Johnson PL4 Manual

*5035761* WARNING
Read this Operator Guide thoroughly. It contains important
safety information. When operating your boat, always
have this Operator Guide onboard.
!!
PL4
4 Stroke
40/50 HORSEPOWER
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 BRP US Inc. 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.
Evinrude® Johnson®
Evinrude®/Johnson® Genuine Parts Hi-Vis™ gearcase lubricant
Evinrude®/Johnson® 4-Stroke outboard oil S.L.O.W.™
Evinrude®/Johnson® Ultra™ 4-Stroke synthetic blend oil SystemCheck™
Evinrude®/Johnson® anti-corrosion spray Triple-Guard® grease
2+4® fuel conditioner Ultra-HPF
™ gearcase lubricant
99011-87J06-BBD

© 2004 BPR US Inc. 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
BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA ................................................................................................ 5
BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA ................................................................................... 8
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ............................................................................ 9
FEATURES ............................................................................................................................................................... 12
ENGINE SPECIFICATIONS ...................................................................................................................................... 14
REMOTE CONTROL ................................................................................................................................................. 15
ENGINE MONITORING ...................................................................................................... 17
FUEL AND OIL ................................................................................................................... 18
FUEL ......................................................................................................................................................................... 18
OIL ............................................................................................................................................................................. 19
ADDITIVES ................................................................................................................................................................ 19
FUEL SYSTEM .......................................................................................................................................................... 19
BREAK-IN (10 HOURS) ............................................................................................................................................ 20
ENGINE STARTING ........................................................................................................... 21
BEFORE START-UP ................................................................................................................................................. 21
ENGINE STOPPING ................................................................................................................................................. 22
SHIFTING AND SPEED CONTROL ......................................................................................................................... 23
EMERGENCY STARTING ........................................................................................................................................ 24
FUEL ECONOMY ...................................................................................................................................................... 25
OPERATION ....................................................................................................................... 26
POWER TRIM AND TILT .......................................................................................................................................... 26
PROPELLER SELECTION ....................................................................................................................................... 29
MOORING ................................................................................................................................................................. 29
FLUSHING ................................................................................................................................................................ 29
ENGINE OVERHEATING .......................................................................................................................................... 30
TRAILERING ............................................................................................................................................................. 32
TILT SUPPORT ......................................................................................................................................................... 32
IMPACT DAMAGE .................................................................................................................................................... 33
STORING .................................................................................................................................................................. 33
SPECIAL OPERATING CONDITIONS ..................................................................................................................... 34
MAINTENANCE .................................................................................................................. 35
ENGINE EMISSIONS INFORMATION ...................................................................................................................... 35
10-HOUR INSPECTION ............................................................................................................................................ 36
OFF-SEASON STORAGE ........................................................................................................................................ 36
PRE-SEASON SERVICE .......................................................................................................................................... 38
BATTERY .................................................................................................................................................................. 39
CRANKCASE OIL AND FILTER .............................................................................................................................. 40
ADJUSTMENTS ........................................................................................................................................................ 42
LUBRICATION .......................................................................................................................................................... 43
WATER PRESSURE ................................................................................................................................................. 44
FUEL LINE FILTER ................................................................................................................................................... 44
FUSES ....................................................................................................................................................................... 45
SPARK PLUGS ......................................................................................................................................................... 45
PROPELLER ............................................................................................................................................................. 46
ANTICORROSION ANODES .................................................................................................................................... 47
TROUBLE CHECK CHART ...................................................................................................................................... 48
ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 50

