2006_30 owners 4 stk

Our First Words to the Owner/OperatorThis Operators Guide is an essential part of your Johnson outboard. It contains pertinent informationwhich, if followed, will provide you with a thorough understanding needed for proper operation, mainte-nance, care and above all safety!The safety section of this Guide comes first because it is our first priority and it should be yours too. It isstrongly recommended that you read this Guide from front cover to rear cover. Following this recommen-dation will assure the completeness of the information that is essential to your safety, the safety of anypassengers and other boaters. An Operators Readiness Test has been prepared on the last page of thisGuide.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 forthe safety of all passengers and other boaters. Please make safety your first priority and complete a boat-ing safety course through your local Coast Guard, Power Squadron, Red Cross or State Boating LawAgency.The pleasures of owning and operating a Johnson outboard can be significant. We strongly believe therewards 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 its all about and, with your cooperation, the pertinent information in this Guide can en-sure a safe and enjoyable experience.Enjoy the great outdoors on the water...

The following trademarks are the property of Bombardier Recreational Products or its affiliates:

WARNINGBe careful! Human error is caused by many factors: carelessness, fatigue, overload, preoccu-pation, unfamiliarity of operator with the product, drugs and alcohol to name a few. Damage toyour boat and outboard can be fixed in a short period of time, but injury or death has a lastingeffect.For your safety and the safety of others, read this Guide from cover to cover and follow allsafety warnings and recommendations. Do not disregard any of the safety precautions andinstructions. Anyone operating your boat should first read and understand this Guide before they operateyour boat and motor.

Evinrude JohnsonEvinrude/Johnson Genuine Parts 2+4 fuel conditionerEvinrude/Johnson 4-Stroke outboard oil Hi-Vis gearcase lubricantEvinrude/Johnson Ultra 4-Stroke synthetic blend oil Triple-Guard greaseEvinrude/Johnson anti-corrosion spray Ultra-HPF gearcase lubricant

99011-89J06-BBD

2005 BRP US Inc. All rights reserved.TM, Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

1

Contents

GENERAL INFORMATION ................................................................................................... 2SAFETY THE RIGHT PLACE TO GET STARTED ................................................................................................ 2PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4BRP LIMITED WARRANTY FOR 2006 JOHNSON 4-STROKE OUTBOARD ENGINES

SOLD IN THE UNITED STATES AND CANADA ................................................................................................ 5BRP LIMITED WARRANTY FOR 2006 JOHNSON 4-STROKE OUTBOARD ENGINES

SOLD OUTSIDE THE UNITED STATES AND CANADA ................................................................................... 8CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9FEATURES ............................................................................................................................................................... 12ENGINE SPECIFICATIONS ...................................................................................................................................... 14REMOTE CONTROL ................................................................................................................................................. 15

ENGINE MONITORING ...................................................................................................... 17FUEL AND OIL ................................................................................................................... 18

FUEL ......................................................................................................................................................................... 18OIL ............................................................................................................................................................................. 19ADDITIVES ................................................................................................................................................................ 19FUEL SYSTEM .......................................................................................................................................................... 19BREAK-IN (10 HOURS) ............................................................................................................................................ 20

ENGINE STARTING ........................................................................................................... 21BEFORE START-UP ................................................................................................................................................. 21ENGINE STOPPING ................................................................................................................................................. 22SHIFTING AND SPEED CONTROL ......................................................................................................................... 23EMERGENCY STARTING ........................................................................................................................................ 23FUEL ECONOMY ...................................................................................................................................................... 24

OPERATION ....................................................................................................................... 25POWER TRIM AND TILT .......................................................................................................................................... 25MOORING ................................................................................................................................................................. 27PROPELLER SELECTION ....................................................................................................................................... 28FLUSHING ................................................................................................................................................................ 28LOW OIL PRESSURE WARNING ............................................................................................................................ 29OVER-REVOLUTION LIMITING SYSTEM ............................................................................................................... 29ENGINE OVERHEATING .......................................................................................................................................... 29TRAILERING ............................................................................................................................................................. 30TILT SUPPORT ......................................................................................................................................................... 30IMPACT DAMAGE .................................................................................................................................................... 31STORING .................................................................................................................................................................. 31CARRYING AND TRANSPORTING ......................................................................................................................... 32SPECIAL OPERATING CONDITIONS ..................................................................................................................... 33

MAINTENANCE .................................................................................................................. 34ENGINE EMISSIONS INFORMATION ...................................................................................................................... 3410-HOUR INSPECTION ............................................................................................................................................ 35OFF-SEASON STORAGE ........................................................................................................................................ 35PRE-SEASON SERVICE .......................................................................................................................................... 36CRANKCASE OIL ..................................................................................................................................................... 37ADJUSTMENTS ........................................................................................................................................................ 38LUBRICATION .......................................................................................................................................................... 39BREATHER AND FUEL LINE .................................................................................................................................. 40SPARK PLUGS ......................................................................................................................................................... 41PROPELLER ............................................................................................................................................................. 41ANTICORROSION ANODES .................................................................................................................................... 42BONDING WIRES ..................................................................................................................................................... 42BATTERY .................................................................................................................................................................. 43TROUBLE CHECK CHART ...................................................................................................................................... 44ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 45

INSTALLATION .................................................................................................................. 47TRANSOM HEIGHT AND SHAFT LENGTH ............................................................................................................ 47INSTALLING THE ENGINE ...................................................................................................................................... 48

2 - General Information

GENERAL INFORMATION

SAFETY THE RIGHT PLACE TO GET STARTED

This Operators Guide contains essential informa-tion to help prevent personal injury and damage toequipment. It will acquaint the operator and pas-sengers with the Evinrude/Johnson outboard andits controls, operation, maintenance and boatingsafety measures. Make sure all operators read, un-derstand and follow the contents. This Guideshould be kept in a waterproof bag with the productat all times during operation. If the product owner-ship is transferred, this Guide should be forwardedto the subsequent owners.This Operators Guide uses the following signalwords identifying important safety messages.These safety alert signal words mean:ATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!

IMPORTANT: Identifies information that will helpprevent damage to machinery and appears next toinformation that controls correct assembly and op-eration of the product.Although the mere reading of such informationdoes not eliminate the hazard, the understandingand application of the information will promote thecorrect use of your outboard engine.

A responsible, educated boater will fully appreciatethe pleasures of boating and will be a safe boater.Boating Safety Classes are conducted by the U.S.Coast Guard Auxiliary, the U.S. Power Squadronand some Red Cross Chapters. For informationabout classes, call toll free 1-800-336-BOAT. Foradditional information about boating safety and reg-ulations call: U.S. Coast Guard Boating Safety Hot-line 1-800-368-5647. Outside North Americaplease contact your Dealer or distributor for detailsabout boating safety.

SAFETY MEASURES General

SAFETY MEASURES Operation

DANGERIndicates an imminently hazardous situa-tion which, if not avoided, WILL result indeath or serious injury.

WARNINGIndicates a potentially hazardous situationwhich, if not avoided, CAN result in severeinjury or death.

CAUTIONIndicates a potentially hazardous situationwhich, if not avoided, MAY result in minor ormoderate personal injury or property dam-age. It also may be used to alert againstunsafe practices.

To fully appreciate the pleasures, enjoymentand excitement of boating there are some ba-sic rules that should be observed and fol-lowed by any boater. Some rules may be newto you and others may be common sense orobvious... irrespective, take them seriously!Failure to follow this safety information andsafe boating rules could result in injury to you,your passengers or other water users.

Become completely familiar with the controland operation of your boat and motor beforeembarking on your first trip or taking on a pas-senger(s). If you have not had the opportunityto do so with your Dealer, practice driving ina suitable area and feel the response of eachcontrol. Be familiar with all controls before ap-plying the throttle above idle speed. As theoperator, you are in control and responsiblefor safe operation.

Be sure at least one of your passengersknows how to handle your boat in case of anemergency.

All passengers should know the location ofemergency equipment and how to use it.

All safety equipment and personal flotationdevices must be in good condition and suit-able for your type of boat. Always comply withthe regulations that apply to your boat.

Contact with rotating propeller is likely to re-sult in serious injury or death. Do not allowanyone near a propeller, even when the en-gine is off. Propeller blades can be sharp andcan continue to turn even after the engine isshut off. Always shut off the engine whenboat is near people in the water.

