombardier Recreational Products ...

Page 50: ...me Address Name Address Owner of Model No Serial No To be completed by customer or selling Dealer 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 Op...

Page 51: ...dations in this Guide and take a boating safety course before you operate your boat and motor 6 Do you know who to ask if you have any questions about your boat and motor 7 Do you know your local marine traffic laws 8 Do you understand that human error can be caused by carelessness fatigue overload preoccupa tion unfamiliarity of operator with the product drugs and alcohol just to name a few WARNI...

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