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 fol-
lowed by any boater. Some rules may be new
to you and others may be common sense or
obvious... irrespective, take them seriously!
Failure 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
operator, 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 re-
sult in serious injury or death. Do not allow
anyone near a propeller, even when the en-
gine is off. Propeller blades can be sharp and
can continue to turn even after the engine is
shut off. Always 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 carbon monox-
ide (CO), which is odorless, colorless, and
tasteless, and can lead to unconsciousness,
brain damage, or death if inhaled in sufficient
concentrations. CO accumulation can occur
while docked, anchored, or underway, 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 oth-
er boats, provide proper ventilation, shut off
your engine when not needed, and be aware
of the risk of backdrafting and conditions that
create CO accumulation. In high concentra-
tions, CO can be fatal within minutes. Lower
concentrations are just as lethal over long pe-
riods of time.
Proceed with caution and at very low speed
in shallow water. Grounding or abrupt stops
may result in injury. Also be alert for debris
and objects in the water.
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 obstruc-
tions. Contact with underwater obstructions
may result in loss of control and personal in-
jury.
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
passengers when boating conditions are
hazardous, and by children and nonswim-
mers 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.
Failure to correctly install the outboard could
result 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 substan-
dard parts could result in injury or product
malfunction.
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
personal injury or death. Further information
can be obtained from your authorized
Evinrude/Johnson Dealer. In many instances
proper 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 prudently
and have fun. Do not forget that all persons
must assist other boaters in case of emer-
gency.
Prevent injury from contact with rotating pro-
peller; remove propeller before flushing or
before performing any maintenance.

4- General Information
PRODUCT REFERENCES,
ILLUSTRATIONS AND
SPECIFICATIONS
BRP US Inc. reserves the right to make changes at
any time, without notice, to features, specifications
and model availability. The right is also reserved to
change any specification or part at any time without
incurring any obligation to update older models.
The information 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
BRP US Inc. offers technical literature specifically
for your outboard. A service manual, a parts cata-
log, 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 Unit-
ed States and Canada visit www.evinrude.com or
www.johnson.com.
Declaration of Conformity
BRP US Inc. declares that the outboard to which
this Operator’s Manual applies conforms to the es-
sential requirements outlined in CE Machinery Di-
rective 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
BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD
ENGINES SOLD IN THE UNITED STATES AND CANADA
1. SCOPE OF THE LIMITED WARRANTY
BRP US Inc. warrants its 2005 Johnson® 4-stroke outboard engines 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:
THIRTY-SIX (36) CONSECUTIVE MONTHS for private, recreational use; or
TWELVE (12) CONSECUTIVE MONTHS for commercial use, except that emission-related components
providing 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 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 BRP US Inc. parts and accessories one-year limited warranty.
California residents who purchased or warranty-registered a Product in California should refer to BRP US
Inc.'s California Emissions Control Warranty Statement.
3. CONDITIONS TO HAVE WARRANTY COVERAGE
This warranty coverage is available only on Johnson 4-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 BRP US Inc. specified pre-delivery inspection process has been com-
pleted 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 BRP US Inc. 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. BRP US Inc. may require proof of proper maintenance prior to authorizing warranty
coverage.

6- General Information
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 BRP US Inc.
5. WHAT BRP US INC. WILL DO
BRP US Inc.'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 BRP US
Inc. Such repair or replacement of parts will be done without charge for parts and labor, at any authorized
Dealer. BRP US Inc.'s responsibility is limited to making the required repairs or replacements of parts with
new or BRP US Inc.-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.
BRP US Inc. 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 BRP US Inc., which in its reasonable judg-
ment, 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 BRP US Inc. BRP US Inc. 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 warranty 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 BRP US Inc. 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 US Inc. limited warranty, BRP US
Inc. recommends 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 BRP US Inc. 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
BRP US INC. LIMITED WARRANTY FOR 2005 JOHNSON 4-STROKE OUTBOARD
ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your BRP US Inc. distributor/dealer authorized to distribute
Johnson 4-Stroke products in the country in which the sale occurs.
If further assistance is required, please contact BRP US Inc. Customer Support Services, 250 Sea Horse
Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier Recreational Products Inc. where the Prod-
uct was registered for warranty.

General Information - 9
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, describes
the 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 conventional
carbureted two-stroke engines, saving money and resources.
Longer Emission Warranty
Protects consumer for worry free operation.
One Star – Low Emission
The one-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air 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 Emission
The two-star label identifies Personal Watercraft, Outboard, Sterndrive and Inboard engines that meet the
Air 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 Emission
The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Out-
board marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003
exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star
– Low Emission engines.
Four Stars – Super Ultra Low Emission
The four-star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine
engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also
comply 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-SMOG
www.arb.ca.gov
YOUR EMISSION CONTROL WARRANTY RIGHTS AND OBLIGATION
The California Air Resources Board and BRP US Inc. are pleased to explain the emission control system
warranty on your
Johnson 4-stroke outboard. In California, new outboard engines must be designed, built,
and equipped to meet the State's stringent anti-smog standards. BRP US Inc. must warrant the emission
control system on your outboard for the periods of time listed below provided there has been no abuse,
neglect, or improper 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 US Inc. will repair your outboard at no cost to you including
diagnosis, parts, and labor provided that such work is performed by an authorized BRP US Inc. dealer.