General Information - 3

SAFETY MEASURES Installation and Maintenance

Outboard Installation

Maintenance

Whenever running the engine, assure thereis proper ventilation to avoid carbon monox-ide (CO), which is odorless, colorless, andtasteless, and can lead to unconsciousness,brain damage, or death if inhaled in sufficientconcentrations. CO accumulation can occurwhile docked, anchored, or underway, and inmany confined areas such as the boat cabin,cockpit, swim platform, and heads. It can beworsened or caused by weather, mooringand operating conditions, and other boats.Avoid exhaust fumes from your engine or oth-er boats, provide proper ventilation, shut offyour engine when not needed, and be awareof the risk of backdrafting and conditions thatcreate CO accumulation. In high concentra-tions, CO can be fatal within minutes. Lowerconcentrations are just as lethal over long pe-riods of time.

Proceed with caution and at very low speedin shallow water. Grounding or abrupt stopsmay result in injury. Also be alert for debrisand objects in the water.Be familiar with the waters you are operatingin. The gearcase of this outboard extends be-low the water surface and could potentiallycome in contact with underwater obstruc-tions. Contact with underwater obstructionsmay result in loss of control and personal in-jury.Avoid standing up or shifting weight suddenlyin light weight boats.

Keep your passengers seated in seats. Theboats bow, gunwale, transom and seatbacks are not intended for use as seats.

Insist on the use of personal flotation devices,approved by the U.S. Coast Guard, by allpassengers when boating conditions arehazardous, and by children and nonswim-mers at all times.

Respect no wake zones, rights of other waterusers and the environment. As the "skipper"and owner of a boat you are responsible fordamage to other boats caused by the wake ofyour boat. Allow no one to throw refuse over-board.

Know the marine traffic laws and obey them.

Remember, gasoline fumes are flammableand explosive. Always adhere to the fuelingprocedure contained in this Operators Guideand those given to you by the fueling station.Always verify fuel level before use and duringthe 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 liquidsin any storage or engine compartments.

Do not operate your boat if you are under theinfluence of drugs or alcohol.

High performance boats have a high power-to-weight ratio. If you are not experienced inthe operation of a high performance boat, donot attempt to operate one at, or near, its topspeed until you have gained that experience.

For more information, see your Evinrude/Johnson Dealer for a copy of Introduction toHigh Performance Boating, P/N 335763.

The outboard must be correctly installed.Failure to correctly install the outboard couldresult in serious injury, death or propertydamage. We strongly recommend that yourDealer install your outboard to ensure properinstallation.

Do not overpower your boat by using an en-gine that exceeds the horsepower indicatedon the boats capacity plate. Overpoweringcould result in loss of control. If your boat hasno capacity plate, contact your Dealer or theboats manufacturer.

When replacement parts are required, useEvinrude/Johnson Genuine Parts or partswith equivalent characteristics, includingtype, strength and material. Using substan-dard parts could result in injury or productmalfunction.

Only perform service procedures which aredetailed in this Operators Guide. Attemptingto perform maintenance or repair on your out-board if you are not familiar with the correctservice and safety procedure could causepersonal injury or death. Further informationcan be obtained from your authorizedEvinrude/Johnson Dealer. In many instancesproper tools and training are required for cer-tain service or repair procedures.

Maintain your boat and engine in top condi-tion at all times. Adhere to the Engine Main-tenance and Inspection Schedule.

Operate your boat and outboard prudentlyand have fun. Do not forget that all personsmust assist other boaters in case of emer-gency.

Prevent injury from contact with rotating pro-peller; remove propeller before flushing orbefore performing any maintenance.


PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS

Bombardier Recreational Products (BRP) reservesthe right to make changes at any time, without no-tice, to features, specifications and model availabil-ity. The right is also reserved to change anyspecification or part at any time without incurringany obligation to update older models. The informa-tion in the Guide is based on the latest specifica-tions available at the time of publication.Photographs and illustrations used in this Guidemight not depict actual models or equipment butare intended as representative views for referenceonly. The continuing accuracy of this Guide cannotbe guaranteed.Certain features of systems discussed in this Guidemight not be found on all models in all marketing ar-eas.

Owners Identification

North America At the time of purchase, yourDealer will complete your outboard registrationforms. Your portion provides proof of ownershipand date of purchase.Outside North America See your Dealer ordistributor for details.

Model and Serial NumbersThe model and serial numbers appear on a plate at-tached to the stern bracket or swivel bracket.Record your outboards:

Model Number _________________________________

Serial Number __________________________________

Purchase Date _________________________________

Ignition Key Number _____________________________

Stolen Outboards

North America Report your outboard as stolento Customer and Dealer Support Services, 250 SeaHorse Drive, Waukegan, IL 60085, U.S.A. Give theoutboards model and serial numbers and enclosea copy of the police report.Outside North America Report the theft to theBombardier Recreational Products distributorwhere the outboard was registered.

Technical Literature

BRP offers technical literature specifically for youroutboard. A service manual, a parts catalog, or anextra Operators Guide can be purchased from yourselling Dealer. For the name and location of thenearest Evinrude/Johnson Dealer in the UnitedStates and Canada log on to www.evinrude.comor www.johnson.com.

Declaration of Conformity

BRP declares that the outboard to which this Oper-ators Manual applies conforms to the essential re-quirements outlined in CE Machinery Directive98-37-EC, as amended.

WARNINGWhen replacement parts are required, useEvinrude/Johnson Genuine Parts or partswith equivalent characteristics, includingtype, strength and material. Using substan-dard parts could result in injury or productmalfunction.


BRP LIMITED WARRANTY FOR 2006 JOHNSON 4-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA

1. SCOPE OF THE LIMITED WARRANTYBombardier Recreational Products Inc. ("BRP") warrants its 2006 Johnson 4-stroke outboard enginessold 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 PERIODThis limited warranty will be in effect from the date of purchase by the first retail consumer or the date theProduct is first put to use, whichever occurs first, for a period of:

THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related componentsproviding input to emission controls (e.g. sensors) are warranted for twenty-four (24) months or two hun-dred (200) hours of engine use, whichever occurs first. The Product is used commercially when it is usedin connection with any work or employment that generates income, during any part of the warranty period.The Product is also used commercially when, at any point during the warranty period, it is installed on aboat that has commercial tags or is licensed for commercial use.

The repair or replacement of parts or the performance of service to Product under this warranty does notextend the life of this limited warranty beyond its original expiration date. All Evinrude /Johnson GenuineParts and accessories installed by an authorized dealer at the time of sale, including but not limited to pro-pellers, bear the standard BRP parts and accessories one-year limited warranty.

California residents who purchased or warranty-registered a Product in California should refer to BRP'sCalifornia Emissions Control Warranty Statement.

3. CONDITIONS TO HAVE WARRANTY COVERAGEThis warranty coverage is available only on Johnson 4-stroke outboard engines purchased as new andunused from a dealer authorized to distribute Johnson products in the country in which the sale occurred("Dealer"), and then only after the BRP specified pre-delivery inspection process has been completed anddocumented by the purchaser and Dealer. Warranty coverage only becomes available upon proper reg-istration of Product by Dealer or owner.

Only the original purchaser and any subsequent owners who reside in the United States and Canada andhave purchased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warran-ty coverage hereunder. Such limitations are necessary in order to allow BRP to protect the safety of itsproducts, its consumers, and the general public.

As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintainwarranty coverage. BRP may require proof of proper maintenance prior to authorizing warranty coverage.


4. WHAT TO DO TO OBTAIN WARRANTY COVERAGEThe 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 appearanceof the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op-portunity to repair the defect. The expenses of transporting Product to and from Dealer for warranty ser-vice are to be borne by the owner.

If the Product has not previously been registered, the owner may also be required to present proof of pur-chase to Dealer for warranty repairs. Owner is required to sign the repair/work order prior to the start ofthe repair in order to validate the warranty repair.

All parts replaced under this warranty become the property of BRP.

5. WHAT BRP WILL DOBRP's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts ofProduct found to be defective in material or workmanship, in the reasonable judgment of BRP. Such repairor replacement of parts will be done without charge for parts and labor, at any authorized Dealer. BRP'sresponsibility is limited to making the required repairs or replacements of parts with new or BRP-certifiedre-manufactured parts. No claim of breach of warranty shall be cause for cancellation or rescission of thesale of Product to owner.

