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Johnson 2 Stroke 40 HORSEPOWER User Manual

Johnson 2 Stroke 40 HORSEPOWER
52 pages
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R, RL
2 Stroke
40 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.
!
!
*215599*
2005
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Johnson 2 Stroke 40 HORSEPOWER Specifications

General IconGeneral
BrandJohnson
Model2 Stroke 40 HORSEPOWER
CategoryOutboard Motor
LanguageEnglish

Summary

Owner's Welcome and Safety

Operator's Guide Purpose

Emphasizes the guide for understanding operation, maintenance, and safety.

Operator Safety Responsibility

Highlights operator's role in ensuring safety of passengers and others.

Brand Trademarks

Lists trademarks of Bombardier Motor Corporation of America and its affiliates.

General Information and Safety

Getting Started Safely

Essential information to prevent injury and equipment damage; read guide thoroughly.

Understanding Safety Alerts

Explains DANGER, WARNING, CAUTION, and IMPORTANT signal words for safety messages.

Boating Safety Resources

Information on U.S. Coast Guard Auxiliary, Power Squadron, Red Cross classes.

General Information - Continued

Key Operational Safety Measures

Covers CO hazard, shallow water, passengers, PFDs, fuel safety, and avoiding impairment.

Installation and Maintenance Safety

Stresses proper installation, using correct parts, and following maintenance procedures.

Product References and Specifications

Model and Serial Number Identification

Location of model and serial numbers for owner identification and security.

Technical Literature and Documentation

Information on purchasing service manuals, parts catalogs, and operator's guides.

Limited Warranty - US and Canada

Warranty Scope and Period

Defines warranty coverage for defects and outlines coverage periods.

Warranty Coverage Conditions

Lists conditions for coverage, including dealer purchase and maintenance.

Limited Warranty - US and Canada (Continued)

BMCA Warranty Obligations

States BMCA's commitment to repair/replace defective parts at no charge.

Warranty Exclusions and Voiding Conditions

Lists items not covered and conditions that void the warranty.

Limited Warranty - US and Canada (Continued)

Liability Limitations and Transfer

Limits liability, excludes damages, and details warranty transfer.

Consumer Assistance and Support

Provides contact information for resolving warranty disputes.

Limited Warranty - Outside US and Canada

Warranty Information for International Sales

Refers to distributor/dealer for warranty details for sales outside North America.

Features and Components

Key Component Identification (1-9)

Identifies and describes components labeled 1 through 9 in the illustration.

Key Component Identification (10-18)

Identifies and describes components labeled 10 through 18 in the illustration.

Features and Components (Continued)

Key Component Identification (19-26)

Identifies and describes components labeled 19 through 26 in the illustration.

Key Component Identification (27-34)

Identifies and describes components labeled 27 through 34 in the illustration.

Engine Specifications

Engine Performance Details

Covers displacement, type, operating ranges, power, and RPM.

Fuel, Ignition, and Lighting Specifications

Lists ignition timing, fuel/oil, ignition features, AC lighting, torque.

Physical and Operational Dimensions

Covers propeller size, fuel tank, weight, transom height, sound, vibration.

Emergency Stop Switch

Proper Use and Testing

Explains connecting clip, snapping lanyard, and testing system operation.

Safety Precautions for Switch

Warns about accidental activation and stresses regular inspection.

Fuel and Oil

Fuel Requirements and Handling

Specifies fuel types, octane, alcohol limits, and safe fueling practices.

Oil Recommendations and Warnings

Recommends specific oils and warns about lubrication failure risks.

Fuel and Oil - Additives and Mixing

Fuel Additives and Conditioner

Advises using approved additives and explains conditioner benefits.

Fuel/Oil Ratio Guidelines

Details required fuel/oil ratios for new engines, normal, and high performance use.

Mixing Fuel and Oil Procedures

Provides chart and guidelines for mixing oil with fuel for portable and permanent tanks.

Fuel Systems and Break-In Procedure

Fuel System and Hose Requirements

Covers quick-disconnect hoses, hose diameter, and tank restrictions.

Break-In Procedure Importance

Stresses importance of break-in for engine seating and performance.

Break-In Operation and Ratio

Details steps for the first 10 hours, including varying speeds and the 25:1 ratio.

Engine Starting - Before Start-Up

Pre-Start Checklist and Warnings

Covers break-in, water supply, tilt lever, CO hazard, and engine cover.

Propeller Danger and Impact Protection

Warns about propeller contact and explains impact protection features.

