BOMBARDIER 2005 Johnson User manual

Commercial
2 Stroke
55 HORSEPOWER
12 pt12 pt
WARNING
Read this Operator Guide thoroughly. It contains important
safety information. When operating your boat, always
have this Operator Guide onboard.
!!
*215603*
2005

Our First Words to the Owner/Operator
This Operator’s Guide is an essential part of your Johnson outboard. It contains pertinent information
which, 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 is
strongly 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 any
passengers and other boaters. 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. 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 Law
Agency.
The pleasures of owning and operating a
Johnson outboard can be significant. We strongly believe the
rewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.
Good safety practices not only protect you but also protect the people around you.
Having fun is what it’s all about and, with your cooperation, the pertinent information in this Guide can en-
sure a safe and enjoyable experience.
Enjoy the great outdoors on the water...
The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates:
WARNING
Be 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 to
your boat and outboard can be fixed in a short period of time, but injury or death has a lasting
effect.
For your safety and the safety of others, read this Guide from cover to cover and follow all
safety warnings and recommendations. Do not disregard any of the safety precautions and
instructions.
Anyone operating your boat should first read and understand this Guide before they operate
your boat and motor.
2+4® fuel conditioner Hi-Vis™ gearcase lubricant
Evinrude® Johnson®
Evinrude®/Johnson® anti-corrosion spray Triple-Guard® grease
Evinrude®/Johnson® Genuine Parts Twist-Grip
™
Evinrude®/Johnson® XD25™ formula Ultra-HPF ™ gearcase lubricant

© 2004 Bombardier Motor Corporation of America. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
1
Contents
GENERAL INFORMATION ................................................................................................... 2
SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ..................................... 5
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
2-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ......................... 8
FEATURES ............................................................................................................................................................... 10
ENGINE SPECIFICATIONS ...................................................................................................................................... 12
EMERGENCY STOP SWITCH .................................................................................................................................. 13
FUEL AND OIL ................................................................................................................... 14
FUEL ......................................................................................................................................................................... 14
OIL ............................................................................................................................................................................. 15
ADDITIVES ................................................................................................................................................................ 15
FUEL/OIL RATIO ...................................................................................................................................................... 15
MIXING FUEL AND OIL ............................................................................................................................................ 15
FUEL SYSTEMS ....................................................................................................................................................... 16
BREAK-IN (10 HOURS) ............................................................................................................................................ 16
ENGINE STARTING ........................................................................................................... 17
BEFORE START-UP ................................................................................................................................................. 17
ENGINE STOPPING ................................................................................................................................................. 19
SHIFTING AND SPEED CONTROL ......................................................................................................................... 20
EMERGENCY STARTING ........................................................................................................................................ 20
FUEL ECONOMY ...................................................................................................................................................... 21
OPERATION ....................................................................................................................... 22
MOTOR ANGLE ADJUSTMENT .............................................................................................................................. 22
TRAILERING ............................................................................................................................................................. 22
TILTING ..................................................................................................................................................................... 22
TILT SUPPORT ......................................................................................................................................................... 24
PROPELLER SELECTION ....................................................................................................................................... 24
MOORING ................................................................................................................................................................. 24
FLUSHING ................................................................................................................................................................ 24
ENGINE OVERHEATING .......................................................................................................................................... 25
IMPACT DAMAGE .................................................................................................................................................... 26
STORING .................................................................................................................................................................. 26
SPECIAL OPERATING CONDITIONS ..................................................................................................................... 27
MAINTENANCE .................................................................................................................. 28
10-HOUR INSPECTION ............................................................................................................................................ 28
OFF-SEASON STORAGE ........................................................................................................................................ 28
PRE-SEASON SERVICE .......................................................................................................................................... 29
ADJUSTMENTS ........................................................................................................................................................ 30
LUBRICATION .......................................................................................................................................................... 32
WATER PRESSURE ................................................................................................................................................. 34
FUEL PUMP FILTER ................................................................................................................................................ 34
FUEL LINE FILTER ................................................................................................................................................... 34
SPARK PLUGS ......................................................................................................................................................... 35
PROPELLER ............................................................................................................................................................. 36
ANTICORROSION ANODES .................................................................................................................................... 37
TROUBLE CHECK CHART ...................................................................................................................................... 38
ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 39
INSTALLATION ........................................................................................................................................................ 41
AC LIGHTING ........................................................................................................................................................... 44