In the event that warranty service is required outside of the fifty United States or Canada, owner will bearresponsibility for any additional charges due to local practices and conditions, such as, but not limited to,freight, insurance, taxes, license fees, import duties, and any and all other financial charges, includingthose levied by governments, states, territories and their respective agencies.

BRP reserves the right to improve, modify or change Products from time to time without assuming anyobligation to modify Products previously manufactured.

6. EXCLUSIONS - The following are not warranted under any circumstances: Replacement of parts due to normal wear and tear; Routine maintenance parts and services including but not limited to: maintenance requirements, engine

and lower unit oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zincanodes, 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, failureto follow the procedures and recommendations in the Operator's Guide;

Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or useof parts or accessories not manufactured or approved by BRP, which in its reasonable judgment, areeither incompatible with Product or adversely affect its operation, performance, or durability, or resultingfrom repairs done by a person that is not an authorized Dealer;

Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation ofthe Product in a manner inconsistent with the recommended operation described in the Operator'sGuide;

Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalismor any act of God;

Operation without proper fuel, oil or lubrication or with fuels, oils or lubricants which are not suitable foruse with the Product (see the Operator's Guide);

Damage resulting from rust or corrosion; Damage caused from cooling system blockage by foreign material; Damage resulting from sand or debris in the water pump; Cosmetic or paint changes due to exposure to the elements.

This warranty will be voided in its entirety and rendered null and void where: Product has been altered or modified in such a way so as to adversely affect its operation, performance

or durability, or change its intended use, horsepower or emission levels; or Product is or has been used for racing at any point, even by a prior owner.


7. LIMITATIONS OF LIABILITYALL 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 KINDARE 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 aboat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering ortowing, storage, telephone, cell phone, fax or telegram charges, rental of a like or replacement Product orboat during warranty services or down time, taxi, travel, lodging, loss of or damage to personal property,inconvenience, cost of insurance coverage, loan payments, loss of time, loss of income, revenue or prof-its, or loss of enjoyment or use of Product.SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIM-ITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTI-FIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOUSPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROMSTATE 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 BRP. BRP reserves the right to modify this warranty at any time, being understood thatsuch modification will not alter the warranty conditions applicable to the Products sold while this warrantyis in effect.

8. TRANSFERIf the ownership of Product is transferred during the warranty coverage period, this warranty shall also betransferred and be valid for the remaining coverage period provided that the former or new owner promptlycontacts BRP or Dealer and gives the name and address of the new owner.

9. CONSUMER ASSISTANCE In the event of a controversy or dispute in connection with this BRP limited warranty, BRP recommends

that you first try to resolve the issue at the dealership level by discussing the issue with Dealer's servicemanager or owner;

If further assistance is required, please contact the BRP Customer Support Services, 250 Sea HorseDrive, Waukegan, IL, 60085, 1-847-689-7090.

Revision February 2005


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.


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, describesthe meaning of the star rating system.

The Star Label means Cleaner Marine Engines

The Symbol for Cleaner Marine Engines:Cleaner Air and Water

For a healthier lifestyle and environment. Better Fuel Economy

Burns up to 30 to 40 percent less gas and oil than conventionalcarbureted two-stroke engines, saving money and resources.

Longer Emission WarrantyProtects consumer for worry free operation.

One Star Low EmissionThe one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir Resource Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission stan-dards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.Two Stars Very Low EmissionThe two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet theAir Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission stan-dards. Engines meeting these standards have 20% lower emissions than One Star Low Emission en-gines.Three Stars Ultra Low EmissionThe three-star label identifies engines that meet the Air Resources Boards Personal Watercraft and Out-board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star Low Emission engines.Four Stars Super Ultra Low EmissionThe four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marineengine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may alsocomply with these standards. Engines meeting these standards have 90% lower emission than One Star Low Emission engines.For more information: Cleaner Watercraft Get the Facts

1-800-END-SMOGwww.arb.ca.gov

YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATIONThe California Air Resources Board and BRP are pleased to explain the emission control system warrantyon your Johnson 4-stroke outboard. In California, new outboard engines must be designed, built, andequipped to meet the State's stringent anti-smog standards. BRP must warrant the emission control sys-tem on your outboard for the periods of time listed below provided there has been no abuse, neglect, orimproper maintenance of your outboard.Your emission control system may include parts such as the carburetor or fuel injection system, the igni-tion system, and catalytic converter. Also included may be hoses, belts, connectors, and other emission-related assemblies.Where a warrantable condition exists, BRP will repair your outboard at no cost to you including diagnosis,parts, and labor provided that such work is performed by an authorized BRP dealer.


Manufacturer's Limited Warranty CoverageThis emission limited warranty covers Johnson 4-stroke outboards certified and produced by BRP for salein 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-strokeoutboards 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 purchaseby the first retail consumer or the date the product is first put to use, whichever occurs first, for a periodof: 4 years, or for 250 hours of use, whichever occurs first.However, warranty coverage based on the hourly period is only permitted for outboards equipped with theappropriate hour meters or their equivalent. If any emission-related part on your engine is defective underwarranty, the part will be repaired or replaced by BRP.Parts covered are:

Component Carbureted SPFI Thermostat X XElectrical System Engine/Ignition Control Module X X Spark Plugs, Boots, and/or Wires X X Ignition Coils X X Wiring Harness X XExhaust System Engine Holder X X Oil Pan X X Exhaust Housing X X Exhaust Valves X XFuel System Fuel Pump(s) X X Fuel Injectors X Vapor Separator X Carburetor and Internal Parts X Accelerator Pump X Choke System X Crankcase Ventilation System Components X X Fuel Lines, Fittings, Clamps X XAir Induction System Timing Chain/Belt and Tensioner X X Camshaft and Followers X X Intake Valves X X Electronic Dash Pot System X Throttle Body Assembly X Idle Air Control X Closed Throttle Position Switch X Throttle Linkage X X Intake Manifold X XSensors Air Temperature Sensor X Cam Position Sensor X Crankshaft Position Sensor X X Throttle Position Sensor X Exhaust Temp Sensor X Intake Manifold Pressure Sensor X Cylinder Temperature Sensor X XGaskets All Emission Component Gaskets X X


The emission warranty covers damage to other engine components that is caused by the failure of a war-ranted part.The BRP Operator's Guide provided contains written instructions for the proper maintenance and use ofyour outboard. All emission warranty parts are warranted by BRP for the entire warranty period of the out-board, unless the part is scheduled for replacement as required maintenance in the Operator's Guide. Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted byBRP for the period of time before the first scheduled replacement date for that part. Emission warrantyparts that are scheduled for regular inspection but not regular replacement are warranted by BRP for theentire warranty period of the outboard. Any emission warranty part repaired or replaced under the termsof this warranty statement is warranted by BRP for the remainder of the warranty period of the originalpart. All parts replaced under this limited warranty become the property of BRP.Maintenance receipts and records should be transferred to each subsequent owner of the outboard.Owner's Warranty ResponsibilitiesAs the outboard owner, you are responsible for the performance of the required maintenance listed in yourOperator's Guide. BRP recommends that you retain all receipts covering maintenance on your outboard,but BRP cannot deny warranty solely for the lack of receipts or your failure to ensure the performance ofall scheduled maintenance.As the outboard owner, you should however be aware that BRP may deny you warranty coverage if youroutboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.You are responsible for presenting your outboard to an authorized BRP dealer as soon as a problem ex-ists. The warranty repairs will be completed in a reasonable amount of time, not to exceed 30 days.For any questions regarding your warranty rights and responsibilities or for the name and location of thenearest 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.


FEATURES

Item Description Item Description1 Motor Cover 7 Water Pump Indicator2 Clamp Screw 8 Flushing Plug3 Clamp Bracket 9 Crankcase Oil Drain Screw4 Anode 10 Trim Tab5 Water Intake 11 Anti-Ventilation Plate6 Lubricant Level Plug 12 Lubricant Drain/Fill Plug


Item Description Item Description1 Low Oil Pressure Light 4 Fuel Tank2 Fuel Connector 5 System Check Gauge (1)

3 Remote Control (1)

(1) Not supplied with outboard

4

3

5


ENGINE SPECIFICATIONS

30 ModelsDisplacement 36.4 cu. in. (597 cc)Engine Type Four-Cycle, In-line, 3 CylinderFull Throttle Operating Range 5500 to 6100 RPMPower (1)

(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.

30 HP (22.4 kw) @ 5800 RPMIdle RPM in Gear (2)

(2) Emission Control Information.

