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38

 - Maintenance

BREATHER AND FUEL LINE

Inspect the breather and fuel line for leaks, cracks,
swelling, or other damage. If the breather and fuel
line are damaged in any way, they must be re-
placed. See your Dealer.

SPARK PLUGS

Inspect spark plugs periodically. Replace if elec-
trodes are badly worn, insulators are cracked, or if
they are badly fouled.
To remove spark plugs, twist and remove all spark
plug leads. Unscrew spark plug from cylinder head. 

To install spark plugs, wipe spark plug seats clean
with a clean rag. Install spark plugs finger tight, then
tighten to specified torque. Refer to 

Engine Speci-

fications

.

IMPORTANT: 

Avoid engine damage by installing

spark plugs into COOL cylinder head and not over-
tightening.
Before installing the spark plug lead, apply a light
coat of 

Triple-Guard

 grease to the ribbed portion of

the spark plug. This will help prevent corrosion be-
tween the spring terminal and the spark plug.

1.

Ribbed portion of the spark plug

WARNING

Leaking fuel is a fire and explosion hazard.
All parts in the fuel system should be
inspected frequently and replaced if signs
of deterioration or leakage are found.
Inspect the fuel system each time you
refuel, each time you remove the engine
cover, and annually.

WARNING

The ignition system presents a serious
shock hazard. The primary circuit operates
in excess of 250 volts; the secondary circuit
operates in excess of 25,000 volts. Use cau-
tion to avoid injury from shock or injury
resulting from your reaction to shock. Do
not handle primary or secondary ignition
components while the engine is cranking or
running.

Summary of Contents for 4 HORSEPOWER

Page 1: ...WARNING Read this Operator Guide thoroughly It contains important safety information When operating your boat always have this Operator Guide onboard R4 RL4 4 Stroke 4 5 6 HORSEPOWER 2005...

Page 2: ...rd 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 p...

Page 3: ...15 FUEL AND OIL 16 FUEL 16 OIL 17 ADDITIVES 17 FUEL SYSTEM 17 BREAK IN 10 HOURS 18 ENGINE STARTING 19 BEFORE START UP 19 ENGINE STOPPING 21 SHIFTING AND SPEED CONTROL 22 EMERGENCY STARTING 22 OPERATIO...

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 se...

Page 5: ...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 b...

Page 6: ...our outboard s Model Number _________________________________ Serial Number __________________________________ Purchase Date _________________________________ Ignition Key Number _____________________...

Page 7: ...y does not extend the life of this limited warranty beyond its original expiration date All Evinrude Johnson Genuine Parts and accessories installed by an authorized dealer at the time of sale includi...

Page 8: ...e Products from time to time without assuming any obligation to modify Products previously manufactured 6 EXCLUSIONS The following are not warranted under any circumstances Replacement of parts due to...

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 repre...

Page 10: ...ty 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 Custome...

Page 11: ...ies engines that meet the Air Resources Board s Personal Watercraft and Out board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standa...

Page 12: ...If any emission related part on your engine is defective under warranty the part will be repaired or replaced by BRP US Inc Parts covered are Component Carbureted SPFI Thermostat X X Electrical System...

Page 13: ...under this limited warranty become the property of BRP US Inc Maintenance receipts and records should be transferred to each subsequent owner of the outboard Owner s Warranty Responsibilities As the o...

Page 14: ...gency Stop Switch STOP Button Lanyard 5 Steering Friction 16 Throttle Friction 6 Tilt Lock Lever 17 Throttle Grip 7 Angle Adjustment Rod 18 Fuel Connector 1 1 5 and 6 HP models only 8 Anti Corrosion A...

Page 15: ...Description 23 Choke Knob 28 Spark Plug 24 Oil Inspection Window 29 Starter Grip 25 Fuel Shut Off Valve 30 Engine Cover Bumpers 26 Fuel Tank 1 1 Not supplied in all marketing areas 31 Emergency Starte...

Page 16: ...Pump Posted AKI 90 RON Refer to Fuel and Oil Crankcase Oil Capacity Filter Evinrude Johnson Ultra 4 Stroke synthetic blend oil Refer to Fuel and Oil 23 7 fl oz 0 7 Liter See your Dealer Starting Rope...

Page 17: ...g it DO NOT cut or retie the lanyard 1 Emergency STOP switch An extra clip is provided on the emergency stop lan yard another person can insert it in the stop switch and start the motor in an emergenc...

Page 18: ...Gasoline will oxidize and weather the result is loss of octane volatile compounds and the production of gum and varnish deposits which can damage the outboard WARNING Gasoline is extremely flammable a...

Page 19: ...ent gum and varnish deposits from form ing in fuel system components and will remove moisture from the fuel system It can be used con tinuously and should be used during any period when your engine is...

Page 20: ...er to Lu brication 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 cato...

Page 21: ...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...