2- General Information
GENERAL INFORMATION
SAFETY — THE RIGHT PLACE TO GET
STARTED
This Operator’s Guide contains essential informa-
tion to help prevent personal injury and damage to
equipment. It will acquaint the operator and pas-
sengers with the
Evinrude/Johnson outboard and
its controls, operation, maintenance and boating
safety measures. Make sure all operators read, un-
derstand and follow the contents. This Guide
should be kept in a waterproof bag with the product
at all times during operation. If the product owner-
ship is transferred, this Guide should be forwarded
to the subsequent owners.
This Operator’s Guide uses the following signal
words identifying important safety messages.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
IMPORTANT: Identifies information that will help
prevent damage to machinery and appears next to
information that controls correct assembly and op-
eration of the product.
Although the mere reading of such information
does not eliminate the hazard, the understanding
and application of the information will promote the
correct use of your outboard engine.
A responsible, educated boater will fully appreciate
the 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 Squadron
and some Red Cross Chapters. For information
about classes, call toll free 1-800-336-BOAT. For
additional information about boating safety and reg-
ulations call: U.S. Coast Guard Boating Safety Hot-
line 1-800-368-5647. Outside North America
please contact your Dealer or distributor for details
about boating safety.
SAFETY MEASURES — General
SAFETY MEASURES — Operation
DANGER
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or
moderate personal injury or property dam-
age. It also may be used to alert against
unsafe practices.
To fully appreciate the pleasures, enjoyment
and excitement of boating there are some ba-
sic rules that should be observed and followed
by any boater. Some rules may be new to you
and others may be common sense or obvi-
ous... irrespective, take them seriously! Fail-
ure to follow this safety information and safe
boating rules could result in injury to you, your
passengers or other water users.
Become completely familiar with the control
and operation of your boat and motor before
embarking on your first trip or taking on a pas-
senger(s). If you have not had the opportunity
to do so with your Dealer, practice driving in a
suitable area and feel the response of each
control. Be familiar with all controls before ap-
plying the throttle above idle speed. As the op-
erator, you are in control and responsible for
safe operation.
Be sure at least one of your passengers
knows how to handle your boat in case of an
emergency.
All passengers should know the location of
emergency equipment and how to use it.
All safety equipment and personal flotation
devices must be in good condition and suit-
able for your type of boat. Always comply with
the regulations that apply to your boat.
Contact with rotating propeller is likely to result
in serious injury or death. Do not allow anyone
near a propeller, even when the engine is off.
Propeller blades can be sharp and can contin-
ue to turn even after the engine is shut off. Al-
ways shut off the engine when boat is near
people in the water.