900 50Ignition Timing Idle (1)

W.O.T.Not AdjustableNot Adjustable

Exhaust Emission Control System: per SAE J1930 (1)

EM (Engine Modification)

Fuel Requirements (1) 87 Pump Posted AKI (90 RON) Refer to Fuel and OilCrankcase Oil

CapacityFilter

Evinrude/Johnson Ultra 4-Stroke synthetic blend oil101 fl. oz. (3 liters)See Your Dealer

Warning Signals Engine Overheat and Low Oil PressureIgnition Features S.L.O.W. (Speed Limiting Overheat Warning)Starting Remote electricAlternator 4-Amps, Non-regulatedBattery, Minimum (3)

(3) Not supplied in all marketing areas.

500 CCA (620 MCA) with 90 Minutes Reserve Capacity OR 65 Ampere-Hour, 12 Volt

Spark Plug (1)Torque

Refer to ECI Label 11 to 14 ft. lbs. (15 to 19 Nm)

Gearcase LubricantCapacity

Evinrude/Johnson Ultra-HPF gearcase lubricant7.8 fl. oz. (230 ml)

Propeller 10 1/4 x 12 in. (26 x 30 cm)Fuel Tank (3) Capacity 6 U.S. gallons (22.7 liters)Weight (4)

(4) Does not include fuel or oil.

211.6 lbs. (96 kg)Transom Height 19-1/2 to 20 in. (49.5 to 50.8 cm)Sound at Drivers Ear(LpA) ICOMIA 39.94

76.2 dB(A)


REMOTE CONTROL

IMPORTANT: When selecting the remote control system for your boat, specify Evinrude/Johnson com-ponents. Evinrude/Johnson offers remote controls, cables and wiring kits designed specifically for yourEvinrude/Johnson outboards. Evinrude/Johnson controls deliver the cable stroke your outboard needs forpositive shift and throttle control, and they incorporate such safety and convenience features as: Start-in-gear prevention Plug-in compatibility with Evinrude/Johnson modular wiring system

Evinrude/Johnson Redesigned side mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever5. Throttle friction control6. Emergency stop clip and lanyard

Evinrude/Johnson Concealed side mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle button5. Throttle friction control

Evinrude/Johnson Binnacle mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Fast idle button4. Throttle friction control5. Emergency stop clip and lanyard

Evinrude/Johnson Side mount control1. Handle - shift and throttle2. Trim/tilt switch (where equipped)3. Neutral lock tab4. Fast idle lever5. Emergency stop clip and lanyard6. Throttle friction control

WARNINGIf you choose a non-Evinrude/Johnson remote control, be sure it has a start-in-gear preven-tion feature. This feature can prevent injuries resulting from unexpected boat movement whenthe engine starts.

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Emergency Stop/Key SwitchA combination emergency stop switch and keyswitch is a feature of Evinrude/Johnson prewiredremote controls and all Evinrude/Johnson controlwiring kits. Use of the emergency stop feature ishighly recommended on all boats.Connect the clip to the emergency stop/key switch.Snap the lanyard to a secure place on the opera-tors clothing or life vest not where it might tearaway instead of activating the stop switch. Discon-necting the clip and lanyard will stop the engine andprevent the boat from becoming a runaway if thedriver moves beyond the range of the lanyard. If thelanyard is too long, it can be shortened by knottingor looping it. DO NOT cut and retie the lanyard. Inan emergency situation, the engine can be startedwithout the clip in place. Follow the normal startingprocedure. Reinstall a clip as soon as possible.

1. Clip2. Emergency stop / key switch3. Lanyard

WARNINGAvoid knocking or pulling the clip off thestop switch during normal boating. Avoidbumping the key if operating without theclip on the switch. The resulting unexpectedloss of forward motion can throw occupantsforward, causing injury.Your emergency stop switch can be effec-tive only when in good working condition.At each outing, inspect clip and lanyard forcuts, breaks, or wear. Replace worn or dam-aged parts.Keep the lanyard free from obstructions andentanglements.At each outing, test the systems operation.With the engine running, remove the clipfrom the switch by pulling the lanyard. If theengine does not stop running, see yourDealer.

Engine Monitoring - 17

ENGINE MONITORING

IMPORTANT: Your outboard must be equippedwith the System Check (or equivalent) enginemonitor. Operating your outboard without the Sys-tem Check (or equivalent) engine monitor will voidyour warranty for failures related to the functionsmonitored on your engine. When you turn the key switch ON, the SystemCheck engine monitor horn performs a self-test bysounding a 1/2-second beep. The gauge self-testsby turning the warning lights on, then off in se-quence. During engine start-up, pause with the keyswitch in the ON position to observe the horn andgauge perform the self-test. If the self-test does nothappen as stated, see your Dealer.The System Check engine monitor alerts the oper-ator with a 10-second beep of the horn and a warn-ing light on the gauge when certain engineproblems occur. The appropriate warning lightwill stay on until the key switch is turned OFF.

1. System Check Gauge2. System Check Gauge with Tachometer

"WATER TEMP" or HOTThe engine is overheating. Serious engine damagecan occur quickly.If the engine is overheating, it will also limit enginespeed to 2000 RPM. This additional protection fea-ture is referred to as S.L.O.W. If the engine wasrunning faster than 2000 RPM when the S.L.O.W.system activated, it will shake noticeably.IMPORTANT: Refer immediately to Engine Over-heating.

NO OIL or LOW OILIf, during operation, your engine begins vibratingnoticeably and will not exceed 2000 RPM (fast idle),the low oil pressure warning might have been acti-vated. The engines warning system automaticallylimits its RPM when crankcase oil pressure falls be-low what the engine requires.Oil pressure can fall due to operating conditionssuch as rough seas. or it can fall in response to in-sufficient supply of oil. Once the engines warningsystem has been activated, you must take appropri-ate action to restore adequate oil pressure and re-set the warning system before the engine canoperate normally.For information about evaluating low oil pressureand possible on-the-water fixes, refer to Low OilPressure Warning.

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18 - Fuel and Oil

FUEL AND OIL

FUEL

Your outboard is certified to operate on unleadedautomotive gasoline with an octane rating equal toor higher than that specified in Minimum Octanechart. When using gasoline that contains MTBE oralcohol, follow these guidelines:Using unleaded gasoline that contains methyl ter-tiary butyl ether (MTBE) is acceptable ONLY if theMTBE content does not exceed 15% by volume.Using alcohol-extended fuels is acceptable ONLY ifthe alcohol content does not exceed:10% ethanol by volume; or5% methanol with 5% cosolvents by volume

Minimum Octane

Your outboard has been designed to operate usingthe above fuels; however, be aware of the follow-ing:The boats fuel system may have different require-ments regarding the use of alcohol fuels. Refer tothe boats owner Guide.Alcohol attracts and holds moisture that can causecorrosion of metallic parts in the fuel system.Alcohol blended fuel can cause engine perfor-mance problems.IMPORTANT: Always use fresh gasoline. Gasolinewill oxidize and weather; the result is loss of octane,volatile compounds, and the production of gum andvarnish deposits which can damage the outboard.

WARNINGGasoline is extremely flammable and highlyexplosive under certain conditions. Followthe instructions in this section explicitly.Improper handling of fuel could result inproperty damage, serious injury, or death.Always turn off the engine before fueling.Never permit anyone other than an adult torefill the fuel tank.Do not fill the fuel tank all the way to the top,or fuel may overflow when it expands due toheating by the sun.Remove portable fuel tanks from the boatbefore fueling.Always wipe off any fuel spillage.Do not smoke, or allow open flames orsparks, or use electrical devices such ascellular phones in the vicinity of a fuel leakor while fueling.Always work in a well ventilated area.

Inside the U.S. 87 (R+M)/2 AKIOutside the U.S. 90 RON

WARNINGLeaking fuel is a fire and explosion hazard.All parts in the fuel system should beinspected frequently and replaced if signsof deterioration or leakage are found.Inspect the fuel system each time yourefuel, each time you remove the enginecover, and annually.