10 - General Information
Manufacturer's Limited Warranty Coverage
This emission limited warranty covers Johnson 4-stroke outboards certified and produced by BRP US Inc.
for sale in California, that are originally sold in California to a California resident, or subsequently warranty-
registered to a California resident. The BRP US Inc. U.S. and Canada limited warranty conditions for
Johnson 4-stroke outboards 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 purchase
by the first retail consumer or the date the product is first put to use, whichever occurs first, for a period
of: 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 the
appropriate hour meters or their equivalent. If any emission-related part on your engine is defective under
warranty, the part will be repaired or replaced by BRP US Inc.
Parts covered are:
Component Carbureted SPFI
Thermostat XX
Electrical System
Engine/Ignition Control Module XX
Spark Plugs, Boots, and/or Wires XX
Ignition Coils XX
Wiring Harness XX
Exhaust System
Engine Holder XX
Oil Pan XX
Exhaust Housing XX
Exhaust Valves XX
Fuel System
Fuel Pump(s) XX
Fuel Injectors X
Vapor Separator X
Carburetor and Internal Parts X
Accelerator Pump X
Choke System X
Crankcase Ventilation System Components XX
Fuel Lines, Fittings, Clamps XX
Air Induction System
Timing Chain/Belt and Tensioner XX
Camshaft and Followers XX
Intake Valves XX
Electronic Dash Pot System X
Throttle Body Assembly X
Idle Air Control X
Closed Throttle Position Switch X
Throttle Linkage XX
Intake Manifold XX
Sensors
Air Temperature Sensor X
Cam Position Sensor X
Crankshaft Position Sensor XX
Throttle Position Sensor X
Exhaust Temp Sensor X
Intake Manifold Pressure Sensor X
Cylinder Temperature Sensor XX
Gaskets
All Emission Component Gaskets XX

General Information - 11
The emission warranty covers damage to other engine components that is caused by the failure of a war-
ranted part.
The BRP US Inc. Operator's Guide provided contains written instructions for the proper maintenance and
use of your outboard. All emission warranty parts are warranted by BRP US Inc. for the entire warranty
period of the outboard, unless the part is scheduled for replacement as required maintenance in the Op-
erator's Guide.
Emission warranty parts that are scheduled for replacement, as required maintenance, are warranted by
BRP US Inc. for the period of time before the first scheduled replacement date for that part. Emission war-
ranty parts that are scheduled for regular inspection but not regular replacement are warranted by BRP
US Inc. for the entire warranty period of the outboard. Any emission warranty part repaired or replaced
under the terms of this warranty statement is warranted by BRP US Inc. for the remainder of the warranty
period of the original part. All parts replaced under this limited warranty become the property of BRP US
Inc.
Maintenance receipts and records should be transferred to each subsequent owner of the outboard.
Owner's Warranty Responsibilities
As the outboard owner, you are responsible for the performance of the required maintenance listed in your
Operator's Guide. BRP US Inc. recommends that you retain all receipts covering maintenance on your
outboard, but BRP US Inc. cannot deny warranty solely for the lack of receipts or your failure to ensure
the performance of all scheduled maintenance.
As the outboard owner, you should however be aware that BRP US Inc. may deny you warranty coverage
if your outboard or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifi-
cations.
You are responsible for presenting your outboard to an authorized BRP US Inc. dealer as soon as a prob-
lem exists. 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 the
nearest authorized BRP US Inc. dealer, contact BRP US Inc. Customer Support Services, 250 Sea Horse
Drive, Waukegan, IL 60085, 1-847-689-7090 or visit www.johnson.com.