General Information - 3
SAFETY MEASURES — Installation and
Maintenance
Outboard Installation
Maintenance
Whenever running the engine, assure there is
proper ventilation to avoid the accumulation of
carbon monoxide (CO), which is odorless, col-
orless, and tasteless, and can lead to uncon-
sciousness, brain damage, or death if inhaled
in sufficient concentrations. CO accumulation
can occur while docked, anchored, or under-
way, and in many confined areas such as the
boat cabin, cockpit, swim platform, and heads.
It can be worsened or caused by weather,
mooring and operating conditions, and other
boats. Avoid exhaust fumes from your engine
or other boats, provide proper ventilation, shut
off your engine when not needed, and be
aware of the risk of backdrafting and condi-
tions that create CO accumulation. In high
concentrations, CO can be fatal within min-
utes. Lower concentrations are just as lethal
over long periods of time.
Proceed with caution and at very low speed in
shallow water. Grounding or abrupt stops may
result in personal injury or property damage.
Also be alert for debris and objects in the wa-
ter.
Be familiar with the waters you are operating
in. The gearcase of this outboard extends be-
low the water surface and could potentially
come in contact with underwater obstructions.
Contact with underwater obstructions may re-
sult in loss of control and personal injury.
Avoid standing up or shifting weight suddenly
in light weight boats.
Keep your passengers seated in seats. The
boat’s bow, gunwale, transom and seat backs
are not intended for use as seats.
Insist on the use of personal flotation devices,
approved by the U.S. Coast Guard, by all pas-
sengers when boating conditions are hazard-
ous, and by children and nonswimmers at all
times.
Respect no wake zones, rights of other water
users and the environment. As the "skipper"
and owner of a boat you are responsible for
damage to other boats caused by the wake of
your boat. Allow no one to throw refuse over-
board.
Know the marine traffic laws and obey them.
Remember, gasoline fumes are flammable
and explosive. Always adhere to the fueling
procedure contained in this Operator’s Guide
and those given to you by the fueling station.
Always verify fuel level before use and during
the ride. Apply the principle of 1/3 fuel to des-
tination, 1/3 back and 1/3 reserve fuel supply.
Do not carry spare fuel or flammable liquids in
any storage or engine compartments.
Do not operate your boat if you are under the
influence of drugs or alcohol.
High performance boats have a high power-
to-weight ratio. If you are not experienced in
the operation of a high performance boat, do
not attempt to operate one at, or near, its top
speed until you have gained that experience.
For more information, see your Evinrude/
Johnson
Dealer for a copy of Introduction to
High Performance Boating, P/N 335763.
The outboard must be correctly installed. Fail-
ure to correctly install the outboard could re-
sult in serious injury, death or property
damage. We strongly recommend that your
Dealer install your outboard to ensure proper
installation.
Do not overpower your boat by using an en-
gine that exceeds the horsepower indicated
on the boat’s capacity plate. Overpowering
could result in loss of control. If your boat has
no capacity plate, contact your Dealer or the
boat’s manufacturer.
When replacement parts are required, use
Evinrude®/Johnson® Genuine Parts or parts
with equivalent characteristics, including type,
strength and material. Using substandard
parts could result in injury or product malfunc-
tion.
Only perform service procedures which are
detailed in this Operator’s Guide. Attempting
to perform maintenance or repair on your out-
board if you are not familiar with the correct
service and safety procedure could cause per-
sonal injury or death. Further information can
be obtained from your authorized
Evinrude/
Johnson
Dealer. In many instances proper
tools and training are required for certain ser-
vice or repair procedures.
Maintain your boat and engine in top condition
at all times. Adhere to the Engine Mainte-
nance and Inspection Schedule.
Operate your boat and outboard prudently
and have fun. Do not forget that all persons
must assist other boaters in case of emergen-
cy.
Prevent injury from contact with rotating pro-
peller; remove propeller before flushing or be-
fore performing any maintenance.

4- General Information
PRODUCT REFERENCES,
ILLUSTRATIONS AND
SPECIFICATIONS
Bombardier Motor Corporation of America (BMCA)
reserves the right to make changes at any time,
without notice, to features, specifications and mod-
el availability. The right is also reserved to change
any specification or part at any time without incur-
ring any obligation to update older models. The in-
formation in the Guide is based on the latest
specifications available at the time of publication.
Photographs and illustrations used in this Guide
might not depict actual models or equipment but
are intended as representative views for reference
only. The continuing accuracy of this Guide cannot
be guaranteed.
Certain features of systems discussed in this Guide
might not be found on all models in all marketing ar-
eas.
Owner’s Identification
North America — At the time of purchase, your
Dealer will complete your outboard registration
forms. Your portion provides proof of ownership
and date of purchase.
Outside North America — See your Dealer or
distributor for details.
Model and Serial Numbers
The model and serial numbers appear on a plate at-
tached to the stern bracket or swivel bracket.
Record your outboard’s:
Model Number ___________________________
Serial Number ___________________________
Purchase Date ___________________________
Ignition Key Number ______________________
Stolen Outboards
North America — Report your outboard as stolen
to Customer and Dealer Support Services, 250 Sea
Horse Drive, Waukegan, IL 60085 U.S.A. Give the
outboard’s model and serial numbers and enclose
a copy of the police report.
Outside North America — Report the theft to the
Bombardier Recreational Products distributor
where the outboard was registered.
Technical Literature
BMCA offers technical literature specifically for your
outboard. A service manual, a parts catalog, or an
extra Operator’s Guide can be purchased from your
selling Dealer. For the name and location of the
nearest
Evinrude/Johnson Dealer in the United
States and Canada log on to www.evinrude.com
or www.johnson.com.
Declaration of Conformity
BMCA declares that the outboard to which this Op-
erator’s Manual applies conforms to the essential
requirements outlined in CE Machinery Directive
98-37-EC, as amended.
WARNING
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts
with equivalent characteristics, including
type, strength and material. Using substan-
dard parts could result in injury or product
malfunction.