Fuel and Oil - 19

OIL

Your 4-stroke engine requires oil in the crankcase.Evinrude/Johnson Ultra 4-Stroke syntheticblend oil is recommended for this outboard en-gine. It allows for extended oil change intervals andis best for high load applications. Evinrude/JohnsonUltra 4-Stroke synthetic blend oil delivers ultra vis-cosity stability, sludge protection, friction reducingproperties, and superior corrosion protection.If Evinrude/Johnson Ultra 4-Stroke synthetic blendoil is unavailable, you may use Evinrude/Johnson 4-Stroke outboard oil. This oil providesexcellent wear and corrosion resistance under nor-mal operating conditions. For your engines oil ca-pacity, refer to Engine Specifications.IMPORTANT: Failure to follow this recommenda-tion could void the engine warranty if a lubrication-related failure occurs.

ADDITIVES

IMPORTANT: Only use fuel additives approved byBRP for your outboard. Use of other fuel additivescan result in poor performance or engine damage.Evinrude/Johnson 2+4 fuel conditioner will helpprevent gum and varnish deposits from forming infuel system components and will remove moisturefrom the fuel system. It can be used continuouslyand should be used during any period when yourengine is not being operated on a regular basis. Itsuse will reduce spark plug fouling, fuel system icing,and fuel system component deterioration.

FUEL SYSTEM

IMPORTANT: Fuel distribution hoses in the boatmust deliver fuel at the rate of flow needed by theengine. Minimum inside diameter of fuel hosesmust be 5/16 in. (8 mm).Fuel systems with built-in tanks, particularly thosethat include antisiphon valves and filter/primerunits, may have restrictions that will not allow theengine fuel pump to deliver sufficient fuel under allconditions. This can result in a loss of performanceand possible engine damage. If a performanceproblem exists, see your Dealer.To avoid difficulty when restarting, never run theengine with the fuel hose disconnected, or run theengine out of fuel.

WARNINGIf your motor is equipped with a quick-dis-connect fuel hose, disconnect the fuel hosefrom the motor and from the fuel tank whenthe motor is not being used for a period oftime. Disconnecting the hose will avert fuelleaks in the hose or at the engine.

20 - Fuel and Oil

BREAK-IN (10 HOURS)IMPORTANT: 4-Stroke outboards are shippedwithout oil in the crankcase. You must add oil tothe crankcase before starting the engine for thefirst time. It is recommended you add Evinrude/Johnson 4-Stroke outboard oil. Refer to Changingthe Oil for acceptable substitute lubricants.Follow this procedure to protect your new outboardduring its initial hours of operation. Careful break-inallows internal engine components to seat proper-ly, resulting in maximum engine performance.Failure to carefully follow the break-in procedurescan result in engine damage. High speed operation without sufficient enginewarm-up can result in engine damage. Perform the 10-Hour break-in procedure with theboat and engine in the water, using an appropriatepropeller.DO NOT perform break-in using a flushing device.DO NOT start-up or run the engine out of water.DO NOT leave a running engine unattended.IMPORTANT: Before the start-up of your new en-gine: Read Engine Starting, Engine Stopping and

Speed Control. Check the crankcase oil level. Refer to Crank-

case Oil. Perform prelaunch checks of all equipment. Check the gearcase lubricant level. Refer to Lu-

brication.

Launch the boat and start the engine according tothe 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 thecause, or see your Dealer before you continue.

Verify shift function by shifting into gear and ob-serving that the boat moves and that the move-ment is in the same direction as the shifter.

Change the RPM often. Avoid holding a throttlesetting longer than 15 minutes.

Check the crankcase oil level often. Add oil ifneeded.

First 10 minutes of operation Run the enginein gear at idle only.Balance of First 2 hours of operation Oper-ate in gear below 3500 RPM or 1/2 throttle only.With easy planing boats, use full throttle to quicklyaccelerate boat onto plane. Immediately reducethrottle to one-half as soon as the boat is on plane.BE SURE boat remains on plane at this throttle set-ting.Third hour of operation Run the engine ingear at various speeds up to 4000 RPM or 3/4 throt-tle only.Balance of first 10 hours of operation Runthe engine in gear at various engine speeds includ-ing full throttle, but remain at full throttle no longerthan 5 minutes.Change the engine speed every 15 minutes.DO NOT exceed recommended maximum engineRPM. Refer to Engine Specifications.

Engine Starting - 21

ENGINE STARTING

BEFORE START-UP

Verify crankcase oil level before start-up. Refer toCrankcase Oil.Review and follow Break-In (10 hours) if the en-gine is new.You MUST supply water to the engine before at-tempting to start it. Engine damage can occurquickly. Refer to Engine Overheating or Flushing.Be sure the engine is in the normal operating posi-tion. Refer to Tilt Support.

Connect the fuel hose to the fuel connector.

1. Fuel hose to fuel connector

If equipped, open vent screw on fuel tanks fillercap.Squeeze fuel primer bulb, outlet end up, until firm.

Connect the clip to the emergency stop/key switch.Snap the lanyard to a secure place on the opera-tors clothing or life vest not where it might tearaway instead of activating the stop switch.

1. Clip2. Emergency stop / key switch3. Lanyard

DANGERDO NOT run the engine indoors or withoutadequate ventilation or permit exhaustfumes to accumulate in confined areas.Engine exhaust contains carbon monoxidewhich, if inhaled, can cause serious braindamage or death.

WARNINGThe engine cover is a machinery guard. DONOT operate your outboard with the coveroff unless you are performing maintenance,and then be careful to keep hands, hair, andclothing clear of all moving parts. Contactwith moving parts could cause injury.

DANGERContact with a rotating propeller is likely toresult in serious injury or death. Assure theengine and prop area is clear of people andobjects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.

22 - Engine Starting

Move the tilt lock lever to the LOCK position.

1. Tilt lock lever in LOCK position

Move the remote control handle to NEUTRAL. Re-fer to Shifting and Speed Control.

1. NEUTRAL

Start-upTurn the key switch fully clockwise to the STARTposition. Crank the engine no longer than 10 sec-onds.

1. START

IMPORTANT: The starter motor can be damaged ifoperated continuously for more than 10 seconds.Upon start-up, release the key.If the engine did not start, release the key momen-tarily, then try again.BEFORE cranking your engine, connect the batteryas instructed in Battery.

If your outboard does not react normally to thisstarting procedure or it fails to start, refer to TroubleCheck Chart.

After Engine StartsDO NOT turn the key switch to START while the en-gine is running. Damage to the starter system couldresult.Allow the engine to idle in NEUTRAL for about 5minutes to warm up before shifting.IMPORTANT: To avoid engine damage after start-up do not exceed 2000 RPM in NEUTRAL. Do notexceed 1500 RPM in NEUTRAL for extended peri-ods of time.Check the water pump indicator. A steady stream ofwater indicates the water pump is working. If asteady stream of water from the water pump indica-tor is not visible, stop the engine. Refer to EngineOverheating.

1. Water pump indicator

ENGINE STOPPING

Move control handle to NEUTRAL.Turn key switch counterclockwise to OFF. Removethe key when the boat will be unattended.To avoid difficulty when restarting, never stop theengine by running it with the fuel hose disconnectedor otherwise running it out of fuel.

WARNINGAlways shift to NEUTRAL before startingthe engine to prevent sudden boat move-ment, which can cause injury.

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WARNINGDo not connect electrical equipment to theengines charging system. The connectedequipment and the engine could both bedamaged.

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Engine Starting - 23

SHIFTING AND SPEED CONTROL

IMPORTANT: Carefully check the function of allcontrol and engine systems before leaving thedock. DO NOT shift the engine into FORWARD orREVERSE while it is shut off. If the following direc-tions are not suitable for your boats control, seeyour Dealer before proceeding.

ShiftingWith engine running and control handle in NEU-TRAL:

Side Mount and Concealed Side Mount Control Unlock the control handle (lift the neutral lock tab bysqueezing the hand grip). Briskly and decisively,move the control handle fore or aft until it engag-es the gear detent.

1. Side mount NEUTRAL lock tab hand grip2. Concealed side mount NEUTRAL lock tab

hand grip

Binnacle Mount ControlBriskly and decisively, move the control handle foreor aft until it engages the gear detent.

IMPORTANT: When shifting from FORWARD toREVERSE or from REVERSE to FORWARD,pause at NEUTRAL until the engine is at idle speedand the boat has slowed.

Speed ControlAfter gear engagement, move the control handleslowly in the same direction to increase speed.

