2003 Johnson Evinrude 90HP, 105HP, 115HP 2-Stroke Parts Catalog Manual

90, 105, 115HP MODELS J90PLSTC J90GLSTA J115PLSTS J115GLSTA J115PXSTS J105WPLSTM 90, 105, 115 60° V4

ABOUT THIS CATALOG Bombardier 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 this catalog is based on the latest specifications available at the time of publication. Illustrations are for reference only and might not depict the actual equipment described. Specifications and recommendations are based on the latest information available at the time of publication. The con- tinuing accuracy of this booklet cannot be guaranteed. Certain features or equipment shown in this catalog might not be found on all models in all marketing areas. IMPORTANT: This catalog is a part reference. Refer to the appropriate Service Manual for exact service and maintenance information. FEATURES Use exact engine model number, including any suffix letter, when indentifying parts in this catalog. WARNING 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 malfunction. Indented part names indicate that the parts are included in the preced- ing assembly. 1 582365 LEAD Assy, Spark Plug 2 581027 *COVER & TERMINAL Ass y 3 510231 **TERMINAL, Spring 4 580339 *COVER & TERMINAL Ass y 5 510231 **TERMINAL, Spring 6 328701 LOCK WASHER, COIL & stop sw. grd

1 90, 105, 115 60° V4 TABLE OF CONTENTS ENGINE COVER ........................................................................................................................ 2 DECALS (GRAPHITE MODELS) ............................................................................................... 3 DECALS (WHITE MODELS) ...................................................................................................... 4 FUEL HOSE AND FILTER - J105WPLSTM MODEL ................................................................ 5 STEERING LINK KIT .................................................................................................................. 5 DUAL STEERING CONNECTOR KIT ........................................................................................ 5 LOWER ENGINE COVER ...................................................................................................... 6-7 ENGINE ELECTRICAL HARNESS ASSEMBLY .................................................................... 8-9 ELECTRICAL SYSTEM ...................................................................................................... 10-11 FUEL COMPONENTS ........................................................................................................ 12-13 FUEL COMPONENTS - J105WPLSTM MODEL ............................................................... 14-15 PRIMER SYSTEM - J105WPLSTM MODEL ............................................................................ 15 CARBURETOR & INTAKE MANIFOLD ............................................................................. 16-17 THROTTLE LINKAGE .............................................................................................................. 18 CRANKSHAFT & PISTONS ..................................................................................................... 19 CYLINDER & CRANKCASE ............................................................................................... 20-21 ELECTRIC STARTER .............................................................................................................. 22 EXHAUST HOUSING ............................................................................................................... 23 MIDSECTION ...................................................................................................................... 24-25 POWER TRIM/TILT HYDRAULIC ASSEMBLY ........................................................................ 26 POWER TRIM/TILT ELECTRICAL ........................................................................................... 27 GEARCASE - PLS, GLS MODELS .................................................................................... 28-29 GEARCASE - PXS, WPL MODELS ................................................................................... 30-31 LITERATURE PAINT COLOR NAME SPRAY CAN PPG # 1 1. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER ENGINE COVERS PPG # 2 2. ONE COAT FINISH FOR MIDSECTION & GEARCASE PRIMER 771227 DP40401 – BLACK 3 3. USED ON ENGINE CRANKCASE ASSEMBLY. 771234 9696 – GRAPHITE 771232 35718 – WHITE 771226 90538 – CLEARCOAT 772414 – – 5005463 SERVICE MANUAL– ENGLISH 215424 OPERATOR’S GUIDE – ENGLISH 215425 OPERATOR’S GUIDE – FRENCH 215426 OPERATOR’S GUIDE – SPANISH 215427 OPERATOR’S GUIDE – PORTUGUESE 215400 OPERATOR’S GUIDE (J105WPLSTM) – ENGLISH 215401 OPERATOR’S GUIDE (J105WPLSTM) – FRENCH 215402 OPERATOR’S GUIDE (J105WPLSTM) – SPANISH 215403 OPERATOR’S GUIDE (J105WPLSTM) – PORTUGUESE

