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Johnson R Operator's Manual

9.9/10/15 horsepower
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2004
Operator's Guide
9.9/10/15 HORSEPOWER
R, RL, RH, RHL, TE, TEL

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  • Page 1 2004 Operator's Guide 9.9/10/15 HORSEPOWER R, RL, RH, RHL, TE, TEL...
  • Page 2 An Operator’s Readiness Test has been prepared on the last page of this Guide. Be safe! All passengers should be familiar with the proper operation of your boat and Johnson outboard. Be certain they fully understand and respect the controls and operation. Each operator is responsible for the safety of all passengers and other boaters.

  • Page 3: Table Of Contents

    SAFETY — THE RIGHT PLACE TO GET STARTED ....................2 PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ..............4 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ................5 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ..............

  • Page 4: General Information

    1-800-336-BOAT. For equipment. It will acquaint the operator and pas- additional information about boating safety and reg- sengers with the Evinrude/Johnson outboard and ulations call: U.S. Coast Guard Boating Safety Hot- its controls, operation, maintenance and boating line 1-800-368-5647.
  • Page 5 It can be worsened or caused by weather, For more information, see your Evinrude/ mooring and operating conditions, and other Johnson DEALER for a copy of Introduction boats. Avoid exhaust fumes from your engine to High Performance Boating, P/N 335763.

  • Page 6: Product References, Illustrations And Specifications

    Bombardier Motor Corporation of America reserves DEALER. For the name and location of the nearest the right to make changes at any time, without no- Evinrude/Johnson DEALER in the United States tice, to features, specifications and model availabil- and Canada log on to www.evinrude.com or ity.

  • Page 7: Bombardier Limited Warranty For Johnson 2-Stroke Outboard Engines Sold In The United States And Canada

    This warranty coverage is available only on Johnson 2-stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred ("Dealer"), and then only after the Bombardier specified pre-delivery inspection process has been com- pleted and documented by the purchaser and Dealer.
  • Page 8 5. WHAT BOMBARDIER WILL DO Bombardier's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product found to be defective in material or workmanship, in the reasonable judgment of Bombar- dier. Such repair or replacement of parts will be done without charge for parts and labor, at any authorized Dealer.
  • Page 9 7. LIMITATIONS OF LIABILITY ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN- TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA- TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY. ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO: expense for gasoline, expense for transporting Product to and from Dealer, removal of Product from a boat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering or...

  • Page 10: Bombardier Limited Warranty For Johnson 2-Stroke Outboard Engines Sold Outside The United States And Canada

    ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty, see your Bombardier distributor/dealer authorized to distribute Johnson 2-stroke products in the country in which the sale occurs. If further assistance is required, please contact Bombardier Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier where the Product was registered for war- ranty.
  • Page 11 NOTES General Information -...

  • Page 12: Features

    FEATURES 10 11 Item Description Item Description Water Pump Indicator Emergency Restart Clip Tilt/Run Lever Emergency Stop Switch/Stop Button Anticorrosion Anode Shift Lever Lubricant Drain/Fill Plug Neutral Indicator Lubricant Level Plug Choke Knob Battery Cable Starer Handle Clamp Screws Manual Starter Carrying Handle Flushing Inlet Screw Tilt Friction Nut...
  • Page 13 000288 Item Description Item Description Mounting Hardware Water Intakes Fuel Connector Fish Line Trap Steering Handle and Twist-Grip Throttle Propeller Idle Speed Adjustment Antiventilation Plate Retention Lug Lift Grip Model and Serial Number Plate Engine Cover Latch Steering Friction Adjustment Screw Spark Plugs Clip and Lanyard Assembly Starter Motor...

  • Page 14: Engine Specifications

    R, RH – 74 lbs. (33.6 kg) RL, RHL – 77 lbs. (34.9 kg) Transom Height R, RH – 14 1/2 to 15 in. (36.8 to 38.1 cm) RL, RHL – 19 1/2 to 20 in. (49.5 to 50.8 cm) Sound at Driver’s Ear 86.0 dB(A)

  • Page 15: Emergency Stop Switch

    EMERGENCY STOP SWITCH An extra clip is provided — another person can in- sert it in the stop switch and start the motor in an emergency. If equipped, the emergency stop switch is on the steering handle. Use of the emergency stop feature is highly recommended on all boats.

  • Page 16: Fuel And Oil

    FUEL AND OIL FUEL Minimum Octane Inside the U.S. 87 (R+M)/2 AKI WARNING Outside the U.S. 89 RON Your outboard has been designed to operate using Gasoline is extremely flammable and highly the above fuels; however, be aware of the follow- explosive under certain conditions.

  • Page 17: Oil

    Install filler cap and tip tank gently to distribute not available, you must use an NMMA-certified TC- oil. W3 oil such as Evinrude/Johnson direct injection oil or Evinrude biodegradable outboard oil. IMPORTANT: Failure to follow this recommenda- tion could void the engine warranty if a lubrication- related failure occurs.

