90, 115HP
4 STROKE MODELS
J90PL4STS
BJ90PL4STS
J90PX4STS
BJ90PX4STS
J115PL4STS
BJ115L4STS
J115PX4STS
BJ115X4STS
90, 115 4 STROKE
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 used in this catalog may not depict actual models or equipment, but are intended as repre-
sentative views for reference only. The continuing accuracy of this catalog 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 Bombardier 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 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, 115 4 STROKE
TABLE OF CONTENTS
DECALS ......................................................................................................................................................................................... 2
ENGINE COVER ............................................................................................................................................................................ 2
LOWER ENGINE COVER .............................................................................................................................................................. 3
CYLINDER HEAD .......................................................................................................................................................................... 3
CYLINDER & CRANKCASE............................................................................................................................................................ 4
CRANKSHAFT & PISTONS ........................................................................................................................................................... 5
TIMING CHAIN ............................................................................................................................................................................... 5
CAMSHAFT .................................................................................................................................................................................... 6
INTAKE MANIFOLD ....................................................................................................................................................................... 7
AIR SILENCER ............................................................................................................................................................................... 7
FLYWHEEL COVER ...................................................................................................................................................................... 8
FLYWHEEL .................................................................................................................................................................................... 8
RECTIFIER ..................................................................................................................................................................................... 9
IGNITION COIL .............................................................................................................................................................................. 9
ENGINE ELECTRICAL HARNESS .............................................................................................................................................. 10
ENGINE CONTROL MODULE & POWER TRIM SWITCH .......................................................................................................... 10
FUEL VAPOR SEPARATOR ........................................................................................................................................................ 11
FUEL PUMP ................................................................................................................................................................................. 11
FUEL INJECTOR ......................................................................................................................................................................... 12
THROTTLE BODY ....................................................................................................................................................................... 12
SENSOR GROUP ........................................................................................................................................................................ 13
OIL PUMP .................................................................................................................................................................................... 13
EXHAUST ADAPTER ................................................................................................................................................................... 14
EXHAUST HOUSING ................................................................................................................................................................... 14
OIL PAN ....................................................................................................................................................................................... 15
STERN BRACKET ....................................................................................................................................................................... 15
SWIVEL BRACKET ...................................................................................................................................................................... 16
GEARCASE .................................................................................................................................................................................. 17
GEARS ......................................................................................................................................................................................... 18
WATER PUMP ............................................................................................................................................................................. 19
THERMOSTAT ............................................................................................................................................................................. 20
SHIFT ROD .................................................................................................................................................................................. 20
SHIFT LINKAGE ........................................................................................................................................................................... 21
STARTER MOTOR ...................................................................................................................................................................... 21
TRIM CYLINDER .......................................................................................................................................................................... 22
TRIM MOTOR .............................................................................................................................................................................. 23
STEERING AND CONTROL COMPONENTS ............................................................................................................................. 23
GASKET SET ............................................................................................................................................................................... 24
LITERATURE
PAINT
COLOR
NAME
SPRAY CAN
PPG #
1
1. ONE COAT FINISH FOR MIDSECTION & GEARCASE
PPG #
2
2. BASE COAT PLUS CLEARCOAT FOR UPPER & LOWER
ENGINE COVERS
PRIMER 771227 DP40401 –
BLACK
3
3. USED ON ENGINE CRANKCASE ASSEMBLY.
771234 9696 –
WHITE 771226 90538 –
CLEARCOAT 772414 – –
5005467 SERVICE MANUAL
5033281 OPERATOR’S GUIDE – ENGLISH
5033282 OPERATOR’S GUIDE – FRENCH
5033283 OPERATOR’S GUIDE – SPANISH
5033284 OPERATOR’S GUIDE – PORTUGUESE
2
DECALS
ENGINE COVER
5
4 3
2
1
6
7
EPC3500
Ref P/N Name of Part Qty
1 5033237 DECAL, Stri pe, Stbd A 1
2 5033236 DECAL, Stri pe, Port A 1
3 5033242 DECAL, "BOMBARDIER" A 2
4 5032867 DECAL, "Johnson" - Port, Stbd A 2
5 5033239 DECAL, "90HP" 1
6 5033240 DECAL, "115HP" 1
7 5032816 DECAL, FUEL 1
A
Included with "ENGINE COVER Assy".