2 ENGINE COVER 8 4 2 2 3 3 5 5 7 6 1 EPC3073 Ref P/N Name of Part Qty Ref P/N Name of Part Qty 1 5005010 ENGINE COVER Assy A,D 1 4 344387 *SEAL, Engine cover 1 1 5005027 ENGINE COVER Assy B,D 1 5 346780 *BRACKET, Front & Rear 2 1 5005249 ENGINE COVER Assy B,C,D 1 6 348211 *SOUND BLANKET, Port 1 2 328744 *SCREW, Hook 4 7 348212 *SOUND BLANKET, Stbd 1 3 5001931 *HOOK 2 8 431929 ADHESIVE KIT, Locating brackets 1 A WHITE - Engine Cover B GRAPHITE - Engine Cover C J105WPLSTM Model Only D IMPORTANT: When ordering "ENGINE COVER Assy" also order appropriate "HP" decals.

3 90, 105, 115 60° V4 DECALS (GRAPHITE MODELS) 2 3 7 5 6 1 9 8 4 EPC3672 Ref P/N Name of Part Qty Ref P/N Name of Part Qty 1 350231 DECAL, "BOMBARDIER", F/R A,B 2 6 350234 DECAL, Stripe - Port A,B 1 2 350230 DECAL, "JOHNSON", Port/Stbd A,B 2 7 350237 DECAL, 90 HP, Front/Rear 2 3 350236 DECAL, "JOHNSON", Front/Rear A,B 2 8 350371 DECAL, 105 HP, Front/Rear 2 4 350378 DECAL, "COMMERICAL" B 2 9 350238 DECAL, 115 HP, Front/Rear 2 5 350232 DECAL, Stripe - Stbd A,B 1 A Included with P/N 5005027 "ENGINE COVER Assy" B Included with P/N 5005249 "ENGINE COVER Assy"

4 DECALS (WHITE MODELS) 2 6 7 5 3 4 1 EPC3673 Ref P/N Name of Part Qty Ref P/N Name of Part Qty 1 350165 DECAL, "BOMBARDIER", F/R A 2 5 350189 DECAL, "JOHNSON", Front/Rear A 2 2 350199 DECAL, "JOHNSON", Port/Stbd A 2 6 350190 DECAL, 90 HP, Front/Rear 2 3 350185 DECAL, Stripe - Port A 1 7 350191 DECAL, 115 HP, Front/Rear 2 4 350186 DECAL, Stripe - Stbd A 1 A Included with P/N 5005010 "ENGINE COVER Assy"

5 90, 105, 115 60° V4 FUEL HOSE AND FILTER - J105WPLSTM MODEL STEERING LINK KIT DUAL STEERING CONNECTOR KIT EPC1259 Ref P/N Name of Part Qty 439186 HOSE & FILTER ASSY. A 1 176853 *PRIMER BULB & HOSE KIT A 1 1 **HOSE, Outlet, 99 in. (2,5m) B 1 2 **HOSE, Inlet, 19½ in. (495mm) B 1 3 176444 **PRIMER BULB ASSY. 1 4 553166 ***CLAMP 2 5 911616 ***HOSE CLAMP 2 6 333437 **CLAMP, Band 2 7 176445 **FUEL CONNECTOR 1 8 334913 ***O-RING 1 9 338520 *FILTER SCREEN 1 A Not Shown B Cut to Length from P/N 125115- 3/8 in. I.D. EPC3016 Ref P/N Name of Part Qty 175125 STEERING LINK KIT 1 1 315077 *LOCKNUT 2 2 175110 *ROD Assy 1 3 319453 *WASHER 2 EPC3017 Ref P/N Name of Part Qty 175322 DUAL CABLE STEERING KIT A 1 1 123077 *SCREW, Cable to connector 2 2 126296 *BRACKET, Steering tube 1 3 123204 *NUT, Steering tube 2 4 126299 *CONNECTOR, Cables to rod 1 5 315077 *LOCKNUT 4 6 319453 *WASHER 2 7 328694 *SCREW, Bracket 4 8 126617 *STEERING TUBE 1 9 319316 *WASHER, Steering tube 2 10 319253 *LUBE FITTING, 45° 2 11 337586 *WIPER NUT 1 A Accessory