  • Page 18: Fuel Systems

    FUEL SYSTEMS IMPORTANT: Before the first start-up of your new engine: • Read Engine Starting, Engine Stopping, and Shifting and Speed Control. WARNING • Check the gearcase lube level. Refer to Lubrica- tion. If your motor is equipped with a quick-dis- •...

  • Page 19: Engine Starting

    ENGINE STARTING Move tilt/run lever to RUN. Be sure the engine is in normal operating position. Refer to Tilting and Tilt DANGER Support. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.
  • Page 20 Connect the fuel hose to the fuel connector. If equipped, attach the clip and lanyard assembly to the emergency stop switch. Snap the lanyard to se- cure place on your clothing or life vest. 1. Fuel hose connector 2. Fuel connector 1.
  • Page 21 Twist the throttle grip to START. Rope Start While seated, grasp the starter handle and pull slowly until starter engages, then pull hard. Repeat, if needed, until motor starts. To prevent damage to starter assembly, allow starter cord to rewind be- fore releasing starter handle.

  • Page 22: Engine Stopping

    IMPORTANT: Starter motor can be damaged if op- ENGINE STOPPING erated continuously for more than 10 seconds. DO NOT press start button to START position when en- Twist the throttle grip to SHIFT position or slower. gine is running. Starter and flywheel will be dam- Move shift lever to NEUTRAL.

  • Page 23: Shifting And Speed Control

    SHIFTING AND SPEED CONTROL IMPORTANT: Carefully check the function of all control and engine systems before leaving the dock. DO NOT shift the engine into FORWARD or REVERSE while it is shut OFF. Shifting With the engine running, twist the throttle grip to SHIFT or slower.
  • Page 24 Move tilt/run lever to RUN position. Place motor in Electric Start Models its normal operating position. WARNING DO NOT use jumper cables and a booster battery to start engine. Do not charge a bat- tery in the boat with an external charger. Fumes vented during either operation can lead to an explosion.

  • Page 25: Fuel Economy

    Tip the manual starter housing to remove the start- All Models er lockout link. Secure the lockout link in the lower Follow the starting procedures in Start-up (Cold engine cover, away from moving engine parts. Engine). While seated, pull hard on emergency starting cord to start motor.

  • Page 26: Operation

    OPERATION TRAILERING DANGER Trailer your boat with the motor in a vertical posi- DO NOT run the engine indoors or without tion. If your trailer does not provide adequate road adequate ventilation or permit exhaust clearance, the motor can be trailered by using an fumes to accumulate in confined areas.

  • Page 27: Shallow-Water Drive

    Tilt UP Tilt DOWN Move tilt/run lever to TILT position. Move tilt/run lever to RUN position. 1. Tilt/run lever – TILT position 1. Tilt/run lever – RUN position Grasp tilt grip on engine cover and tilt motor to the Grasp tilt grip on engine cover and raise motor full tilt position.

  • Page 28: Propeller Selection

    Engage Disengage Move tilt/run lever to the TILT position. Move tilt/run lever to the RUN position. 1. Tilt/run lever – TILT position 1. Tilt/run lever – RUN position 2. NEUTRAL 2. NEUTRAL Grasp tilt grip on engine cover and tilt motor half- Grasp tilt grip on engine cover and tilt motor slightly.

  • Page 29: Flushing

    FLUSHING 4) Start the water — keep pressure between 20 to 40 psi (140 to 300 kPa). DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

  • Page 30: Engine Overheating

    ENGINE OVERHEATING If the stream of water from the water pump indicator becomes intermittent or stops, reduce speed to idle and: IMPORTANT: Do not run your engine — even for a • Shift to NEUTRAL; brief start-up — without supplying water to it. Refer •...

  • Page 31: Impact Damage

    IMPACT DAMAGE If you hit any object, stop immediately and examine the engine for loosening of attaching hardware and clamp screws, if equipped. Inspect for damage to Your engine can be damaged from impact with un- swivel and stern brackets, steering components, derwater objects.

  • Page 32: Special Operating Conditions

    After operating your outboard, rinse it with fresh wa- After submersion, all boat and engine electrical, fu- ter and wipe it dry. Apply Evinrude/Johnson Anti- el, and oiling systems must be inspected for signs Corrosion Spray to any surface subject to corro- of water intrusion.

  • Page 33: Maintenance

    MAINTENANCE Maintenance, replacement, or repair of the To do the off-season storage preparations yourself, emission control devices and systems may be gather the supplies and perform the following steps. performed by any marine SI (spark ignition) en- 2+4 fuel conditioner gine repair establishments or individual.

  • Page 34: Pre-Season Service

    If so, in- Replace damaged or missing parts with Evinrude/ stall the propeller after you shut OFF the engine Johnson Genuine Parts , or equivalent. and disconnect the flusher. Refer to Flushing. Battery — Remove it, clean it, check its condition Refer to Propeller to install the propeller.

  • Page 35: Battery

    BATTERY Each outboard needs one battery that is: • 12-volt, heavy-duty, designated "marine"; • Vented/refillable or maintenance-free; and • Rated according to the minimum requirements in Engine Specifications. Deep-cycle batteries are suitable IF they meet or exceed the minimum CCA requirements. Ask your DEALER about your outboard’s require- ments before installing longer battery cables, a bat- tery switch or a battery insulator.

