2005 Johnson Evinrude 90HP, 115HP 4-Stroke Parts Catalog Manual

© 2004 BRP US Inc. All rights reserved. TM, ® Trademarks of Bombardier Recreational Products Inc. or its affiliates. 2005 90, 115 HP (1950cc) 4 Stroke Models Parts Catalog J115PL4SOR BJ115L4SOR J115PX4SOR BJ115X4SOR J90PL4SOR BJ90PL4SOR J90PX4SOR BJ90PX4SOR 90, 115 4 STROKE

ABOUT THIS CATALOG Bombardier Recreational Products 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 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. Certain features, equipment or accessories shown in this catalog might not be found on or included with all models in all marketing areas. IMPORTANT: This catalog is a part reference. Refer to the appropriate Evinrude/Johnson Service Man- ual for exact service and maintenance information. Use exact engine model number, including any suffix letter, when indentifying parts in this catalog. The continuing accuracy of this catalog cannot be guaranteed. PARTS LIST REFERENCE 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. For the latest service part number information visit www.dealerport.com EPC (Electronic Parts Catalogs) on the DealerPort™ website. 1 584348 BATTERY CABLE, 10ft. (3.M) (DR Models Only) 1 2 351839 SCREW, Starter to C/C New 2 3 586774 STARTER SOLENOID Assy 1 (Solenoid Assy. included on DR, DE & DP models) 4 N/A *DRIVE KIT NS 1 5 586103 **GROMMET, Starter solenoid mount Opt. 2 6 341512 BOLT, Double ended-Harness ground A 1 A Only used on WR, WPR Models Following Example for Reference Only d e f g c a b c a c d e f g Additional part information. "N/A" Indicates part is NOT AVAILABLE or NOT AVAILABLE individually. "*" Indicates parts are included in the preceding assembly. EXAMPLE SHOWN: (Ref #3) - P/N 586774 includes (Ref #4) - P/N 586101 and (Ref # 5) - "GROMMET". Also (Ref #4) - P/N 586101 includes (Ref # 5) - "GROMMET". b "A " Upper case alpha characters used as callout indicate additional part information is shown at the bottom of the list. "Opt." Indicates part is an OPTIONAL or ACCESSORY part. "New" Indicates part and/or part number has been added or changed from previous model year. "NS" Indicates part is Not Shown in illustration.

1 90, 115 4 STROKE TABLE OF CONTENTS LITERATURE .............................................................................................................................. 2 PAINT .......................................................................................................................................... 2 MODEL FEATURES .................................................................................................................... 3 PARTS SHIPPED WITH ENGINE “IN BOX” ............................................................................... 3 PROFILE DRAWING ................................................................................................................... 4 2005 LITERATURE - ALL MODELS ........................................................................................... 5 DECALS ...................................................................................................................................... 6 ENGINE COVER ......................................................................................................................... 6 LOWER ENGINE COVER ........................................................................................................... 7 CYLINDER HEAD ....................................................................................................................... 7 CYLINDER & CRANKCASE ........................................................................................................ 8 CRANKSHAFT & PISTONS ........................................................................................................ 9 TIMING CHAIN ............................................................................................................................ 9 CAMSHAFT ............................................................................................................................... 10 INTAKE MANIFOLD .................................................................................................................. 11 AIR SILENCER.......................................................................................................................... 11 FLYWHEEL COVER ................................................................................................................. 12 FLYWHEEL ............................................................................................................................... 12 RECTIFIER................................................................................................................................ 13 IGNITION COIL ......................................................................................................................... 13 ENGINE ELECTRICAL HARNESS ........................................................................................... 14 ENGINE CONTROL MODULE & POWER TRIM SWITCH ....................................................... 14 FUEL VAPOR SEPARATOR ..................................................................................................... 15 FUEL PUMP .............................................................................................................................. 15 FUEL INJECTOR ...................................................................................................................... 16 THROTTLE BODY .................................................................................................................... 16 SENSOR GROUP ..................................................................................................................... 17 OIL PUMP ................................................................................................................................. 17 EXHAUST ADAPTER ................................................................................................................ 18 EXHAUST HOUSING ................................................................................................................ 18 OIL PAN .................................................................................................................................... 19 STERN BRACKET .................................................................................................................... 19 SWIVEL BRACKET ................................................................................................................... 20 GEARCASE ............................................................................................................................... 21 GEARS ...................................................................................................................................... 22 WATER PUMP .......................................................................................................................... 23 THERMOSTAT .......................................................................................................................... 24 SHIFT ROD ............................................................................................................................... 24 SHIFT LINKAGE ........................................................................................................................ 25 STARTER MOTOR ................................................................................................................... 25 TRIM CYLINDER....................................................................................................................... 26 TRIM MOTOR ........................................................................................................................... 27 STEERING & CONTROL COMPONENTS ............................................................................... 27 GASKET SET (ACCESSORY) .................................................................................................. 28 WATER PRESSURE HOSE KIT (ACCESSORY) ..................................................................... 28 DUAL ENGINE TIE BAR CONNECTOR (ACCESSORY) ......................................................... 29 DUAL ENGINE TIE BAR (ACCESSORY) ................................................................................. 29 DUAL CABLE STEERING KIT - PARALLEL ENTRY (ACCESSORY) ..................................... 29 TILLER UPGRADE KIT (ACCESSORY) .............................................................................. 30-31 TILLER HANDLE ASSEMBLY (ACCESSORY) ................................................................... 32-33 PROPELLERS & HARDWARE ...................................................................................................34

