1. Johnson Bombardier 25 Hp Manual
2. 2003 Johnson Bombardier 150 Manual

. 2004 Operator's Guide 90 THRU 175 HORSEPOWER PL, PX, CX, GL.

An Operator’s Readiness Test has been prepared on the last page of this Guide. 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. SAFETY — THE RIGHT PLACE TO GET STARTED.2 PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS.4 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA.5 BOMBARDIER LIMITED WARRANTY FOR JOHNSON 2-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA.

1-800-336-BOAT. For equipment. It will acquaint the operator and pas- additional information about boating safety and reg- sengers with the Evinrude/Johnson outboard and ulations call: U.S.

Coast Guard Boating Safety Hot- its controls, operation, maintenance and boating line 1-800-368-5647. It can be worsened or caused by weather, For more information, see your Evinrude/ mooring and operating conditions, and other Johnson DEALER for a copy of Introduction boats. Avoid exhaust fumes from your engine to High Performance Boating, P/N 335763. Bombardier Motor Corporation of America reserves DEALER.

For the name and location of the nearest the right to make changes at any time, without no- Evinrude/Johnson DEALER in the United States tice, to features, specifications and model availabil- and Canada log on to www.evinrude.com or ity. This warranty coverage is available only on Johnson 2-stroke outboard engines purchased as new and unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred ('Dealer'), and then only after the Bombardier specified pre-delivery inspection process has been com- pleted and documented by the purchaser and Dealer.

WHAT BOMBARDIER WILL DO Bombardier's obligations under this warranty are limited to, at its sole discretion, repairing or replacing parts of Product found to be defective in material or workmanship, in the reasonable judgment of Bombar- dier. Such repair or replacement of parts will be done without charge for parts and labor, at any authorized Dealer. 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.

ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA For a copy of the Limited Warranty, see your Bombardier distributor/dealer authorized to distribute Johnson 2-stroke products in the country in which the sale occurs. If further assistance is required, please contact Bombardier Customer Support Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of Bombardier where the Product was registered for war- ranty. General Information. FEATURES 000096 Item Description Item Description Maintenance Valve Lubricant Level Plug Fuel Filter Power Trim & Tilt Reservoir Engine Cover Latch Tilt Limiter Cam Fuel Fitting Speedometer Pick-up Connector Oil Supply Fitting Water Intake Battery Cable Air Silencer Engine Wire Harness System Check Gauge Tilt Support System Check Tachometer.

9,10 000097 Item Description Item Description Trailering Tilt Switch Flushing Port Power Trim & Tilt: Manual Release Water Pump Indicator Trailering Bracket Motor Cover Latch Trim Limiter Rod Fuse/Spare Fuse Holder Water Intake Remote Control Trim Tab Steering Connector Kit ECI Label Trim Gauge Model &. Alternator 20-Amp, Fully Regulated Gearcase – Lubricant Evinrude/Johnson Ultra-HPF™ gearcase lubricant Capacity PL, VL Models – 26 fl. (770 ml) PX Models – 44 fl. (1300 ml) Pwr. Trim/Tilt – Fluid Capacity 21 fl.

(622 ml) Propeller. P/N 514021 Fuel Filter P/N 433190 Alternator 35-Amp, Fully Regulated Gearcase – Lubricant Evinrude/Johnson Ultra-HPF™ gearcase lubricant Capacity 44 fl.

(1300 ml) Standard Rotation Pwr. Trim/Tilt – Fluid Capacity 21 fl.

(622 ml) Propeller Refer to Propeller Selection Fuel Tank Capacity –. Evinrude/Johnson outboards.

Trim/tilt switch (where equipped) Johnson controls deliver the cable stroke your out- 3. Fast idle button board needs for positive shift and throttle control, and they incorporate such safety and convenience 4.

Throttle Friction Control features as: 5. Emergency Stop/Key Switch WARNING A combination emergency stop switch and key switch is a feature of Evinrude/Johnson prewired remote controls and all Evinrude/Johnson control Avoid knocking or pulling the clip off the wiring kits. Use of the emergency stop feature is stop switch during normal boating.

ENGINE MONITORING IMPORTANT: Your outboard must be equipped If you want to continue to operate your outboard be- with the System Check ® (or equivalent) engine fore repairs are made, check the oil tank for con- monitor. Operating your outboard without the Sys- tents and condition. 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 biodegradable outboard oil.