12 - General Information
FEATURES
Item Description Item Description
1Fuel Line Filter 10 Battery Cable
2Emission Test Port 11 Power Trim & Tilt Reservoir
3Trim Limiter Rod 12 Fuel Connector
4Anti-ventilation Plate 13 30 Amp Fuse and Spare Fuses
5Propeller 14 Starter Motor Pinion
6Lubricant Drain/Fill Plug 15 Steering Connector
7Water Intakes 16 Installation Hardware
8Lubricant Level Plug 17 Tool Kit
9Anticorrosion Anode 18 Crankcase Oil Drain Screw Gasket
15
16
17
14
13
12
11
10
9
8
7
6
5
4
3
2
1
000131
18

General Information - 13
Item Description Item Description
19 15 Amp Fuse and Spare Fuses 28 Water Pump Indicator
20 Electric Fuel Pump 29 Engine Cover Latch
21 Trailering Tilt Switch 30 Dipstick
22 Tilt Support 31 Crankcase Oil Filter
23 Power Trim & Tilt: Manual Release 32 Oil Fill Cap
24 Trim Tab/Anode 33 Lifting Eye
25 ECI Label 34 Remote Control (1)
(1) not supplied with outboard
26 Model and Serial Number Plate 35 Fuel Tank (1)
27 Crankcase Oil Drain Screw 36 SystemCheck ™ Gauge (1)
19
20
21
22
23
25
7
24
27
28
29
30
31
32
33
26
000132
36
34
35

14 - General Information
ENGINE SPECIFICATIONS
40, 50 Models
Displacement 49.7cu. in. (815 cc)
Engine Type Four-Cycle, In-line, 3 Cylinder
Dual Overhead Cam, Electronic Fuel Injection
Full Throttle Operating Range 40 - 5200 to 5800 RPM
40 - 5600 to 6200 RPM (3)
50 - 5900 to 6500 RPM
Power (1)
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
40 - 40 HP (29.4 kw) @ 5500 RPM
40 - 40 HP (29.4 kw) @ 5900 RPM (4)
50 - 50 HP (36.8 kw) @ 6200 RPM
Idle RPM in Gear (2)
(2) Emission Control Information.
850 ± 50
Ignition Timing – Idle (2)
W.O.T.
Not Adjustable
Not Adjustable
Exhaust Emission Control System:
per SAE J1930 (2)
SFI
Fuel Requirements (2) 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil
Crankcase – Oil
Capacity
Filter
Evinrude/Johnson Ultra ™ 4-Stroke synthetic blend oil – Refer to Fuel and Oil
2.3 qts. (2.2 Liters)
See your Dealer
Warning Signals Engine Overheat and Low Oil Pressure
Ignition Features
S.L.O.W.™
Starting Remote electric
Battery, Minimum (3)
(3) Not supplied in all marketing areas.
(4) European model only (Model number BJ40PL4SO).
500 CCA (620 MCA) with 90 minutes reserve capacity
OR 60 ampere-hour, 12 volt
Spark Plug (2)
Torque
Refer to ECI Label
11 to 14 ft. lbs. (15 to 19 N·m)
Fuse Refer to Fuses
Fuel Line Filter P/N 5030702 – Refer to Fuel Line Filter
Alternator 13-Amp, Fully Regulated
Gearcase - Lubricant
Capacity
Evinrude/Johnson Ultra-HPF™ gearcase lube
21 fl. oz. (610 ml)
Pwr. Trim/Tilt - Fluid Capacity 12 fl. oz. (350 ml)
Propeller (3) 40 - 11 1/2 x 13 in. (29.2 x 33.0 cm)
50 - 11 3/8 x 14 in. (28.9 x 35.6 cm)
Weight 243 lbs. (110 kg)
Sound at Driver’s Ear
(LpA) ICOMIA 39.94
40 - 76.7 dB(A)
50 - 78.6 dB(A)
Transom Height 19 1/2 to 20 in. (49.5 to 50.8 cm)