2 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 777172 DP40401 – BLACK 3 3. USED ON ENGINE CRANKCASE ASSEMBLY. 777179 9696 – WHITE 777171 90538 – CLEARCOAT 772414 – – 5005998 SERVICE MANUAL – ENGLISH 5005999 SERVICE MANUAL – FRENCH 5035765 OPERATOR’S GUIDE – ENGLISH 5035766 OPERATOR’S GUIDE – FRENCH 5005924 SPECIAL TOOLS CATALOG

3 90, 115 4 STROKE MODEL FEATURES PARTS SHIPPED WITH ENGINE “IN BOX” Cylinder Configuration Fuel Induction Model Number Shaft Length Color Steering Starting J90PL4SOR 20 in. White Remote Electric BJ90PL4SOR 20 in. White Remote Electric J90PX4SOR 25 in. White Remote Electric BJ90PX4SOR 25 in. White Remote Electric J115PL4SOR 20 in. White Remote Electric BJ115PL4SOR 20 in. White Remote Electric J115PX4SOR 25 in. White Remote Electric BJ115PX4SOR 25 in. White Remote Electric Model Specific All Models Charging 4 Cylinder Injection 40 Amp P/N Name of Part Qty Application 5035765 Owners Manual 1 All Models 5033854 Propeller Hardware Kit 1 All Models 5033567 Thrust Washer, Propeller 1 All Models 5033856 Spacer, prop bushing stop 1 All Models 5033829 Battery cable 1 All Models 5032181 Clamp, battery cable 1 All Models 5030347 Clamp, harness connector 1 All Models 5033870 Steering link 1 All Models 5030840 Seal, steering cable 1 All Models 5030832 Tube 1 All Models 5030386 Bolts, transom 4 All Models 5030418 Nuts, transom bolt 4 All Models 5030839 Cap, transom bolt 4 All Models 5030436 Washer, transom bolt 4 All Models 5030438 Washer, transom bolt 4 All Models 5030462 Washer, transom lock 4 All Models 5035627 Tool kit 1 All Models 5035965 Cable grommet 1 All Models 5035626 Band, cable grommet 1 All Models 5033582 Cable stopper 1 All Models 5034131 Bolt, cable stopper 1 All Models 5034142 Washer, cable stopper 1 All Models 5030575 Clip 2 All Models 5031080 Washer 2 All Models

4 PROFILE DRAWING FORWARD 575mm (22 3/4 in.) L: 998 (39 3/8 in.) UL:1116 (44 in.) 132mm (5 1/4 in.) 568 (22 3/8 in.) 629mm (24 7/8 in.) L: 539mm (21 1/4 in.) UL: 666mm (26 1/4 in.) L: 1556mm (61 3/8 in.) UL: 1683mm (66 3/8 in.) 69° 14° 370mm (14 5/8 in.) 757mm (29 7/8 in.) 811mm (32 in.) 75mm (3 in.) 346mm (13 5/8 in.) 346mm (13 5/8 in.) (9 1/2 in.) (9 1/2 in.) 240mm 240mm 30° 30° ALL MEASURMENTS BASED ON: TRANSOM ANGLE 14° TRANSOM THICKNESS 3 in. (76.2mm) MAXIMUM GRAPHICAL REPRESENTATION ONLY: TOTAL RANGE 75° POWER TRIM & TILT: ALL DIMENSIONS ± 1/4 in. (6.35mm) S = 15 in. (381mm) Model L = 20 in. (508mm) Model UL = 25 in. (635mm) Model All Evinrude® / Johnson® outboards are designed to function within the minimum clearances outlined in ABYC transom and motor well Standard S-12-83.