General Information - 5
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005
JOHNSON 2-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA
1. SCOPE OF THE LIMITED WARRANTY
Bombardier Motor Corporation of America* ("BMCA") warrants its 2005 Johnson ® 2-stroke outboard en-
gines sold by authorized
Johnson dealers in the fifty United States and Canada ("Product") from defects
in material or workmanship for the period and under the conditions described below.
2. WARRANTY COVERAGE PERIOD
This limited warranty will be in effect from the date of purchase by the first retail consumer or the date the
Product is first put to use, whichever occurs first, for a period of:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private, recreational use; or
TWELVE (12) CONSECUTIVE MONTHS for commercial use. The Product is used commercially when it
is used in 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 a boat 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 not
extend the life of this limited warranty beyond its original expiration date. All
Evinrude®/Johnson Genuine
Parts
and accessories installed by an authorized dealer at the time of sale, including but not limited to pro-
pellers, bear the standard BMCA parts and accessories one-year limited warranty.
3. CONDITIONS TO HAVE WARRANTY COVERAGE
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 BMCA specified pre-delivery inspection process has been completed
and documented by the purchaser and Dealer. Warranty coverage only becomes available upon proper
registration of Product by Dealer or owner.
Only the original purchaser and any subsequent owners who reside in the United States and Canada and
have 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 BMCA to protect the safety of its
products, its consumers, and the general public.
As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain
warranty coverage. BMCA may require proof of proper maintenance prior to authorizing warranty cover-
age.
4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE
The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect.
Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance
of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op-
portunity to repair the defect. 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 of
the repair in order to validate the warranty repair.
All parts replaced under this warranty become the property of BMCA.

6- General Information
5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DO
Bombardier Motor Corporation of America’s obligations under this warranty are limited to, at its sole dis-
cretion, repairing or replacing parts of Product found to be defective in material or workmanship, in the
reasonable judgment of BMCA. Such repair or replacement of parts will be done without charge for parts
and labor, at any authorized Dealer. BMCA's responsibility is limited to making the required repairs or re-
placements of parts with new or BMCA-certified re-manufactured parts. No claim of breach of warranty
shall be cause for cancellation or rescission of the sale of Product to owner.
In the event that warranty service is required outside of the fifty United States or Canada, owner will bear
responsibility 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, including
those levied by governments, states, territories and their respective agencies.
BMCA reserves the right to improve, modify or change Products from time to time without assuming any
obligation to modify Products previously manufactured.
6. EXCLUSIONS – The following are not warranted under any circumstances:
• Replacement of parts due to 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, zinc
anodes, thermostats, timing belts, starter motor bushings, trim motor brushes, filters, propellers, propel-
ler bushings and spark plugs;
• Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure
to follow the procedures and recommendations in the Operator's Guide;
• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use
of parts or accessories not manufactured or approved by BMCA, which in its reasonable judgment, are
either incompatible with Product or adversely affect its operation, performance, or durability, or resulting
from repairs done by a person that is not an authorized Dealer;
• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of
the Product in a manner inconsistent with the recommended operation described in the Operator's
Guide;
• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism
or any act of God;
• Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for
use 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.