General Information - 15
REMOTE CONTROL
IMPORTANT: When selecting the remote control
system for your boat, specify Evinrude/Johnson
components. Evinrude/Johnson offers remote con-
trols, cables and wiring kits designed specifically for
your
Evinrude/Johnson outboards. Evinrude/
Johnson
controls deliver the cable stroke your out-
board needs for positive shift and throttle control,
and they incorporate such safety and convenience
features as:
Start-in-gear prevention
Plug-in compatibility with
Evinrude/Johnson modu-
lar wiring system
Evinrude/Johnson Concealed side mount control
1. Handle – shift and throttle
2. Trim/tilt switch (where equipped)
3. Neutral lock tab
4. Fast idle button
5. Throttle friction control
Evinrude/Johnson Binnacle mount control
1. Handle – shift and throttle
2. Trim/tilt switch (where equipped)
3. Fast idle button
4. Throttle friction control
5. Emergency stop clip and lanyard
Evinrude/Johnson Side mount control
1. Handle – shift and throttle
2. Trim/tilt switch (where equipped)
3. Neutral lock tab
4. Fast idle lever
5. Emergency stop clip and lanyard
6. Throttle friction control
WARNING
If you choose a non- Evinrude/Johnson
remote control, be sure it has a start-in-gear
prevention feature. This feature can prevent
injuries resulting from unexpected boat
movement when the engine starts.
3
4
6
1
2
5

16 - General Information
Emergency Stop/Key Switch
A combination emergency stop switch and key
switch is a feature of
Evinrude/Johnson prewired
remote controls and all
Evinrude/Johnson control
wiring kits. Use of the emergency stop feature is
highly recommended on all boats.
Connect the clip to the emergency stop/key 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 and retie the lanyard. In
an emergency situation, the engine can be started
without the clip in place. Follow the normal starting
procedure. Reinstall a clip as soon as possible.
1. Clip
2. Emergency stop / key switch
3. Lanyard
WARNING
Avoid knocking or pulling the clip off the
stop switch during normal boating. Avoid
bumping the key if operating without the
clip on the switch. The resulting unexpected
loss of forward motion can throw occupants
forward, causing 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.

Engine Monitoring - 17
ENGINE MONITORING
IMPORTANT: Your outboard must be equipped
with the
SystemCheck (or equivalent) engine mon-
itor. Operating your outboard without the System-
Check
(or equivalent) engine monitor will void your
warranty for failures related to the functions moni-
tored on your engine.
When you turn the key switch ON, the
System-
Check
engine monitor horn performs a self-test by
sounding a 1/2-second beep. The gauge self-tests
by turning the warning lights on, then off in se-
quence. During engine start-up, pause with the key
switch in the ON position to observe the horn and
gauge perform the self-test. If the self-test does not
happen as stated, see your Dealer.
The
SystemCheck engine monitor alerts the opera-
tor with a 10-second beep of the horn and a warning
light on the gauge when certain engine problems
occur. The appropriate warning light will stay on
until the key switch is turned OFF.
If the engine management module (
EMM ) senses
that the problem could cause permanent engine
damage, it will also limit engine speed to 3000
RPM. This additional protection feature is referred
to as
S.L.O.W. ™ If the engine was running faster
than 3000 RPM when the
S.L.O.W . system activat-
ed, it will shake noticeably.
1.
SystemCheck gauge
2.
SystemCheck gauge with tachometer
"NO OIL"
The engine’s oil pressure is too low to continue nor-
mal operation. Serious engine damage can occur
quickly. The
EMM will limit the engine speed to
3000 RPM.
Causes of low oil pressure can include:
• Insufficient oil in the crankcase.
• Air in the system causing oil to foam.
• Malfunction of oil delivery components.
• Blockage of oil system components.
To RESET the
S.L.O.W. protection system, slow
the engine to 800 RPM or shut it OFF.
Return to harbor if you cannot restore adequate oil
pressure. For more information about evaluating
low oil pressure, refer to Low Oil Pressure Warn-
ing.
"WATER TEMP" or HOT
The engine is overheating. Serious engine damage
can occur quickly.
If the engine is overheating, it will also activate
S.L.O.W. and limit engine speed to 3000 RPM.
IMPORTANT: Refer immediately to Engine Over-
heating.
CAUTION
In the S.L.O.W. mode, the engine speed is
limited. Under certain conditions, the
engine’s limited speed may reduce maneu-
verability of your boat.
If the
S.L.O.W. mode is activated and you
are unable to correct the problem, seek
assistance and/or return to safe harbor.
Serious engine damage, engine shutoff,
and/or reduced maneuverability may be
imminent.
2
1

18 - 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. 90 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.