5 90, 115 4 STROKE 2005 LITERATURE - ALL MODELS Description P/N 2005 Part Catalog Set - Paper 5006044 2005 Part Catalog Microfiche Set 5006045 Illustrated Parts & Accessory Catalog 5006046 2005 Genuine Parts Accessory Parts Dealer Catalog 778880 2004 Part Catalog CD (PDF Set) 5006072 2005 Part Catalog CD (PDF Set) 5006075 2005 English Service Manual Set - 2 Stroke 5005980 2005 French Service Manual Set - 2 Stroke 5005981 2005 English Service Manual Set - 2 Stroke D.I. & E-TEC 5005982 2005 French Service Manual Set - 2 Stroke D.I. & E-TEC 5005983 2005 English Service Manual Set - 4 Stroke 5005984 2005 French Service Manual Set - 4 Stroke 5005985 Description P/N 2004 Special Tools Catalog 5005924 1913-2005 Model Number Reference Guide 5006145 2005 Warranty Procedures & Flat Rate Guide - English 5006217 2005 Warranty Procedures & Flat Rate Guide - French 5006218 Predelivery & Installation Guide - All Models - English 5006079 Predelivery & Installation Guide - All Models - French 5006121 Literature Sets Shop Catalogs Description English Operator's Guide French Operator's Guide Part Catalog English Service Manual French Service Manual Description English Operator's Guide French Operator's Guide Part Catalog English Service Manual French Service Manual 3.5 HP 215587 215588 5006019 5005962 5005963 4/5/6 HP 5035751 5035752 5006036 5005988 5005989 6 & 8 HP 215589 215590 5006020 5005962 5005963 9.9/15 HP Rope 5035753 5035754 5006037 5005990 5005991 9.9/15 HP 215597 215598 5006021 5005964 5005965 9.9/15 HP Remote 5035755 5035756 5006037 5005990 5005991 15 HP Commercial 215597 215598 5006021 5005964 5005965 25 HP Rope & Tiller Electric 5035769 5035770 5006038 5005992 5005993 25/30 HP Rope 215593 215594 5006022 5005964 5005965 25 HP Remote 5035771 5035772 5006038 5005992 5005993 25/30 HP Tiller Electric 215593 215594 5006023 5005964 5005965 30 HP Rope & Tiller Electric 5035757 5035758 5006038 5005992 5005993 25/30 HP Remote 215595 215596 5006024 5005964 5005965 30 HP Remote 5035759 5035760 5006038 5005992 5005993 25 HP Commercial 215593 215594 5006022 5005964 5005965 40/50 HP 5035761 5035762 5006039 5005994 5005995 40 HP Rope 215599 215600 5006025 5005966 5005967 60/70 HP 5035763 5035764 5006040 5005996 5005997 50 HP Remote 215601 215602 5006025 5005966 5005967 90/115 HP 5035765 5035766 5006041 5005998 5005999 40 HP E-TEC Rope 215638 215640 5006027 5005968 5005969 140 HP 5035765 5035766 5006042 5005998 5005999 40-50 HP ETEC Remote 215639 215641 5006027 5005968 5005969 200/225 HP 5035767 5035768 5006043 5006000 5006001 60 HP E-TEC Commercial 215568 215659 5006027 5005968 5005969 75/90 HP E-TEC 215642 215643 5006028 5005970 5005971 55 HP Commercial 20 in. 215603 215604 5006029 5005972 5005973 55 HP Commercial 22.5 in. 215603 215604 5006029 5005972 5005973 115 HP Commercial 215605 215606 5006030 5005974 5005975 90 - 115 HP Carbureted 215605 215606 5006030 5005974 5005975 135 - 175 HP Carbureted 215605 215606 5006031 5005974 5005975 100 - 115 HP D.I. 215610 215611 5006032 5005976 5005977 135 - 175 HP D.I. 215610 215611 5006033 5005976 5005977 200 - 250 HP D.I. 215610 215611 5006035 5005978 5005979 200 - 250 HP E-TEC 215645 215647 5006061 5006059 5006060 2 Stroke Models 4 Stroke Models

6 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 5034204 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 5035966 ENGINE COVER Assy New A 1 2 5033862 *BRACKET 1 3 5033866 *BRACKET, FASTENER 2 4 5030519 *RIVET New 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 5034538 TOOL SET New 1 A IMPORTANT: When ordering "ENGINE COVER Assy" also order appropriate "HP" Decal.

7 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 35 37 34 EPC3465 Ref P/N Name of Part Qty 1 5033857 SEAL, SIDE COVER - UPPER 1 2 5034642 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 5036047 PANEL, FRONT New 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 5036048 BUSHING, FRONT New 1 27 5035965 GROMMET, CONTROL CABLE New 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 5032150 FUEL CONNECTOR 1 35 5032817 BOLT (6X15) 1 37 5030430 WASHER 1 16 17 18 19 20 12 11 9 10 3 4 2 1 5 7 21 14 13 17 15 6 8 22 EPC3467 Ref P/N Name of Part Qty 1 5035936 HEAD, CYLINDER New 1 2 5033636 *GUIDE, VALVE 16 3 5033638 *BOLT, CAM SHAFT HOUSING 21 4 5030515 *PIN 18 5 5033639 BOLT, CYLINDER HEAD New 10 6 5034645 GASKET, CYLINDER HEAD 1 7 5033638 BOLT New 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 1 Cut to length from P/N 5032912 15 5030541 O RING 1 16 HOSE, BREATHER 1 Cut to length from P/N 5031064 17 5032822 CLIP 2 18 5030985 BOLT 11 19 5034124 BOLT 4 20 5034132 SCREW New 7 21 5033634 SPARK PLUG (BKR6E) 4 22 5034541 BOLT 8

8 CYLINDER & CRANKCASE 13 6 5 2 1 6 5 10 9 8 7 11 4 3 12 EPC3466 Ref P/N Name of Part Qty 1 5033646 HOOK, ENGINE 1 2 5034129 BOLT 2 3 5034542 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 5034545 *BOLT 10 12 5034544 PLUG 1 13 5030521 PLUG 1

2005 Johnson Evinrude 90HP, 115HP 4-Stroke Parts Catalog Manual

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