Fast Idle in NEUTRAL

Concealed Side Mount and Binnacle MountControlsIMPORTANT: Avoid excessive engine RPM inNEUTRAL adjust the throttle so the engine doesnot overspeed.With the control handle in NEUTRAL, push the fastidle button while using the other hand to move thecontrol handle forward, past the forward gear de-tent and into the throttle range. If equipped with aneutral lock tab, squeeze it to begin handle travel.

1. Fast idle button

When ready to shift, move the control handle backto NEUTRAL. Engine speed will reduce and theshift function will automatically engage for move-ment into FORWARD or REVERSE.

EMERGENCY STARTING

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WARNINGWhen using Emergency Starting proce-dures, the start-in-neutral-only feature isinoperative. Make sure shift lever is in NEU-TRAL position to prevent injuries fromunexpected boat movement when theengine starts.The engine cover is a machinery guard. Toprevent injury from moving engine compo-nents, keep hands, clothes, and hair clear ofpowerhead.Prevent electric shock by keeping clear ofthe ignition coils and spark plug leads whenthe motor is being started or is running.Shock can cause serious personal injuryunder certain conditions.DO NOT turn flywheel by hand. Use startercord only.

24 - Engine Starting

If the electric starter fails or the batterys voltage istoo low to power the starter, use the cord from thetool kit and these instructions to start your enginemanually.IMPORTANT: The battery must have enough re-serve voltage to activate the electric pump or theengine will not start using the emergency startingprocedures. Do your best to determine battery sta-tus by listening for the electric fuel pump audible cy-cle before continuing the emergency startingprocedures. The electric fuel pump cycles eachtime the key switch is turned from OFF to ON.Place key switch in OFF position with the motor innormal operating position. Refer to Power Trimand Tilt.Move the control handle to NEUTRAL, then removeengine cover.Loosen the lock nut. Remove the cable from thebracket. Separate end of cable from the cam.

1. Locknut2. Cam

Remove the three screws securing the manual start-er. Remove the three screws securing the flywheelcover.

Tie a knot in one end of the emergency starter cord.Thread the small bar from the tools kit halfwaythrough one knot so it forms a handle.Connect the clip to the emergency stop / key switch.Place knot of starter cord in notch on flywheel pul-ley. Wrap cord around pulley clockwise.

Turn the key switch to the ON position ONLY, listencarefully for the electric fuel pump to cycle.While seated, pull the starter cord quickly and com-pletely. The first pull is needed to energize the elec-trical system. Rewind the starter cord and pullagain. Repeat as needed until the engine starts.

1. NEUTRAL

If your engines electrical system is functional, thealternator should charge the battery once the en-gine is running. If it is not, the engine will quit run-ning once the battery voltage is too low to power theelectrical components.DO NOT attempt to replace the flywheel cover orthe engine cover while the engine is running.Snap lanyard to secure place on clothing and pro-ceed to the nearest landing for service.

FUEL ECONOMY

The economy throttle range can save fuel, depend-ing on boat load and hull design. When boat reach-es top speed, throttle back from FULL SPEED tothe economy throttle range. You will save fuel with-out a noticeable loss of speed.

1. Concealed side mount control2. Binnacle mount control

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Operation - 25

OPERATION

POWER TRIM AND TILT

The trim system features a trim range of 14:You can pivot the engine to any position within thisrange while underway and at any boat speed.The power trim is normally used to improve accel-eration, speed, and ride quality and to adjust forchanging water conditions.The tilt system will tilt your engine an additional 50:

While positioned within the tilt range, DO NOT runthe engine faster than idle speed. If idling a tiltedengine, keep its water intakes submerged at alltimes.The power tilt is often used to tilt the engine forclearance when beaching, mooring, or launching.

1. Trim range 2. Tilt range

Trim GaugeThe trim gauge indicates the bow position that isachieved by the trim angle of your motor.


DANGERContact with a rotating propeller is likely toresult in serious injury or death. Assure theengine and prop area is clear of people andobjects before starting engine or operatingboat. Do not allow anyone near a propeller,even when the engine is off. Blades can besharp and the propeller can continue to turneven after the engine is off. Always shut offthe engine when near people in the water.

WARNINGAny malfunction of the power trim and tiltunit could result in loss of shock absorberprotection if an underwater obstruction ishit. Malfunction can also result in loss ofreverse thrust capability.

26 - Operation

Manual Release

If needed, the outboard will tilt up or down manually: Turn the manual release screw counterclockwise,slowly, about 2 turns.Reposition the engine.Tighten the manual release screw to hold the en-gine in its new position.

1. Manual release screw

TiltingTo operate the power tilt, push and hold the trim/tiltswitch in the bow-up or bow-down position. The en-gine will tilt up or down until the switch is releasedor the engine reaches the end of its travel.

1. Bow up2. Bow down

TrimmingTo operate the power trim, push and hold the trim/tilt switch in the desired bow direction, either bow-up or bow-down. The engine will move until theswitch is released or the engine reaches its maxi-mum position.The boat will be properly trimmed when the trim an-gle provides a bow position that results in the bestboat performance for your operating conditions.You must use a speedometer and tachometer todetermine boat and engine performance at differenttrim positions. To help maintain steering stabilityand good performance, always maintain the propertrim angle, which varies depending on the combina-tion of boat, motor, propeller, and operating condi-tions.To familiarize yourself with power trim, make testruns with the boats bow at various positions. Notethe time it takes for the boat to plane, the tachome-ter and speedometer readings, and the ride and ac-tion of the boat.

WARNINGKeep everyone clear of a tilted engine whenbacking out the manual release screw. Theengine could drop suddenly and forcibly. Besure to tighten the manual release screwafter manually repositioning the engine.Tightening the screw also reactivates theengines shock absorber protection andreverse thrust capability.

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Operation - 27

Bow-UpBOW-UP position will give the best fuel economyand highest top speed.

Operating Conditions:In the bow-up position, your boat may tend to pull tothe left. If this condition exists, correct it by applyinga clockwise force with the steering wheel to keep ona straight path. The trim tab can also be adjusted tocompensate for steering wheel torque, but adjustthe trim tab only if bow-up is commonly used. Referto Trim Tab.When the motor is trimmed to full bow-up position,the boats bow will tend to rise above the water.Excessive bow-up trim may cause propeller ventila-tion, resulting in propeller slippage.

Bow-DownBOW-DOWN position will give the best accelera-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-down position, your boat may tend topull to the right. If this condition exists, correct it byapplying a counterclockwise force with the steeringwheel to keep on a straight path. The trim tab canalso be adjusted to compensate for this steeringwheel torque, but adjust the trim tab only if bow-down is commonly used. Refer to Trim Tab.When the motor is trimmed to full bow-down posi-tion, the boats bow will tend to go deeper into thewater (plow).IMPORTANT: Some boats plow, or are difficult toplane, when operated in the trims lowest position.If your boat handles unsuitably when trimmed fullybow-down, set the angle adjusting rod or trim limiterrod to limit the travel of the power trim. If your motoris not equipped with this rod, purchase one fromyour Dealer.

MOORING

You may moor your boat with the motors gearcaseout of the water by using its tilt feature. Dependingon the model, refer to Tilt Support or Power Trimand Tilt.

WARNINGWhen operating in rough water or crossinga wake, excessive bow-up trim may result inthe boats bow suddenly rising skyward,possibly ejecting occupants.

WARNINGSome boat/motor/propeller combinationsmay encounter boat instability and/or highsteering torque when operated at highspeed at or near the motors trim range lim-its (full bow-up or bow-down). Boat stabilityand steering torque can also vary due tochanging water conditions. If any adverseconditions occur, reduce throttle and/oradjust trim angle to maintain control. If youexperience boat instability and/or highsteering torque, see your Dealer to correctthese conditions.

WARNINGIf the bow of the boat plows the water athigh speeds, the boat may bow steer or spinsuddenly, possibly ejecting occupants.

28 - Operation

PROPELLER SELECTION

To select the correct propeller for your boating ap-plication, your boat and motor MUST be water test-ed. See your Dealer for assistance.Refer to Propeller, before removing or installingpropeller.IMPORTANT: The correct propeller for your boat,under normal load conditions, will allow the engineto run near the midpoint of the RPM operatingrange at full throttle. Refer to Engine Specifica-tions.

FLUSHING

See your Dealer for a flushing device designed to fityour engine. Follow manufacturers instructions forinstalling and using it.

Outboard Running1) Place the engine in vertical position in a well-

ventilated area with good drainage.2) Install flushing device and garden hose.3) Cover the water intake hole with tape.