General Information - 7
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
towing, storage, telephone, cell phone, fax or telegram charges, rental of a like or replacement Product or
boat 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 YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM
STATE TO STATE, OR PROVINCE TO PROVINCE.
No distributor, Dealer or any other person is authorized to make any affirmation, representation or war-
ranty regarding Product other than those contained in this limited warranty and, if made, shall not be en-
forceable against BMCA. BMCA reserves the right to modify this warranty at any time, being understood
that such modification will not alter the warranty conditions applicable to the Products sold while this war-
ranty is in effect.
8. TRANSFER
If the ownership of Product is transferred during the warranty coverage period, this warranty shall also be
transferred and be valid for the remaining coverage period provided that the former or new owner promptly
contacts BMCA 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 BMCA limited warranty, BMCA recom-
mends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer's
service manager or owner;
• If further assistance is required, please contact the Bombardier Motor Corporation of America Customer
Support Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090.
Revision March 2004
* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.

8- General Information
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005
JOHNSON 2-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distrib-
utor/dealer authorized to distribute Johnson 2-stroke products in the country in which the sale occurs.
If further assistance is required, please contact Bombardier Motor Corporation of America Customer Sup-
port Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Product
was registered for warranty.

General Information - 9
NOTES

10 - General Information
FEATURES
Item Description Item Description
1Tilt Support Lever 10 Steering Friction Adjustment Screw
2Water Pump Indicator 11 Stop Button/Emergency Stop Switch
3Tilt Friction Nut 12 Clip and Lanyard Assembly (1)
(1) Not supplied in all marketing areas
4Motor Angle Adjustment Rod 13 Emergency Restart Clip (1)
5Anticorrosion Anodes 14 Throttle Friction
6Lubricant Drain/Fill Plug 15 AC Lighting Inlet (2)
(2) Use with Optional Kit
7Lubricant Level Plug 16 Primer Knob
8Stern Brackets 17 Shift Lever
9Clamp Screws 18 Starter Handle
56
7
5
5
4
2
3
1
11
18
17
16
15
13
11
14
12
8
9
10
28
000291

General Information - 11
Item Description Item Description
19 Fuel Tank (1)
(1) Not supplied in all marketing areas
28 Model and Serial Number Plate
20 Installation Hardware 29 Spark Plugs
21 Fuel Connector 30 Water Pressure Tap
22 Idle Speed Adjustment Knob 31 Lifting Eye
23 Steering Handle and
Twist-Grip
TM Throttle 32 Fuel Pump Filter
24 Tilt/Run Lever 33 Starter Housing
25 Water Intakes 34 Fuel Line Filter
26 Propeller (1) 35 ECI Label
27 Trim Tab 36 Tool Kit (2)
(2) Not pictured
26
27
25
28
24
23
22
21
34
33 32 31
30
29
000292
35
19
20

12 - General Information
ENGINE SPECIFICATIONS
55 Model
Displacement 45 cu. in. (737 cc)
Engine Type Two-Cycle, In-line, 2 Cylinder
Loop-Charged
Full Throttle Operating Range 5000 to 5500 RPM
Power (1)
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
55 HP (41 kw) @ 5200 RPM
Idle RPM in Gear (2)
(2) Emission Control Information.
800 ± 30
Ignition Timing –Idle (2)
W.O.T.
1° ± 1° ATDC
19° ± 1° BTDC
Emission Control System:
per SAE J1930 (2)
EM (Engine Modification)
Fuel Requirements (2) 87 Pump Posted AKI (89 RON) – Refer to Fuel and Oil
Fuel/Oil 50:1
Spark Plug (2)
Torque
Refer to ECI Label
18 to 21 ft. lbs. (24 to 28 N·m)
AC Lighting (3)
(3) Available as optional kit.
60 watts AC @ 12 volts
Gearcase – Lubricant
Capacity
Evinrude/Johnson Ultra-HPF™ gearcase lubricant
22 fl. oz. (650 ml)
Propeller (4)
(4) Not supplied in all marketing areas.
13 3/4 x 15 in. (349 x 381 mm)
Fuel Tank (4) Capacity – 6 U.S. gallons (22.7 liters)
Weight (5)
(5) Does not include propeller or fuel.
191 lbs. (86.6 kg)
Transom Height 19 1/2 to 20 in. (495 to 508 mm)
Sound at Driver’s Ear
(LpA) ICOMIA 39.94
84.7 dB(A)
Vibration at Tiller (arms) Less than 2.5 m/s2