2
4
5
6
7
8
9
11
12
13
14
15
18
17
16
3
10
1
3
15
15
4
19
EPC3464
Ref P/N Name of Part Qty
1 5033573 ENGINE COVER Assy A 1
2 5033862 *BRACKET 1
3 5033866 *BRACKET, FASTENER 2
4 5033602 *RIVET 4
5 5033603 *RIVET 3
6 5033574 *HANDLE, TILT UP 1
7 5033859 *LOUVER 1
8 5033860 *SEAL 1
9 5033861 *FASTENER 1
10 5033867 *FASTENER, REAR STBD 1
11 5033868 *FASTENER, REAR PORT 1
12 5030560 *CUSHION 2
13 5033620 *CUSHION 2
14 5033606 *CAP 3
15 5030988 *BOLT 3
16 5030989 *BOLT 4
17 5030990 *BOLT 1
18 5031012 *SCREW 3
19 5032528 TOOL SET 1
A
IMPORTANT: When ordering "ENGINE COVER Assy"
also order appropriate "HP" Decal.
3
90, 115 4 STROKE
LOWER ENGINE COVER
CYLINDER HEAD
16
27
26
25
24
23
22
21
28
31
29
30
2
4
5
6
7
8
9
11
12
13
14
15
20
19
18
17
3
10
1
22
23
24
24
23
25
22
33
32
36
38
35
37
34
EPC3465
Ref P/N Name of Part Qty
1 5033857 SEAL, SIDE COVER - UPPER 1
2 5033858 SEAL, SIDE COVER - LOWER 1
3 5033578 COVER, SIDE STBD 1
4 5032128 PLUG, SIDE COVER 1
5 5033579 COVER, SIDE PORT 1
6 5033869 HOLDER, SIDE COVER 1
7 5033580 PANEL, FRONT 1
8 5030402 BOLT (8X40mm) 2
9 5033589 SCREW (6X35mm) 7
10 5033590 SCREW (6X55mm) 2
11 5030473 WASHER 2
12 5030558 CUSHION 2
13 5033619 CUSHION 2
14 5031906 PIN 2
15 5031279 CLIP 1
16 5033575 LEVER, HOOK RR STBD 1
17 5033576 LEVER, HOOK RR PORT 1
18 5033863 HOOK, ENGINE COVER RR STBD 1
19 5033864 HOOK, ENGINE COVER RR PORT 1
20 5033865 HOOK, ENGINE COVER FRONT 1
21 5033577 LEVER, HOOK FRONT 1
22 5031821 BOLT (6X12mm) 3
23 5031833 WASHER (13.2X25X1.0mm) 3
24 5031858 WASHER, WAVE 3
25 5033518 BUSHING, REAR 2
26 5033617 BUSHING, FRONT 1
27 5033572 GROMMET, CONTROL CABLE 1
28 5033581 HOLDER, CONTROL CABLE 1
29 5033582 STOP, CONTROL CABLE 1
30 5030347 STRAP 1
31 5030989 BOLT 2
32 5034131 BOLT 1
33 5034142 WASHER (6.5X20X2.0mm) 1
34 5034396 FUEL CONNECTOR 1
35 5030031 BOLT (6X15) 1
36 5030051 NUT 1
37 5030430 WASHER 1
38 5034397 SPACER 1
16
17
18
19
20
12
11
9
10
3
4
2
1
5
7
21
14
13
17
15
6
8
EPC3467
Ref P/N Name of Part Qty
1 5033635 HEAD, CYLINDER 1
2 5033636 *GUIDE, VALVE 16
3 5033638 *BOLT, CAM SHAFT HOUSING 21
4 5030515 *PIN 18
5 5031914 BOLT, CYLINDER HEAD 10
6 5033639 GASKET, CYLINDER HEAD 1
7 5031000 BOLT 8
8 5031014 PIN 2
9 5033640 COVER, CYLINDER HEAD 1
10 5033641 PLATE, BREATHER 1