1. Tape

4) Place the shift lever in NEUTRAL with thepropeller removed.

5) Start the water keep pressure between 20to 40 psi (140 to 300 kPa).

1. Flushing device

6) Start the engine run it at idle only andflush it for at least five minutes. Check thewater pump indicator. A steady stream of wa-ter must flow. If it does not, shut OFF the en-gine and investigate. Refer to EngineOverheating.


7) Leave the outboard in vertical position longenough to completely drain the powerhead.

Outboard Not Running1) Remove the plug from the flushing port.

1. Flushing plug

2) Install flushing device and garden hose withthreads matched to flushing port (thread:0.75 11.5 NHR (ANSI)).


WARNINGPrevent injury from contact with rotatingpropeller; remove the propeller beforeflushing.

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Operation - 29

3) Start the water keep pressure between 20to 40 psi (140 to 300 kPa). Flush the enginefor five minutes.

4) Turn off the water, remove the hose and con-nector (if used) and reinstall flushing plug.

5) Leave the outboard in vertical position longenough to completely drain the powerhead.

LOW OIL PRESSURE WARNING

Should crankcase oil pressure drop to a danger-ously low level during engine operation, the low oilpressure light will come on.

1. Low oil pressure light

If the low oil pressure light is on, the engine speedwill not exceed 2000 RPM (FAST idle).If, during operation, your engine slows itself to fastidle and will not exceed that pace, shut OFF the en-gine.If tilted, place the engine in vertical position.Check the oil level on the dipstick and add oil, ifneeded. Refer to Crankcase Oil and EngineSpecifications.Examine the oil fill cap and drain screw for evidenceof oil leakage and make sure they are tight.If the dipstick shows the oil level is okay, leave theengine upright and shut off for ten minutes, thenstart it. If the engine still limits itself to about 2000RPM, see your Dealer.Reset - After oil pressure has been restored, oper-ate the engine below 1500 RPM to reset thewarning system for normal operation.The light will come on for a few seconds after theengine starts. This verifies the warning system isworking.If the light does not come on, stop the engine andsee your Dealer.If the light stays on, check the engine oil level andadd oil if necessary.If the oil level is correct, see your Dealer.IMPORTANT: If you operate the engine with thislight on, severe engine damage can result. Do notrely on the low oil pressure light to indicate the needto add oil. Be sure to periodically check the engineoil level. If the oil level is low, severe engine dam-age can result.

OVER-REVOLUTION LIMITING SYSTEM

This system is activated when engine speed ex-ceeds maximum recommended speed for morethan 10 seconds.If this system activates, engine speed will automat-ically be reduced to approximately 3000 RPM.This system must be reset by moving the throttle tothe idle position for about one second to restore fullengine operation.IMPORTANT: The Over-Revolution Limiting Sys-tem will not be activated at recommended maxi-mum throttle unless propeller pitch is insufficient orother factors (like over-trimming or ventilation)prevail.If the system activates for no apparent reason, seeyour Dealer.

ENGINE OVERHEATING

IMPORTANT: Do not run your engine even for abrief start-up without supplying water to it. Referto Flushing.While boating, the engines water intake must staycompletely submerged and unobstructed. Observeproper transom height and trim angle. While the en-gine is running, the engines water pump indicatormust discharge a steady stream of water. Checkthe indicator often, especially when operating inweeds, muddy and debris-laden water, at extremetrim angles, or in shallow water drive (if equipped).


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. Ifthe engine was running faster than 2000 RPMwhen the S.L.O.W. system activated, it will shakenoticeably.To RESET the S.L.O.W. protection system, the en-gine must be shut OFF and the cooling temperaturerestored.

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30 - Operation

IF the S.L.O.W. protection system activates and thestream 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 and four small gearcase

holes of any blockage; Clean the water pump indicator of any blockage; Lower the motor; and Restart the engine and run at idle.

IF cleaning the screens and indicator does not re-store the water pump indicators steady discharge,SHUT OFF the engine and do not attempt to oper-ate it. See your Dealer. IF cleaning the screens and indicator does restorethe water pump indicators steady discharge, youmight have to run for two minutes in NEUTRAL toallow the engine to cool.IMPORTANT: You must restore cooling to the en-gine to avoid serious engine damage.After any overheat, have your Dealer:Torque the cylinder head screws.Inspect the water pump for excessive wear or dam-age.Inspect the thermostats.Inspect the engine for leaks.

TRAILERING

Trailer your boat with the motor in a vertical posi-tion. If your trailer does not provide adequate roadclearance, the motor can be trailered by using anaccessory trailering bracket. See your Dealer.DO NOT use the tilt support when trailering.IMPORTANT: Whenever using an accessory traile-ring bracket, the motor must be restrained. Bounc-ing during transport will damage the motor andboats transom.

TILT SUPPORT

IMPORTANT: DO NOT use the tilt support leverwhile trailering. Refer to Trailering.

Engage the tilt support lever if you intend to leavethe motor tilted for a period of time: Tilt the motor UP using the trailering tilt switch. Flip the tilt support lever down.

1. Tilt support lever Lower the motor until the tilt support lever rests

solidly on the stern brackets.

Disengage the tilt support lever: Tilt the motor UP. Flip the tilt support level up. Lower the motor to operating position.

WARNINGKeep everyone clear of stern area whenraising or lowering the outboard. Personalinjury or death can result from contact withmoving parts of the outboard.

WARNINGAlways use the power tilt to lift and supportthe motor BEFORE you disengage the tiltsupport lever. If oil pressure is lost whileusing the tilt support lever, the motor candrop suddenly when the support is disen-gaged. If the power tilt will not lift the motor,do not attempt to force the tilt lever from itsposition on the stern brackets. See yourDealer.

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Operation - 31

IMPACT DAMAGEYour engine has a shock absorption system de-signed to help withstand damage from impact withunderwater objects at low to moderate speeds.However, high speed impacts with rigid underwaterobjects like pilings or boulders can be beyond thecapability of the absorption system. Such impactscan result in serious damage to your engine and in-jury to boat occupants from the engine or its partsentering the boat. Occupants can also be ejected orinjured by falling against portions of the boat as aresult of rapid deceleration following impacts. Whenboating in unfamiliar, shallow, or debris-laden wa-ters, seek information on safe boating areas andnavigation hazards from a reliable local source. Re-duce your speed and keep a sharp lookout!

The engines shock absorption system does notwork while operating in reverse. If you back into anobject, either in the water or while trailering, yourboat and engine can be seriously damaged.

If you hit any object, stop immediately and examinethe engine for loosening of attaching hardware andclamp screws, if equipped. Inspect for damage toswivel and stern brackets, steering components,and components in the area of impact. Also, exam-ine the boat for structural damage. Tighten anyloosened hardware. If the collision occurred in thewater, proceed slowly to harbor. Before boatingagain, have your Dealer thoroughly inspect all com-ponents.

STORING

If you must tilt the motor to remove it from the water,lower it and allow the cooling system to drain com-pletely as soon as you clear the launch area.Between uses, store your motor in a vertical posi-tion.For recommendations on extended periods of stor-age, refer to Off-Season Storage.

WARNINGFailure to inspect for damage could result insudden, unexpected component failure,loss of boat control, and personal injury.Unrepaired damage could reduce your boatand engines ability to resist future impacts.

32 - Operation

CARRYING AND TRANSPORTING

If you will be laying the engine down, minimize thepotential for fuel spillage by letting it run out of gasbefore you remove it from the boat. Disconnect thefuel hose at the engine while it is still running. Let itrun until it quits.With the motor tilted up, loosen the carburetor drainscrews and drain the gasoline into a suitable con-tainer. After draining, retighten the drain screwsand tilt down the motor.

1. Carburetor drain screws

Drain the crankcase oil from the engine. Refer toCrankcase Oil.After removing the engine from the boat, position itupright until the cooling system stops draining.Keep the powerhead higher than the gearcase at alltimes, or any water remaining in exhaust passagescould travel to the cylinders and cause seriousdamage.IMPORTANT: Do not rest the engine before the en-gine oil has drained, as oil may enter the cylinderfrom the sump or outer casings may be damaged.IMPORTANT: Do not rest the engine before thecooling water has drained completely, as watermay enter the cylinder through the exhaust port andcause problems.Raise the tiller handle and rest it on a padded sur-face on its port side. Protect the engine cover fromdamage.