General Information - 13
EMERGENCY STOP SWITCH
If equipped, the emergency stop switch is on the
steering handle. Use of the emergency stop feature
is highly recommended on all boats.
Connect the clip to the emergency stop switch.
Snap the lanyard to a secure place on the opera-
tor’s clothing or life vest — not where it might tear
away instead of activating the stop switch. Discon-
necting the clip and lanyard will stop the engine and
prevent the boat from becoming a runaway if the
driver moves beyond the range of the lanyard. If the
lanyard is too long, it can be shortened by knotting
or looping it. DO NOT cut or retie the lanyard.
1. Emergency stop switch
2. Clip
An extra clip is provided — another person can in-
sert it in the stop switch and start the motor in an
emergency.
1. Extra clip
1
2
WARNING
Avoid knocking or pulling the clip off the
stop switch during normal boating. The
resulting unexpected loss of forward
motion can throw occupants forward, caus-
ing injury.
Your emergency stop switch can be effec-
tive only when in good working condition.
At each outing, inspect clip and lanyard for
cuts, breaks, or wear. Replace worn or dam-
aged parts.
Keep the lanyard free from obstructions and
entanglements.
At each outing, test the system’s operation.
With the engine running, remove the clip
from the switch by pulling the lanyard. If the
engine does not stop running, see your
Dealer.
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14 - Fuel and Oil
FUEL AND OIL
FUEL
Your outboard is certified to operate on unleaded
automotive gasoline with an octane rating equal to
or higher than that specified in Minimum Octane
chart. When using gasoline that contains MTBE or
alcohol, follow these guidelines:
Using unleaded gasoline that contains methyl ter-
tiary butyl ether (MTBE) is acceptable ONLY if the
MTBE content does not exceed 15% by volume.
Using alcohol-extended fuels is acceptable ONLY if
the alcohol content does not exceed:
10% ethanol by volume; or
5% methanol with 5% cosolvents by volume
Minimum Octane
Your outboard has been designed to operate using
the above fuels; however, be aware of the follow-
ing:
The boat’s fuel system may have different require-
ments regarding the use of alcohol fuels. Refer to
the boat’s Owner Guide.
Alcohol attracts and holds moisture that can cause
corrosion of metallic parts in the fuel system.
Alcohol blended fuel can cause engine perfor-
mance problems.
IMPORTANT: Always use fresh gasoline. Gasoline
will oxidize and weather; the result is loss of octane,
volatile compounds, and the production of gum and
varnish deposits which can damage the outboard.
WARNING
Gasoline is extremely flammable and highly
explosive under certain conditions. Follow
the instructions in this section explicitly.
Improper handling of fuel could result in
property damage, serious injury, or death.
Always turn off the engine before fueling.
Never permit anyone other than an adult to
refill the fuel tank.
Do not fill the fuel tank all the way to the top,
or fuel may overflow when it expands due to
heating by the sun.
Remove portable fuel tanks from the boat
before fueling.
Always wipe off any fuel spillage.
Do not smoke, or allow open flames or
sparks, or use electrical devices such as
cellular phones in the vicinity of a fuel leak
or while fueling.
Always work in a well-ventilated area.
Inside the U.S. 87 (R+M)/2 AKI
Outside the U.S. 89 RON
WARNING
Leaking fuel is a fire and explosion hazard.
All parts in the fuel system should be
inspected frequently and replaced if signs
of deterioration or leakage are found.
Inspect the fuel system each time you
refuel, each time you remove the engine
cover, and annually.