IMPORTANT: Failure to follow this recommenda- tion could void the engine warranty if a lubrication- related failure occurs. 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. FUEL SYSTEM OIL SYSTEM IMPORTANT: You MUST prime the oil injection system BEFORE you prime the fuel system. Refer WARNING to Installing the Oil Supply Hose If the fuel system is primed first, see your DEALER. After this initial The outboard must be correctly installed.

Connection, the oiling system should NOT need Failure to correctly install the outboard priming unless problems occur due to an air leak in. Filling the Oil Tank Connect the oil supply hose to the oil inlet fitting on the motor. Secure with the clamp (13.8 mm) from Remove the filler cap and fill the tank with recom- the owner’s kit. Finish priming the system by mended outboard lubricant, as specified in Fuel squeezing the oil fill bulb two more times. BREAK-IN (10 HOURS) 1. First 10 minutes of operation — Operate the engine in gear at fast idle only.

IMPORTANT: Follow this procedure to protect your 2. Next 50 minutes — Operate engine in gear new outboard during its initial hours of operation. Below 3500 RPM. ENGINE STARTING If the fuel tank has an operable vent, open it.

Squeeze the fuel primer bulb, outlet end up, until DANGER firm. 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. Connect the clip to the emergency stop/key switch. Snap the lanyard to a secure place on the opera- WARNING tor’s clothing or life vest — not where it might tear away instead of activating the stop switch. DO NOT attempt to shift the engine into FORWARD or REVERSE while it is running at fast idle.

After Engine Starts ENGINE STOPPING DO NOT turn the key switch to START while the en- gine is running. Damage to the starter system could Move control handle to NEUTRAL. Turn key switch counterclockwise to OFF. Remove If the engine starts but needs more fuel to prevent the key when the boat will be unattended.

Binnacle Mount Control When ready to shift, move the control handle back to NEUTRAL. Engine speed will reduce and the Briskly and decisively, move the control handle fore shift function will automatically engage for move- or aft — until it engages the gear detent. Ment into FORWARD or REVERSE. OPERATION The power tilt is often used to tilt the engine for clearance when beaching, mooring, or launching. 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.

If needed, the outboard will tilt up or down manually: Trimming Turn the manual release screw counterclockwise, To operate the power trim, push and hold the trim/ slowly, until it lightly contacts its retaining ring — tilt switch in the desired bow direction, either bow- about 3 and 1/2 turns. Bow-Up Bow-Down BOW-UP position will give the best fuel economy BOW-DOWN position will give the best accelera- and highest top speed.

Tion onto plane and the best towing power for skiing. The bow-down position is normally used for accel- erating from a standing start or from idle speed.

Operating Conditions: In the bow-up position, your boat may tend to pull to Operating Conditions. PROPELLER SELECTION MOORING To select the correct propeller for your boating ap- You may moor your boat with the motor’s gearcase plication, your boat and motor MUST be water test- out of the water by using its tilt feature. Depending ed. FLUSHING 4) Place the remote control lever in NEUTRAL with the propeller removed. 5) Start the water — keep pressure between 20 to 40 psi (140 to 300 kPa). DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. ENGINE OVERHEATING IF the S.L.O.W.

Protection system activates and the stream from the water pump indicator becomes in- termittent or stops, reduce speed to idle and: IMPORTANT: Do not run your engine — even for a Shift to NEUTRAL; brief start-up — without supplying water to it. Refer to Flushing. TRAILERING WARNING Keep everyone clear of stern area when raising or lowering the outboard. Personal injury or death can result from contact with moving parts of the outboard.

Trailering Bracket To engage bracket — Tilt the motor fully using the tilt switch inside the boat or the trailering tilt switch. IMPACT DAMAGE If you hit any object, stop immediately and examine the engine for loosening of attaching hardware and clamp screws, if equipped. Inspect for damage to Your engine has a shock absorption system de- swivel and stern brackets, steering components, signed to help withstand damage from impact with and components in the area of impact. After operating your outboard, rinse it with fresh wa- NEUTRAL. Ter and wipe it dry.

Apply Evinrude/Johnson anti- If it is necessary to return to harbor with one engine corrosion spray to any surface subject to corrosion, not running, you should not attempt to operate the but avoid the anticorrosion anode(s). MAINTENANCE Maintenance, replacement, or repair of the To do the off-season storage preparations yourself, emission control devices and systems may be gather the supplies and perform the following steps: performed by any marine SI (spark ignition) en- 2+4 fuel conditioner gine repair establishments or individual. Replace damaged or missing parts with Evinrude/ Johnson Genuine Parts, or equivalent. Battery — Remove it, clean it, check its condition and water level, then charge it. Store it in a place that’s cool and dry, out of direct sunlight.