11 5033642 GASKET, SPARK PLUG HOLE 4
12 5033643 GASKET, CYLINDER HEAD COVER 1
13 5030633 CAP, OIL FILLER 1
14 PROTECTOR, BREATHER HOSE A 1
15 5030541 O RING 1
16 5031064 HOSE, BREATHER 1
17 5032822 CLIP 2
18 5030985 BOLT 11
19 5034124 BOLT 4
20 5034134 SCREW 7
21 5033634 SPARK PLUG (BKR6E) 4
A
Cut to length from P/N 5032912
4
CYLINDER & CRANKCASE
12
6
5
2
1
6
5
10
9
8
7
11
4
3
EPC3466
Ref P/N Name of Part Qty
1 5033646 HOOK, ENGINE 1
2 5034129 BOLT 2
3 5033647 BLOCK, CYLINDER 1
4 5033637 *BOLT, CRANKCASE 10
5 5033645 *GASKET, OIL GALLERY PLUG 3
6 5033604 *PLUG, OIL GALLERY 3
7 5034146 *COVER, C/C WTR JKT 1
8 5033648 *O RING, C/C WTR JKT COVER 1
9 5031066 *PIN 5
10 5030000 *BOLT 8
11 5030998 *BOLT 10
12 5030521 PLUG 1
5
90, 115 4 STROKE
CRANKSHAFT & PISTONS
TIMING CHAIN
12
4
13
7
6
5
3
2 1
10
9
8
11
EPC3468
Ref P/N Name of Part Qty
1 5033653 PISTON 4
2 5033654 RING SET, PISTON 4
2 5033655 RING SET, PISTON (OS:0.050mm) A 4
3 5033871 PIN, PISTON 4
4 5033623 CIRCLIP 8
5 5033522 CONNECTING ROD Assy 4
6 5033514 *NUT 8
7 5033521 BEARING SET, CONNECTING ROD 4
7 5033911 BEARING SET, CONNECTING ROD A 4
(US:0.25mm)
8 5033523 CRANKSHAFT 1
9 5033529 BEARING SET, CRANKSHAFT - Green 5
9 5033530 BEARING SET, CRANKSHAFT - Black 5
9 5033531 BEARING SET, CRANKSHAFT - No color 5
9 5033532 BEARING SET, CRANKSHAFT - Yellow 5
9 5033533 BEARING SET, CRANKSHAFT - Blue 5
9 5033524 BEARING SET, CRANKSHAFT A 5
(US:0.25mm) - Green
9 5033525 BEARING SET, CRANKSHAFT A 5
(US:0.25mm) - Black
9 5033526 BEARING SET, CRANKSHAFT A 5
(US:0.25mm) - No color
9 5033527 BEARING SET, CRANKSHAFT A 5
(US:0.25mm) - Yellow
9 5033528 BEARING SET, CRANKSHAFT A 5
(US:0.25mm) - Blue
10 5033872 BEARING SET, CRANK THRUST 1
10 5033873 BEARING SET, CRANK THRUST A 1
(OS:0.12mm)
11 5030550 SEAL, OIL 1
12 5033652 PISTON SET (OS:0.50mm) A 4
13 5033656 *RING SET, PISTON (OS:0.50mm) A 4
A
Optional
17
11
6
1
2
9
7
5
14
19
10
4
3
3
8
12
13
16
20
18
15
EPC3470
Ref P/N Name of Part Qty
1 5033662 GEAR, DRIVEN 1
2 5033663 PLUG, DRIVEN GEAR 1
3 5033664 SPROCKET, CAM SHAFT TIMING 2
4 5033585 BOLT (12X25mm) 2
5 5033608 BEARING 1
6 5033609 BEARING 1
7 5033516 O RING 1
8 5031015 PIN 2
9 5034140 CIRCLIP 1
10 5033665 CHAIN, TIMING 1
11 5033666 GUIDE, TIMING CHAIN 1