Fuel and Oil - 15
OIL
Evinrude/Johnson XD25™ formula outboard oil
is recommended for your outboard. It contains a
richer additive package than other TC-W3 oils, min-
imizing carbon build-up and deposits on pistons
and bearing surfaces. It provides 25% greater de-
tergency than minimum TC-W3 requirements.
Evinrude/Johnson brand oils are formulated to give
best engine performance while controlling piston
and combustion chamber deposits, providing supe-
rior lubrication, and ensuring maximum spark plug
life.
If
Evinrude/Johnson XD25 formula outboard oil is
not available, you must use an NMMA-certified TC-
W3 oil such as
Evinrude/Johnson direct injection oil
or
Evinrude/Johnson biodegradable outboard oil.
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 by
BMCA for your outboard. Use of other fuel additives
can result in poor performance or engine damage.
Evinrude/Johnson 2+4 Fuel Conditioner will help
prevent gum and varnish deposits from forming in
fuel system components and will remove moisture
from the fuel system. It can be used continuously
and should be used during any period when your
engine is not being operated on a regular basis. Its
use will reduce spark plug fouling, fuel system icing,
and fuel system component deterioration.
FUEL/OIL RATIO
New Engine
During break-in, you must use a 25:1 (4% oil) fuel/
oil ratio in your fuel tank. Refer to Break-In (10
Hours).
Normal Operation
After break-in, the engine must be operated at a
50:1 (2% oil) fuel/oil ratio.
High Performance
During high performance operation you must use a
25:1 (4% oil) fuel/oil ratio in your fuel tank.
MIXING FUEL AND OIL
Use the following chart and these guidelines to mix
oil with the engine’s fuel.
Portable Tank
Above and below 32° F (0°C), add one gallon of fu-
el. Pour in required amount of oil. Add remaining fu-
el. Install filler cap and tip tank gently to distribute
oil.
Permanently Installed Tank
Above 32° F (0° C), pour oil slowly with the fuel as
tank is filled. Below 32° F (0° C), add one gallon of
fuel to a separate container. Pour in required
amount of oil. Install filler cap and tip container gen-
tly to distribute oil. Slowly pour oil/fuel mixture into
tank with fuel as tank is filled.
Ratio Fuel
6 U.S. Gallons 3 U.S. Gallons 1 Liter
50:1 16 fl. oz. oil 8 fl. oz. oil 20 ml oil
25:1 32 fl. oz. oil 16 fl. oz. oil 40 ml oil