Do not use a booster battery and jumper any steering, throttle, and shift systems. Replace cables to start the engine.

Fumes vented damaged or missing parts with Evinrude/Johnson can cause explosion and fire, resulting in Genuine Parts or equivalent. Property damage, serious injury, or death. BATTERY Each outboard needs one battery that is:. 12-volt, heavy-duty, designated 'marine';. Vented/refillable or maintenance-free; and. Rated according to the minimum requirements in Engine Specifications.

Deep-cycle batteries are suitable IF they meet or exceed the minimum CCA requirements. Ask your DEALER about your outboard’s require- ments before installing longer battery cables, a bat- tery switch or a battery insulator. ADJUSTMENTS Tilt Limiter Cam If your outboard contacts the boat’s motor well while tilting, adjust the tilt limiter cam to limit maxi- Trim Tab mum tilt-up: WARNING Improper trim tab adjustment can cause dif- ficult steering. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. LUBRICATION Steering System The installer was instructed to grease the steering cable ram during installation. Periodic regreasing of Gearcase the steering cable ram with Triple-Guard grease is Replace gearcase lubricant after first 10 hours of required. Refer to Engine Maintenance and In- operation.

Power Trim and Tilt. Remove filler cap and check fluid level. If nec- essary, add enough Evinrude/Johnson Power Trim/ Tilt and Power Steering Fluid to bring the fluid level even with the bottom of the fill cap hole when the unit is at full tilt. DEALER for service. Refer to Engine Maintenance and Inspection Schedule for frequency. An Authorized Evinrude/Johnson DEALER should service the fuel filter. IMPORTANT: A restricted fuel delivery system will not allow the engine fuel pump to deliver sufficient fuel under all conditions.

SPARK PLUGS PROPELLER WARNING WARNING The ignition system presents a serious When servicing the propeller, always shift shock hazard. The primary circuit operates the outboard to NEUTRAL position, turn the in excess of 250 volts; the secondary circuit key switch OFF and disconnect battery neg- operates in excess of 25,000 volts.

90 PL, GL 115 PL, GL Repair Install propeller nut and tighten to a torque of 120 in. If your propeller hits a solid object, the impact is par- lbs. Tially absorbed by the rubber bushing in the hub to help prevent damage to the engine. TROUBLE CHECK CHART IMPORTANT: If you are unable to identify or solve the problem, contact your DEALER. SYMPTOM POSSIBLE CAUSE Starter motor will not operate.

Shift handle not in NEUTRAL. Battery and electrical connections loose or corroded.

Fuse blown. Refer to Fuses. ENGINE MAINTENANCE AND INSPECTION SCHEDULE Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following maintenance chart provides guidelines for engine maintenance and in- spection scheduled to be performed by you and/or by an authorized DEALER.

The schedule should be adjusted according to operating conditions and use. (2) Emission-related component (3) Do not use light duty penetrating lubricants Dealer Performed Service Operator Performed Service Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant Ultra-HPF gearcase lubricant Power Trim/Tilt Fluid Triple-Guard grease Evinrude/Johnson Moly Lube P/N 175356. Evinrude outboard. Evinrude and Johnson Genuine Parts and Johnson engines AND the type of boat you and accessories are designed by the same engi- use. It doesn’t matter whether you have an offshore neering team that designed your outboard.

CHANGE OF ADDRESS / CHANGE OF OWNERSHIP If your address has changed or if there has been a change of ownership, be sure to fill out and mail the card provided on this page. Such notification is likewise necessary for your own safety even after expiration of the original warranty, since Bombardier will be in a position to contact you if correction to your outboard becomes necessary.

Maintenance. NOTES Maintenance. The dealer named on this document has instructed me on the operation, maintenance, safety features and warranty policy, all of which I understand and agree to be bound with. I am also satisfied with the predelivery set-up and inspection of my Evinrude / Johnson Outboard. I have also received a copy of the Operator’s Guide. Readiness Test and a Final Word to the Owner/Operator The Operator’s Readiness Test.1.

Did you read this Guide from front cover to rear cover? Are you ready to take responsibility for the safe operation of your boat and motor?

Johnson Bombardier 25 Hp Manual

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2003 Johnson Bombardier 150 Manual

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