2007 Johnson 4 HP, 5 HP, 6 HP 4-Stroke Outboard Motor Service Manual (P/N 5007219)

The 2007 Johnson service manual, P/N 5007219 (© 2006 BRP US Inc.), covers 4 HP, 5 HP, and 6 HP 4-stroke outboards in short- and long-shaft configurations. It details inspection, service, and overhaul of the powerhead and related systems.

Text search, navigation, and wiring detail: The main text is searchable; covers and some illustration lettering are not. Embedded bookmarks cover chapters and individual procedures, although “Return to Menu” points to a separate file that is not included. Small wiring labels are readable when enlarged.

• Powerhead repair: Removal, disassembly, cylinder-head service, valve-guide replacement, piston and crankshaft inspection, and camshaft timing during reassembly.

• Fuel system: Keihin carburetor overhaul, float-height adjustment, fuel-pump diaphragm inspection, fuel-cock service, and fuel-leakage checks.

• Ignition diagnosis: Digital CDI troubleshooting, ignition-coil and spark-plug-cap resistance tests, engine-stop-switch checks, and wiring diagrams.

• Gearcase repair: Lower-unit teardown, clutch and shift-rod adjustment, gear shimming, backlash and tooth-contact checks, and propeller-shaft thrust-play measurement.

• Cooling and lubrication: Water-pump impeller replacement, thermostat testing, trochoid oil-pump service, and engine-oil-filter inspection.

• Starter and midsection: Recoil-starter overhaul, neutral start interlock adjustment, and service of the tiller handle, driveshaft housing, swivel bracket, and clamp bracket.

Written for technicians who already have the knowledge and skills to service Johnson outboards, this manual assumes access to the specified tools and workshop equipment.

Powerhead Repair and Maintenance

The single-cylinder 138cc powerhead section follows removal from the driveshaft housing through internal inspection and reassembly. Valve-seat servicing, oversize piston identification, and camshaft decompression-component inspection extend the coverage beyond routine maintenance.

Inspection tables detail cylinder bore, piston ring gaps, and camshaft journal clearances. Torque tables cover critical engine and drive-system fasteners, while the cylinder-head assembly procedure distinguishes the 6 HP model’s final-tightening specification from the 4/5 HP versions.

The periodic maintenance chart is backed by cold-engine valve-clearance adjustment, idle-speed setting, and compression-testing procedures that account for the decompression system. The valve-clearance section warns that turning the crankshaft in the wrong direction can damage the water-pump impeller.

The engine oil lubrication chart traces oil flow through the camshaft and crankshaft bearing. Cooling coverage connects thermostat testing with inspection of the water tube, water jackets, and pump.

Keihin Carburetors and Fuel Routing

The specifications distinguish Keihin BC19-3.5 carburetors on the 4/5 HP models, identified as 91J80 and 91J90 respectively, from the BC21-15 on the 6 HP model, identified as 91JB0. These identifiers help match the carburetor to its jetting specifications before parts are selected for a repair.

Separate 4 HP and 5/6 HP hose-routing views show the different fuel-cock and hose arrangements. The fuel section also covers the built-in tank, cap vent, primer bulb, and pump check valves, with tank-capacity data in the specifications.

CDI Testing and Optional Charging Equipment

The ignition troubleshooting chart traces hard-starting and weak-spark faults through the stop switch, plug cap, coil air gap, and CDI/coil unit. An ignition signal chart supports the explanation of electronic timing control and the over-revolution limiter.

The wiring diagram covers the standard ignition circuit and the optional battery charge coil, rectifier/regulator, battery, and fuse. Installation of the charging equipment requires the optional flywheel; the manual illustrates the mounting and wire routing.

Lower Unit, Controls, and Service Tools

An illustrated 42-item tool list supports the service procedures. Gearcase leakage testing calls out the Stevens S34 pressure tester and adapter 772269. Tooth-contact drawings show how incorrect shimming can chip the forward or pinion gear.

A propeller selection chart relates pitch choice to the covered engines. Exploded midsection views identify extension-case hardware used only on long-shaft models, while starter repair includes recoil-spring handling and neutral start interlock function checks.

Follow the manual’s safety precautions for fuel, rotating components, and the tensioned recoil spring; consult a certified marine technician if you lack the required tools.

PDF Page Count and Included Material

The printable English PDF has 185 pages total: 154 service-section pages, including eight notes pages; 24 general marine safety pages, including one blank page; and seven cover/preliminary pages. Those seven pages comprise the front and back covers, three introductory pages, and two unnumbered blanks, all already included in the total.