16 - Fuel and Oil
FUEL SYSTEMS
IMPORTANT: Fuel distribution hoses in the boat
must deliver fuel at the rate of flow needed by the
engine. Minimum inside diameter of fuel hoses
must be 5/16 in. (8 mm).
Fuel systems with built-in tanks, particularly those
that include antisiphon valves and filter/primer
units, may have restrictions that will not allow the
engine fuel pump to deliver sufficient fuel under all
conditions. This can result in a loss of performance
and possible engine damage. If a performance
problem exists, see your Dealer.
To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.
BREAK-IN (10 HOURS)
IMPORTANT: Follow this procedure to protect your
new outboard during its initial hours of operation.
Careful break-in allows internal engine components
to “seat” properly, resulting in maximum engine per-
formance.
Failure to carefully follow the break-in procedures
can result in engine damage.
During break-in, you must use extra oil. The fuel/oil
ratio for the first 10 hours of operation must be 25:1
(4% oil). The fuel/oil ratio during normal operation,
after break-in, must be 50:1 (2% oil).
Perform the 10-Hour break-in procedure with the
boat and engine in the water, using an appropriate
propeller.
DO NOT perform break-in using a flushing device.
DO NOT start-up or run the engine out of the water.
DO NOT leave a running engine unattended.
IMPORTANT: Before the first start-up of your
new engine:
• Read Engine Starting, Engine Stopping, and
Shifting and Speed Control.
• Check the gearcase lubricant level. Refer to Lu-
brication.
• Perform prelaunch checks of all equipment.
Launch the boat and start the engine according
to the procedures in Engine Starting.
• Verify water pump operation often. Look for a
steady stream of water from the water pump indi-
cator. If the stream of water stops, shut off the en-
gine to prevent damage. Find and correct the
cause, or see your Dealer before you continue.
• Verify shift function by shifting into gear and ob-
serving that the boat moves and that the move-
ment is in the same direction as the shifter. Refer
to Shifting and Speed Control.
• Change the RPM often. Avoid holding a throttle
setting longer than 15 minutes.
1. First 10 Minutes of Operation — Operate the
engine in gear at fast idle only.
2. Next 50 Minutes — Operate engine in gear at
various speeds no faster than 3500 RPM.
DO NOT hold a constant throttle setting. Change
engine speed every 15 minutes.
With easy planing boats, use full throttle to quickly
accelerate boat onto plane. Immediately reduce
throttle to one-half as soon as boat is on plane. BE
SURE boat remains on plane at this throttle setting.
3. Second Hour — Use full throttle to accelerate
boat onto plane, then reduce throttle setting to
three-quarters. BE SURE boat remains on plane at
this throttle setting.
At intervals, apply full throttle for periods of one to
two minutes, returning to three-quarters throttle for
a cooling period.
Change engine speed every 15 minutes.
4. Next Eight Hours — Avoid continuous full
throttle operation for extended periods.
Change engine speed every 15 minutes.
DO NOT exceed recommended maximum engine
RPM. Refer to Engine Specifications.
WARNING
If your motor is equipped with a quick-dis-
connect fuel hose, disconnect the fuel hose
from the motor and from the fuel tank when
the motor is not being used for a period of
time. Disconnecting the hose will avert fuel
leaks in the hose or at the engine.

Engine Starting - 17
ENGINE STARTING
BEFORE START-UP
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 occur
quickly. Refer to Engine Overheating or Flushing.
Move tilt/run lever to RUN. Be sure the engine is in
normal operating position. Refer to Tilting.
1. RUN position
Connect the fuel hose to the fuel connector.
1. Fuel hose connector
2. Fuel connector
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
which, if inhaled, can cause serious brain
damage or death.
WARNING
The engine cover is a machinery guard. DO
NOT operate your outboard with the cover
off unless you are performing maintenance,
and then be careful to keep hands, hair, and
clothing clear of all moving parts. Contact
with moving parts could cause injury.
DANGER
Contact with a rotating propeller is likely to
result in serious injury or death. Assure the
engine and prop area is clear of people and
objects before starting engine or operating
boat. Do not allow anyone near a propeller,
even when the engine is off. Blades can be
sharp and the propeller can continue to turn
even after the engine is off. Always shut off
the engine when near people in the water.
WARNING
Your motor has “impact protection” and
“reverse lock” only when the tilt/run lever is
in RUN position. If operated with the tilt/run
lever left in TILT position, the motor could
tilt into the boat suddenly, causing loss of
control or serious injury.
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18 - Engine Starting
If equipped, open vent screw on fuel tank’s filler
cap.
Squeeze fuel primer bulb, outlet end up, until firm.
1. Fuel tank operable vent
2. Fuel primer bulb
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. Emergency stop switch
Twist throttle grip to SHIFT or slower.
1. SHIFT
Move the shift lever to NEUTRAL. Refer to Shifting
and Speed Control.
Twist the throttle grip to START.
1. START
IMPORTANT: Avoid engine damage. DO NOT run
engine above START in NEUTRAL.
Start-up (Cold Engine)
Pull primer knob through its full stroke twice and re-
turn to the warm-up (color line showing) position. If
the motor does not start after a few rope pulls,
prime again.
1. Primer knob
2. Color line
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WARNING
Always shift to NEUTRAL before starting
the engine to prevent sudden boat move-
ment, which can cause injury.
WARNING
Start engine with shift lever in NEUTRAL.
Attempting to manually start the engine
while in gear may damage parts or cause
the start-in-neutral-only feature to become
inoperative.
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