  • Page 36: Adjustments

    ADJUSTMENTS Tilt Friction The tilt friction nut should be adjusted ONLY enough to control return of gearcase from tilt to nor- Idle Speed mal (vertical) position. The idle speed adjusting knob is located at the end of the steering handle. Before turning the knob, be sure the throttle is at SLOW and the motor has reached normal operating temperature: •...

  • Page 37: Lubrication

    LUBRICATION Lubrication Points Refer to Engine Maintenance and Inspection Schedule for lubrication frequency and recom- Gearcase mended lubricant. Replace gearcase lubricant after first 10 hours of operation. Check level and condition of lubricant af- ter next 50 hours of operation. Add lubricant if nec- essary.

  • Page 38: Fuel Pump Filter

    FUEL PUMP FILTER The fuel filter is located in the motor’s fuel pump. An authorized Evinrude/Johnson DEALER should ser- vice the fuel filter. WARNING Prevent excessive fuel spillage by discon- necting fuel hose from motor before disas- sembly. The filter is located under the inlet cover on the fuel pump.

  • Page 39: Spark Plugs

    SPARK PLUGS PROPELLER WARNING WARNING The ignition system presents a serious When servicing the propeller, always shift shock hazard. The primary circuit operates the outboard to NEUTRAL position, and in excess of 250 volts; the secondary circuit twist and remove all spark plug leads so the operates in excess of 25,000 volts.
  • Page 40 Continue to tighten propeller nut until nut slots and Fish Line Trap cotter pin hole are aligned. Install new cotter pin The thrust bushing contains a built-up groove as a and bend ends to secure. trap for fish line. Every 15 to 20 hours of operation, or whenever you suspect the presence of fish line, remove the propeller and check the trap.

  • Page 41: Anticorrosion Anodes

    ANTICORROSION ANODES Galvanic corrosion destroys underwater metal parts and can occur in fresh or salt water; however, salt, brackish and polluted waters will accelerate Your motor is equipped with one or more anodes corrosion. that protect it from galvanic corrosion. Refer to Fea- Metal-based antifouling paint on the boat or motor tures for anode location.

  • Page 42: Ac Lighting

    AC LIGHTING 1. Sleeve 2. Electrical tape covering connection 3. Light bulb Y – Yellow wire YG – Yellow/Grey wire YB – Yellow/Blue wire Some models have an AC (alternating current) lighting system for operating lights on a boat. An AC lighting system is available as an optional kit.

  • Page 43: Trouble Check Chart

    TROUBLE CHECK CHART IMPORTANT: If you are unable to identify or solve the problem, contact your DEALER. SYMPTOM POSSIBLE CAUSE Starter motor will not operate • Shift handle not in NEUTRAL. • Battery and electrical connections loose or corroded. Engine will not start •...

  • Page 44: Engine Maintenance And Inspection Schedule

    ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following maintenance chart provides guidelines for engine maintenance and in- spection scheduled to be performed by you and/or by an authorized DEALER. The schedule should be adjusted according to operating conditions and use.
  • Page 45 (2) Emission-related component (3) Do not use light duty penetrating lubricants Dealer Performed Service Operator Performed Service Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant Ultra-HPF gearcase lubricant Power Trim/Tilt Fluid Triple Guard grease Evinrude/Johnson Moly Lube™ P/N 175356...
  • Page 46 NOTES - Maintenance...
  • Page 47 Maintenance -...

  • Page 48: Installation

    INSTALLATION Transom Height and Shaft Length The transom height dimension listed in Engine Specifications is the height of the boat transom WARNING your engine needs. This dimension is measured at the transom centerline, perpendicular to the bottom of the boat. Your engine must not exceed the maximum horsepower indicated on the boat’s capacity plate.
  • Page 49 If equipped, tighten clamp screws by hand, NOT Installing the Engine with tools. Adjust the motor angle so the antiventilation plate is WARNING parallel with the boat bottom. Refer to Motor Angle Adjustment. The outboard must be correctly installed. The resulting position of the antiventilation plate Failure to correctly install the outboard must be no higher than the boat’s bottom and no could result in serious injury, death or prop-...
  • Page 50 After positioning the engine, use the stern brackets as a template for location and size of holes to drill in When replacing bolts, screws, or other fas- the transom. teners, use Johnson parts or parts of equiv- alent strength and material. - Maintenance...
  • Page 51 CHANGE OF ADDRESS / CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your outboard becomes necessary.

  • Page 53: Confirmation Of Receipt

    I understand and agree to be bound with. I am also satisfied with the predelivery set-up and inspection of my Evinrude / Johnson Outboard. I have also received a copy of the Operator’s Guide.
  • Page 54 - Maintenance...
  • Page 55 Readiness Test and a Final Word to the Owner/Operator The Operator’s Readiness Test..1. Did you read this Guide from front cover to rear cover? 2. Are you ready to take responsibility for the safe operation of your boat and motor? 3.
  • Page 56 *215483*...

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