6 LOWER ENGINE COVER 34 20 19 22 23 21 24 27 26 23 25 28 29 30 36 42 37 35 39 38 33 32 31 34 34 34 40 41 15 43 16 14 13 12 10 11 10 42 6 2 3 4 5 44 1 42 42 9 8 7 16 17 16 18

7 90, 105, 115 60° V4 LOWER ENGINE COVER EPC3074 Ref P/N Name of Part Qty Ref P/N Name of Part Qty 1 5005029 ENGINE COVER, Port A 1 23 308532 *BUSHING, Latch lever 2 1 5005012 ENGINE COVER, Port B 1 24 307256 *LUBRICATION FITTING 1 2 586074 *SWITCH Assy, Trim & tilt 1 25 330234 *SPRING WASHER, Latch handle 1 3 514679 **TERMINAL, Pin 3 26 436048 *CHECK VALVE Assy, Drain 1 4 514686 **CONNECTOR, 3-pin 1 27 202893 *O-RING 1 5 514682 **LOCK WEDGE 1 28 343578 *HOOK, Front & rear 1 6 334656 *NUT, Switch 1 29 342191 *SCREW, Handle to latch 1 7 339575 *SCREW, Ball j oint 1 30 335500 *SEAL, Stbd D 1 8 328735 *WASHER, Screw, ball j oint 1 31 309485 *NUT, Screw, ball j oint 1 9 309485 *NUT, Screw, ball j oint 1 32 328735 *WASHER, Screw, ball j oint 1 10 308532 *BUSHING, Latch lever 2 33 339575 *SCREW, Ball j oint 1 11 435026 *LATCH HANDLE 1 34 *SEAL, Engine cover C AR 12 330234 *SPRING WASHER, Latch handle 1 35 350242 *COVER, Cable entry A 1 13 343578 *HOOK, Front & rear 1 35 350206 *COVER, Cable entry B 1 14 342191 *SCREW, Handle to latch 1 36 5004576 *VALVE Assy 1 15 335499 *SEAL, Port D 1 37 343505 SCREW, Cover 3 16 *SEAL, Engine cover C AR 38 348811 GROMMET, Cable entry 1 17 5004576 *VALVE Assy 1 39 343912 SLEEVE, Fuel & electrical 1 18 307256 *LUBRICATION FITTING 1 40 349556 WASHER, Mount 4 19 5005031 ENGINE COVER, Stbd A 1 41 349557 MOUNT, Lower cover 4 19 5005014 ENGINE COVER, Stbd B 1 42 325115 SCREW, Lower cover 1 3/4 in. (44.5mm) 4 20 315656 *SCREW, Access panel 2 43 333676 SCREW, Lower cover 1 1/4 in. (31.8mm) 1 21 438604 *ACCESS PANEL 1 44 317972 SCREW, Lower cover 4 1/4 in. (107.9mm) 1 22 435026 *LATCH HANDLE 1 A Painted GRAPHITE B Painted WHITE C Cut to length from P/N 331018 D Included in POWERHEAD GASKET SET

8 ENGINE ELECTRICAL HARNESS ASSEMBLY 32 16,35 19,20,24 6 6 8,11 12,15 3,4,5,26 25,28,31 26,27,29,30 17,18,23 10,35 7,9 26 2,12 25,33,34 13,14 7,9 19,21,22 STARTER SOLENOID FUSE ASSEMBLY TEMP SWITCH TAN POWER PACK ENGINE GROUND RECTIFIER / REGULATOR CONTROL HARNESS TEMP SWITCH WHITE/BLACK STRIPE STARTER SOLENOID YELLOW/RED TRIM AND TILT SWITCH OIL TANK OIL METERING CIRCUIT TNT SENDING UNIT GROUND PRIMER SOLENOID CONTROL HARNESS IN POSITION #2 STARTER SOLENOID BLACK PRIMER SOLENOID FUSE COVER DIODE 36 1 37 38

2003 Johnson Evinrude 90HP, 105HP, 115HP 2-Stroke Parts Catalog Manual

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