IMPORTANT: Do not let the gearcase of the out-board sit higher than the powerhead during trans-porting or storing. Water may drain into thepowerhead, causing damage to the engine.

WARNINGUse a proper, safe container to store anygasoline drained from the outboard motor.

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Operation - 33

SPECIAL OPERATING CONDITIONS

Salt WaterFlush the engine internally after use in salt, pollut-ed, or brackish water to help prevent mineral de-posits from clogging cooling passages. Youroutboard has a built-in flushing port to facilitateflushing. Refer to Flushing.During use in salt or brackish water, additional an-odic protection for the boat and outboard may be re-quired. During long periods of mooring, tilt the gearcase outof the water except in freezing temperatures.Upon removal from salt water, leave it in a verticalposition until its cooling system has drained.

Weedy Water Weeds block water intakes and cause your out-board to overheat. Weeds on the propeller createvibration and reduce boat speed. Run at slow speeds and in REVERSE frequently toclear weeds from the propeller and water intakes.Check the water pump indicator often. If REVERSE operation does not clear away weeds,SHUT OFF the engine. Remove weeds from pro-peller area and water intakes before operating athigher speed.

Boat Bottom and Engine External FinishThe condition of your boats bottom affects perfor-mance. A covering of marine growth reducesspeed. For maximum performance, keep the boatsrunning surface clean by wiping it dry after each useand washing it occasionally. After operating your outboard, rinse it with fresh wa-ter and wipe it dry. Apply Evinrude/Johnson anti-corrosion spray to any surface subject to corrosion,but avoid the anticorrosion anode(s). Periodically, wash the entire boat and outboard withsoapy water and apply a coat of automotive wax.Leave the engine cover in place when washing theoutboard.

High AltitudeIf you boat at altitudes above 3000 ft. (900 m), yourengine might benefit from a lower pitched propeller,different carburetor calibration, or both. See yourDealer.IMPORTANT: To avoid permanent powerheaddamage, be sure that an engine modified for highaltitude operation is properly identified and returnedto original calibration and propeller size if operatedbelow 3000 ft. (900 m).

Shallow WaterIMPORTANT: Serious engine damage will occur ifthe gearcase is allowed to drag on the waterwaybottom.

Freezing Weather DURING operation in freezing weather, keep thegearcase submerged at all times. Upon removing your motor from the water, leave itin a vertical position until its cooling system isdrained. IMPORTANT: Water that has leaked into the gear-case, or remained in the cooling system or othercomponents can freeze, causing serious enginedamage.

Submerged Engine If your engine has been under water, have it ser-viced immediately upon recovery. If immediateservice is unavailable, resubmerge it in fresh waterto avoid prolonged exposure to the atmosphere. After submersion, all boat and engine electrical, fu-el, and oiling systems must be inspected for signsof water intrusion. Your Dealer should perform thisservice.

Under TowShould you require a tow from another boat: Shift your engine to NEUTRAL; Tilt its gearcase out of the water; and Off-load all persons into another boat.Keep towing speed slower than planing speed.

34 - Maintenance

MAINTENANCE

Maintenance, replacement, or repair of theemission control devices and systems may beperformed by any marine SI (spark ignition) en-gine repair establishments or individual.

ENGINE EMISSIONS INFORMATION

Manufacturers ResponsibilityBeginning with 1999 model year engines, manufac-turers of marine engines must determine the ex-haust emission levels for each engine horsepowerfamily and certify these engines with the UnitedStates of America Environmental Protection Agen-cy (EPA). An emissions control information label,showing emission levels and engine specifications,must be placed on each engine at the time of man-ufacture.

Dealers ResponsibilityWhen performing service on all Johnson outboardsthat carry an emissions control information label,adjustments must be kept within published factoryspecifications. Replacement or repair of any emission relatedcomponent must be executed in a manner thatmaintains emission levels within the prescribed cer-tification standards.Dealers are not to modify the engine in any mannerthat would alter the horsepower or allow emissionlevels to exceed their predetermined factory speci-fications.Exceptions include manufacturers prescribedchanges, such as altitude adjustments.

Owner ResponsibilityThe owner/operator is required to have enginemaintenance performed to maintain emission levelswithin prescribed certification standards.The owner/operator is not to, and should not allowanyone to, modify the engine in any manner thatwould 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 emission levels beyond factorysettings or specifications will void the product war-ranty.

EPA Emission RegulationsAll new 2002 and more recent Johnson outboardsmanufactured by BRP are certified to the EPA asconforming to the requirements of the regulationsfor the control of air pollution from new watercraftmarine spark ignition engines. This certification iscontingent on certain adjustments being set to fac-tory standards. For this reason, the factory proce-dure for servicing the product must be strictlyfollowed and, whenever practicable, returned to theoriginal intent of the design. The responsibilities list-ed above are general and in no way a complete list-ing of the rules and regulations pertaining to theEPA requirements on exhaust emissions for marineproducts. For more detailed information on this sub-ject, you may contact the following locations:

VIA U.S. POSTAL SERVICE:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)401 M St. NWWashington, DC 20460

VIA EXPRESS or COURIER MAIL:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance ProgramsGroup (6403J)501 3rd. St. NWWashington, DC 20001

EPA INTERNET WEB SITE:www.epa.gov

WARNINGOnly perform service procedures which aredetailed in this Operators Guide. Attempt-ing to perform maintenance or repair onyour outboard if you are not familiar withthe correct service and safety procedurescould cause injury or death.

Maintenance - 35

10-HOUR INSPECTION

After 10 hours of operation, your new engine will bebroken in and its mechanical parts will have seated.At that time, all systems should be checked and anyadjustments needed should be made. Your Dealer will perform this 10-Hour Inspection atyour request and expense (based on local rates),according to what your engine needs refer to En-gine Maintenance and Inspection Schedule, 10-Hour Inspection for a partial list.Follow consistent preventive maintenance by hav-ing your Dealer check and service your engineonce a year or after each 100 hours of operation,whichever comes first.

OFF-SEASON STORAGE

You must protect against natural environmentalconditions that can be damaging to an outboardmotor. Temperature and humidity changes whileyour outboard motor is not in use can cause corro-sion of internal engine parts when they are not pro-tected. Fuel remaining in your fuel tank and in theengine will oxidize and weather which can result inloss of octane and can cause gum deposits in thefuel system. Your warranty does not cover enginefailure caused by these conditions. We strongly rec-ommend that you have your Dealer prepare youroutboard for the off-season. To do the off-season storage preparations yourself,gather the supplies and perform the following steps:

2+4 fuel conditioner Triple-Guard grease Ultra-HPF gearcase lubricantStorage Fogging Oil spray canEvinrude/Johnson Ultra 4-Stroke syntheticblend oil

Stabilize the engines fuel supply with 2+4 fuel con-ditioner during the last hours of operation to ensureproper stabilization, following instructions on thecontainer for mixture. Be sure to run the enginelong enough for the treated fuel to reach the en-gine.

IMPORTANT: Provide a water supply to the engineand start it. Run the engine at idle only.To run the engine on a flusher, refer to Flushing.Oil Start the engine and run it at least five min-utes to warm the crankcase oil.Stop the engine and drain the crankcase while theengine is warm. Refill it with Evinrude/Johnson Ul-tra 4-Stroke synthetic blend oil. Refer to CrankcaseOil. Restart the engine and run it for a few minutesto circulate the fresh oil.IMPORTANT: It is very important that the bearingsurfaces be coated with clean oil before entering aperiod of storage, so be sure you run the engine af-ter changing the oil.Stop the engine.Spark Plugs Remove and examine them.Clean or discard them, if necessary. Refer to SparkPlugs.Spray Evinrude/Johnson Storage Fogging Oil intothe spark plug holes.Install spark plugs; tighten to specifications inSpark Plugs.Crank the engine for a short burst to distribute thefogging oil and to drain the water from the waterpump.Fuel filter(s) Clean or change.Ignition, oil, and fuel systems Check for mis-placed leads and damaged or deteriorated parts.Be sure starter solenoid terminal boot and all con-nectors are in place.

WARNINGPrevent injury from moving engine compo-nents. Before starting the engine:Shift it to NEUTRAL.Keep hands, clothes, and hair clear of pow-erhead. Remove the propeller if you use a flushingdevice.

36 - Maintenance

Screws, bolts, nuts Tighten any that areloose.Propeller Remove and examine. If

2006_30 owners 4 stk

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