Connecting Fuel Hose

Illustrates the process of connecting the fuel hose to the connector.

Engine Starting - Procedures

Fueling and Primer Bulb Operation

Instructs on opening fuel vent and priming the bulb.

Emergency Stop Switch Usage

Explains attaching the emergency stop switch clip and lanyard.

Neutral Shift, Starting Sequence, and Cold Start

Emphasizes neutral shift, starting sequence, and cold engine start-up steps.

Engine Starting - Post Start Procedures

Warm Engine Start-up and Primer

Explains starting a warm engine and the primer's functions.

Starter Handle Operation

Guides on pulling the starter handle to engage the starter.

After Start Checks and Warm-up

Instructs to check water pump indicator and allow engine warm-up.

Shifting and Speed Control

Pre-Departure System Checks

Emphasizes checking all systems before leaving the dock.

Shifting and Speed Control Operation

Details shifting between gears and controlling speed with the throttle grip.

Emergency Starting Procedure

Describes starting the engine using a cord if the starter fails.

Emergency Starting and Fuel Economy

Emergency Starting Conditions and Hook-up

Lists pre-start conditions and how to hook up the start cord.

Emergency Starting Operation

Guides on pulling the cord to start and post-start idle.

Fuel Economy Tips

Provides advice on saving fuel by adjusting throttle position.

Operation - Trim and Tilt

Critical Operation Safety Warnings

Covers CO hazard and rotating propeller danger.

Manual Trim System Operation

Covers Touch-Trim feature, test runs, and operation at idle/underway.

Bow-Up Trim Adjustment

Guides on tilting the motor up for bow-up trim.

Operation - Trim Adjustments and Effects

Bow-Up Trim Effects and Warnings

Covers adjustment, conditions, warnings, stability, and torque.

Bow-Down Trim Adjustment and Effects

Covers adjustment, conditions, and warnings.

Operation - Trailering and Tilting

Trailering Guidelines

Advises trailering with motor vertical and restraining it during transport.

Tilting Motor Operation

Details using the tilt grip and tilt/run lever for tilting motor up or down.

Launching with Tilted Motor

Advises on tilt/run lever position when launching with motor tilted.

Operation - Tilt Support and Motor Angle

Tilt Support Engage/Disengage

Explains how to engage and disengage the tilt support.

Motor Angle Adjustment Procedure

Details adjusting motor angle via rod and locknut for optimum performance.

Operation - Propeller and Flushing

Propeller Selection and RPM

Emphasizes water testing for correct propeller and running near midpoint RPM.

Moorings and Tilt Feature

Explains using tilt feature for mooring with gearcase out of water.

Flushing Procedure and Safety

Guides on flushing, including propeller removal and water pump checks.

Operation - Engine Overheating

Preventing Overheating and S.L.O.W. System

Covers keeping intakes clear, checking pump indicator, and S.L.O.W. protection.

Post-Overheat Dealer Checks

Recommends dealer checks for cylinder head screws, water pump, and thermostats.

Operation - Impact Damage and Storage

Impact Damage and Shock System

Explains shock absorption, risks of high-speed impacts, and reverse operation.

Post-Impact Inspection and Warnings

Advises immediate checks for damage and warns about unrepaired impact risks.

Short-Term Storage Guidelines

Advice for storing the motor between uses, including vertical positioning.

Special Operating Conditions

Salt Water and Weedy Water Operation

Covers flushing, anodic protection, mooring, and handling weeds.

Boat Finish Care and High Altitude

Importance of cleaning finish, and advice for high altitude operation.

Shallow Water, Freezing Weather, and Submerged Engine

Covers risks in shallow/freezing water and submerged engine service.

Towing Procedure

Steps for safely towing the boat, including neutral shift and tilting.

Maintenance - General and Storage

Maintenance Responsibilities and Warnings

States who can perform maintenance and warns against tampering with carburetor.

10-HOUR Inspection Importance

Details the significance and scope of the 10-hour inspection.

Off-Season Storage Preparation

Explains storage risks and lists preparation supplies.

Fuel Stabilization for Storage

Advises using fuel conditioner for engine stabilization during storage.

Maintenance - Storage and Pre-Season

Storage Procedures and System Checks

Covers fogging, system checks, fuel filter, fasteners, propeller, and exterior care.

Gearcase Lubrication and Storage Safety

Details gearcase lubrication, storage height warnings, and fuel tank safety.

Pre-Season Service Recommendations

Advises general checks, hardware, gearcase leak, and anode checks.