Page 22: ...econds before starting 3 Turn the fuel cock lever aft Fuel will flow to the carburetor from the built in tank All Models If equipped attach the clip and lanyard assembly to the emergency stop switch S...

Page 23: ...UTRAL After Engine Starts Gradually push the choke in after the engine is warm Check the water pump indicator A steady stream of water indicates the water pump is working If a steady stream of water f...

Page 24: ...speed 1 Increase speed 2 Decrease speed 3 Throttle grip EMERGENCY STARTING WARNING Exercise caution and use minimal speed when operating the boat in reverse Be sure the shift lever is in desired posi...

Page 25: ...ip to the emergency stop switch STOP button Place knot of starter cord in notch on flywheel pul ley Wrap cord around pulley clockwise Follow the starting procedure in Engine Starting While seated pull...

Page 26: ...OT 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 damag...

Page 27: ...normal trim angle To lower the outboard back down pull the motor slightly toward you pull up on the tilt lock lever and slowly let the motor down 1 Tilt grip 2 Tilt lock lever 3 NEUTRAL IMPORTANT Che...

Page 28: ...ep pressure between 20 to 40 psi 140 to 300 kPa 1 Flushing device 2 Tape 7 Start the engine run it at idle only and flush it for at least five minutes 8 Shut OFF the engine then turn off the water 9 R...

Page 29: ...r stops reduce speed to idle and Shift to NEUTRAL SHUT OFF the engine Tilt the motor up Clean the intake screen of any blockage Clean the water pump indicator of any blockage Lower the motor and Resta...

Page 30: ...boat as a result of rap id deceleration following impacts When boating in unfamiliar shallow or debris laden waters seek in formation on safe boating areas and navigation hazards from a reliable local...

Page 31: ...tor drain screw After draining retighten the drain screw Stand the motor vertically and drain water from the lower unit Horizontal transport Drain the gasoline from the carburetor Raise the tiller han...

Page 32: ...but avoid the anticorrosion anode 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 Al...

Page 33: ...e engine in any manner that would alter the horsepower or allow emissions lev els to exceed their predetermined factory specifica tions Tampering with the carburetor to change horse power or modify em...

Page 34: ...e engine s fuel supply with 2 4 Fuel Conditioner during the last hours of operation to en sure proper stabilization following instructions on the container for mixture Be sure to run the engine long e...

Page 35: ...with Evinrude Johnson Genuine Parts or equivalent Engine Oil Check the engine oil level Refer to Crankcase Oil With the propeller removed check the gearcase for leakage If leakage is evident the gear...

Page 36: ...ing the engine with too much or too little oil in the crankcase will damage it Changing the Oil Refer to Engine Maintenance and Inspection Schedule for frequency After the first 10 hours of operation...

Page 37: ...and recheck crankcase oil level using the dipstick Add oil as indicated 1 Upper limit 2 Lower limit Dispose of used oil in a reasonable manner follow ing all local regulations ADJUSTMENTS Throttle Fri...

Page 38: ...case applications With motor in normal operating position 1 Remove drain fill plug and lubricant level plug from side of gearcase and completely drain gearcase of old lubricant 2 Examine drained lubri...

Page 39: ...Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom mended lubricant 1 Throttle linkage 1 Shift lever 2 Steering bracket 1 Propeller shaft 1 Clamp screws 1...

Page 40: ...ad and not over tightening Before installing the spark plug lead apply a light coat of Triple Guard grease to the ribbed portion of the spark plug This will help prevent corrosion be tween the spring...

Page 41: ...MPORTANT Avoid or limit operation using a dam aged propeller Carry a spare propeller Keep your propeller in good condition Use a file to smooth slight damage to blade edges See your Dealer for repair...

Page 42: ...apped carboned burned or wet Ignition system component failure Engine will not idle properly Motor angle excessive Spark plugs damaged or incorrect Refer to Engine Specifica tions Fuel system contamin...

Page 43: ...y 60 days Every 30 in Saltwater Clamp screws lubricate 1 7 Every 60 days Every 30 in Saltwater Shift lever lubricate 1 7 Every 60 days Every 30 in Saltwater Steering bracket lubricate 1 7 Every 60 day...

Page 44: ...2 Emission related component D Dealer Performed Service O Operator Performed Service 4 Evinrude Johnson anti corrosion spray or Evinrude Johnson 6 in 1 multi purpose lubricant 5 Ultra HPF gearcase lu...

Page 45: ...h 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 s...

Page 46: ...s transom or mount ing bracket and tighten the clamp screws by hand NOT with tools See your Dealer for an accessory transom plate to protect the boat s transom 1 Clamp screws 2 Accessory transom plate...

Page 47: ...ontact 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 Pleas...

Page 48: ...46 Installation BRP US Inc Evinrude Johnson Dealer Support Services 250 Seahorse Drive Waukegan IL 60085...

Page 49: ...e 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 wa...

Page 50: ...48 Installation BRP US Inc...

Page 51: ...ations 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 marin...

Page 52: ...5035751...

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