12 5033667 TENSIONER, TIMING CHAIN 1
13 5031337 *PAD, TIMING CHAIN TENSIONER 1
14 5033668 SPACER, TIMING CHAIN TENSIONER 1
15 5031339 ADJUSTER, TENSIONER 1
16 5034121 BOLT, STUD 1
17 5034125 BOLT 2
18 5031666 BOLT 1
19 5034126 BOLT 1
20 5034138 NUT 1
6
CAMSHAFT
10
11
8
5
3
4
10
11
7
4
9
9
3
7
6
2
1
9
8
9
EPC3469
Ref P/N Name of Part Qty
1 5033901 CAMSHAFT, INTAKE - 90HP 1
1 5033660 CAMSHAFT, INTAKE - 115HP 1
2 5033902 CAMSHAFT, EXHAUST - 90HP 1
2 5033661 CAMSHAFT, EXHAUST - 115HP 1
3 5033669 TAPPET 16
4 5033670 SHIM, TAPPET (T:2.18mm) AR
4 5033671 SHIM, TAPPET (T:2.20mm) AR
4 5033672 SHIM, TAPPET (T:2.23mm) AR
4 5033673 SHIM, TAPPET (T:2.25mm) AR
4 5033674 SHIM, TAPPET (T:2.28mm) AR
4 5033675 SHIM, TAPPET (T:2.30mm) AR
4 5033676 SHIM, TAPPET (T:2.33mm) AR
4 5033677 SHIM, TAPPET (T:2.35mm) AR
4 5033678 SHIM, TAPPET (T:2.38mm) AR
4 5033679 SHIM, TAPPET (T:2.40mm) AR
4 5033681 SHIM, TAPPET (T:2.43mm) AR
4 5033682 SHIM, TAPPET (T:2.45mm) AR
4 5033683 SHIM, TAPPET (T:2.48mm) AR
4 5033684 SHIM, TAPPET (T:2.50mm) AR
4 5033685 SHIM, TAPPET (T:2.53mm) AR
4 5033686 SHIM, TAPPET (T:2.55mm) AR
4 5033874 SHIM, TAPPET (T:2.58mm) AR
4 5033875 SHIM, TAPPET (T:2.60mm) AR
4 5033876 SHIM, TAPPET (T:2.63mm) AR
4 5033877 SHIM, TAPPET (T:2.65mm) AR
4 5033878 SHIM, TAPPET (T:2.68mm) AR
4 5033879 SHIM, TAPPET (T:2.70mm) AR
4 5033880 SHIM, TAPPET (T:2.73mm) AR
4 5033881 SHIM, TAPPET (T:2.75mm) AR
4 5033882 SHIM, TAPPET (T:2.78mm) AR
4 5033883 SHIM, TAPPET (T:2.80mm) AR
4 5033884 SHIM, TAPPET (T:2.83mm) AR
4 5033885 SHIM, TAPPET (T:2.85mm) AR
4 5033886 SHIM, TAPPET (T:2.88mm) AR
4 5033887 SHIM, TAPPET (T:2.90mm) AR
4 5033888 SHIM, TAPPET (T:2.93mm) AR
4 5033889 SHIM, TAPPET (T:2.95mm) AR
4 5033890 SHIM, TAPPET (T:2.98mm) AR
4 5033891 SHIM, TAPPET (T:3.00mm) AR
4 5033892 SHIM, TAPPET (T:3.03mm) A AR
4 5033893 SHIM, TAPPET (T:3.05mm) A AR
4 5033894 SHIM, TAPPET (T:3.08mm) A AR
4 5033895 SHIM, TAPPET (T:3.10mm) A AR
4 5033896 SHIM, TAPPET (T:3.13mm) A AR
5 5033897 VALVE, INTAKE 8
6 5033898 VALVE, EXHAUST 8
7 5033899 SPRING, VALVE 16
8 5033900 RETAINER, VALVE SPRING 16
9 5033687 VALVE COTTER 32
10 5031959 SEAT, VALVE SPRING 16
11 5033614 SEAL, VALVE STEM 16
A
Optional
7
90, 115 4 STROKE
INTAKE MANIFOLD
AIR SILENCER