Fueling and Starting for Service

Instructions for fueling and starting the engine for pre-season checks.

Maintenance - Adjustments

Idle Speed Adjustment Procedure

Explains how to adjust idle speed using the knob.

Steering Friction Adjustment

Details initial friction setting and adjustment screw use.

Trim Tab Adjustment for Steering Torque

Explains trim tab use for compensating steering torque and its limitations.

Maintenance - Adjustments and Lubrication

Trim Tab Adjustment Steps

Step-by-step guide to adjust trim tab based on boat pull direction.

Gearcase Lubrication Schedule and Procedure

Details when to check/replace lubricant and the draining/filling process.

Recommended Lubricants and Warnings

Lists recommended gear lubricants and warns against automotive oils.

Maintenance - Lubrication Points and Fuel Pump

Lubrication Points Identification

Identifies key points for lubrication on swivel bracket, control shafts, and linkages.

Water Pressure Gauge Recommendation

Recommends an optional gauge to monitor cooling system pressure.

Fuel Pump Filter Service

States the fuel filter is in the motor's fuel pump and advises dealer service.

Maintenance - Fuel Filter and Water Pressure

Fuel Filter Service Procedure

Steps for washing, drying, and reassembling the fuel filter.

Fuel Spillage and Leakage Warnings

Warns about preventing fuel spillage and detecting leaks.

Maintenance - Spark Plugs and Propeller

Spark Plug Safety and Service

Covers ignition shock hazard, plug inspection, replacement, and installation.

Propeller Installation and Shaft Lubrication

Guides on propeller installation and annual shaft lubrication.

Maintenance - Propeller and Anodes

Propeller Nut and Repair Advice

Details securing propeller nut, advice on damaged propellers, and condition.

Anticorrosion Anode Function and Checks

Explains anode purpose, location, inspection, replacement, and painting warning.

Maintenance - Trouble Check Chart

Troubleshooting Engine Starting Issues

Lists possible causes for the engine not starting.

Troubleshooting Engine Performance Issues

Lists causes for improper idling, power loss, vibration, and progress issues.

Maintenance - Inspection Schedule Overview

Maintenance Schedule Importance and Lubricants

Stresses routine maintenance, recommended lubricants, and varied schedules.

Periodic Inspection Tasks (Chart)

Lists periodic inspection items for lubrication, checks, and system verification.

Maintenance - Detailed Inspection Schedule

Engine Cover, Guide, and Fuel System Schedule

Schedule for engine cover cleaning, guide review, and fuel system checks.

Fastener, Mount, Ignition, and Gearcase Schedule

Schedule for fastener, engine mount, ignition, and gearcase maintenance.

Powerhead, Spark Plugs, and Pump Schedule

Schedule for powerhead inspection, spark plugs, and water pump service.

Installation - General and Transom Height

Horsepower and Boat Matching Warnings

Warns against exceeding horsepower and mismatching boat/engine.

Transom Height and Stability

Explains transom height's role in stability and measuring it.

Mounting Surface and Lateral Movement Prevention

Stresses sound mounting surfaces and using proper hardware.

Installation - Motor Angle and Mounting

Motor Angle, Plate Position, and Height Risks

Details motor angle adjustment and risks associated with incorrect installation height.

Installation Warnings and Hardware Use

General installation warnings and advice on using mounting hardware.

Installation - Transom Drilling and Fastening

Centering Motor and Drilling Holes

Guides on centering the motor and drilling transom mounting holes.

Applying Caulk and Installing Fasteners

Details applying caulk and installing washers and locknuts.

Retightening Screws and Fastener Quality

Advises retightening screws and using quality replacement fasteners.

Maintenance - AC Lighting System

AC Lighting System Availability and Warnings

Mentions optional AC lighting and warns against direct battery connection.

AC Lighting Installation Details

Advises using 12-volt bulbs and proper wire routing through the engine cover.

Change of Address / Ownership

Notification Requirements and Purpose

Instructs on notifying for address/ownership changes for safety and contact.

Owner Information Fields

Fields for previous and new owner's contact details.

Operator's Guide Receipt Confirmation

Dealer and Owner Information Fields

Fields for dealer and owner details, including model and serial numbers.

Confirmation of Operator Instruction

Owner confirms receipt of instruction on operation, maintenance, safety, and warranty.

Operator Readiness Test and Final Word

Operator Readiness Test Questions

Lists 8 questions to assess operator's readiness and understanding of the guide.

Final Safety Advice

Emphasizes alertness, caution, and adherence to essential information for safety.

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