I am looking for a shop manual for my new Johnson 140 4 stroke. Any suggestions? A Suzuki would probably be ok, but part numbers probably won't be the same. I don't live anywhere near a dealer so taking the rig to a dealer for maintenance is a big hassle. I try to be as self sufficient as possible. I have only 5 hours on the engine and it is coming up on the recommended 10 hour new motor service which is comparable to the annual maintenance schedule. With a shop manual, can an amateur handle the job?

1. 2004 Johnson 140 4-stroke Manual

Specifically, does anyone know about the valve clearance check and adjustments on that motor? I have seen articles about valve checks on the Yamahas but not the Johnson/Suzuki. Used to adjust valves on my old VW so at least understand the concept.

16 June, 2018. [EPUB] JOHNSON 140 HP OUTBOARD MANUAL. Document Filetype: PDF 236.72 KB. 16 June, 2018 - Johnson 140 Hp.

Here's what I've heard. The 140's (my dealer said anywhere from 10 - 25 hours) first service involves oil and filter change, lower unit gear oil change, and valve 'check'.

This next part I'm getting 3rd hand, the tech. That my buddy talked to said he has checked numerous Johnson 4 strokes at the 1st service and has not had to do anything with valves so far. I too am not very close to the dealer, I'm going to change those fluids myself and keep an ear to the motor. It runs so quietly, and has solid lifters, if it developes some looseness in the valve train I think I would hear it. I do plan on taking it in for the 100 hour service though.

2004 Johnson 140 4-stroke Manual

Stringer - 5/8/2004 10:51 PM My dealer told me you cannot buy a shop manual for just the 140, you have to buy the book for all the 4 strokes (Suzuki). I forget how much he said it would cost (alot). I too would like to have one. The owners manual is too limited. Mostly operational. I figure sooner or later someone will come out with one. Your dealer is a liar, I would find another one.

Go to brownspoint.com. Paul Gasior is a great guy, I had some questions about my motor and he helped me in great detail. He didn't even sell me my motor, but I found him and the manual for my motor after my dealer told me they couldn't get the manuals for the general public. I don't go there anymore, I use another guy that is honest. Get that first service done at a dealer, its pricey but the valve check is mandatory according to the manual. I would also plan on checking the zincs in the cooling system every 100 hrs. You should get some spare zincs and gaskets for these as well.

In my opinion a good starter kit for servicing your outboard would include 4 oil filters, 2 zincs for the cooling system with gaskets, a spare oil drain plug and 6 of those monel washers, Spare lower unit gaskets, two low pressure oil filters. Don't wrench on the motor without a torque wrench. This seems like a lot of $$$ to spend but it will prevent you having to pay for shipping on multiple small orders.

You will more than make up for the expense of having to let the dealer service your motor. I hope this helps Don.

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