10
15
14
12
11
9
6
5
2
1
13
3
11
4
7
8
EPC3471
Ref P/N Name of Part Qty
1 5033535 MANIFOLD, INTAKE 1
2 5033688 GASKET 1
3 5033689 COVER, WATER JACKET 1
4 5033690 RING 1
5 5033726 GASKET, IAC VALVE 1
6 5033727 VALVE, IAC 1
7 5033728 HOSE, IAC 1
8 5030121 INSULATOR 1
9 5030979 BOLT, STUD 1
10 5034122 BOLT, STUD 1
11 5030000 BOLT 10
12 5030998 BOLT 8
13 5031069 BOLT 1
14 5033288 PIN 2
15 5031021 NUT 2
8
9
6
1
3
7
2 5
4
EPC3472
Ref P/N Name of Part Qty
1 5031070 ARRESTER, FLAME 1
2 5033694 SILENCER Assy 1
3 5033695 HOLDER 1
4 5033696 DUCT, SILENCER 1
5 5033697 GROMMET, SILENCER 1
6 5030056 WASHER, (6.5X18X1.6mm) 5
7 5033598 WASHER 5
8 5030556 CUSHION 5
9 5030001 BOLT 5
8
FLYWHEEL COVER
FLYWHEEL
1
2
3
4
EPC3473
Ref P/N Name of Part Qty
1 5033650 COVER Assy 1
2 5030639 CUSHION 2
3 5030410 SCREW, (6X18mm) 1
4 5030336 DECAL, CAUTION 1
1
2
4
3
5
6
7
8
9
11
12
10
EPC3474
Ref P/N Name of Part Qty
1 5033550 FLYWHEEL 1
2 5033819 COIL, BATTERY CHARGING 1
3 5034149 COIL, IGNITION TIMING 1
4 5031468 SENSOR, CAM POSITION 1
5 5030832 TUBE 1
6 5033584 BOLT (6X35mm) 4
7 5033512 BOLT (16X50mm) 1
8 5033515 WASHER (16.5X60.5X7.0mm) 1
9 5030989 BOLT 1
10 5034133 SCREW 2
11 5031024 KEY, WOODRUFF 1
12 5033818 DECAL, MAG BOLT 1
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2003 Johnson Evinrude 90HP, 115HP 4-Stroke Parts Catalog Manual
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Description
This manual is suitable for both first-time owners/amateurs and professional technicians. It is designed in an easy-to-read format and provides all the necessary information to perform procedures correctly. Keeping this service manual handy and referring to it frequently is recommended. Regular preventive maintenance as outlined in the manual can help prevent premature failure and unnecessary repairs.
- Models Covered:
- J90PL4STS
- BJ90PL4STS
- J90PX4STS
- BJ90PX4STS
- J115PL4STS
- BJ115L4STS
- J115PX4STS
- BJ115X4STS
- Manual Contents:
- Decals
- Motor Cover
- Recoil Starter Assembly
- Ignition
- Electrical
- Carburetor
- Piston & Crankshaft
- Cylinder & Crankcase
- Stern & Swivel Bracket
- Midsection
- Gearcase
- Exhaust Housing
- Rewind Starter
- Fuel Tank
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
