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BRP Manuals
Outboard Motor
2995 Johnson
Service manual
BRP 2995 Johnson Service Manual
9.9-15 hp 4 stroke outboard motors
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Introduction
Table of Contents
Models Covered in this Manual
Identifying Model and Serial Numbers
Typical Page - a
Typical Page - B
Typical Page - D
Typical Page - C
Symbols
Values
Service Specifications and I
Technical Data
TORQUE Specifications
Tightening Torque -Important Fastners
Tightening Torque - General Bolt
Special Tools
Electrical I Ignition
Fuel and Oil
Gearcase
Powerhead
Starter
Universal
Shop Aids
Installation and Predelivery •
Boat Rigging
Remote Controls
Battery Installation
Fuel System Requirements
Outboard Installation
Hull Preparation
Transom Measuring and Drilling
Lifting the Outboard
Steering Systems
Outboard Mounting
Outboard Rigging
Control Cable Identification
Cable, Hose, and Wire Routing
Control Cable Installation
Fuel and Oil
Fuel Requirements
Minimum Octane
Additives
Oil Requirements
Initial Running Checks
Break-In (10 Hours)
Fuel System
Emergency Stop Switch
Outboard Controls
Start-In-Gear Prevention
Tachometer Pulse Setting
Water Pump Overboard Indicator
Operating Temperature
Propeller Selection
Procedure
Propeller Hardware Installation
Maintenance
Inspection and Maintenance Schedule
10-Hour Inspection
Anti-Corrosion Protection
Sacrificial Anodes
Testing Procedure Continuity
Bonding Wires
Metallic Component Protection
Exterior Finishes
Cooling System
Flushing
Water Intake Screen
Water Pump
Battery
Fuel System
Breather and Fuel Line
Fuel Filter
Lubrication
Engine Oil
Engine Oil Filter
Gearcase Lubricant
Linkages and Fittings
Spark Plugs
Valve Clearance
Measurement
Adjustment
Timing Belt
Idle Speed
Ignition Timing
Storage
Fuel System Treatment
Internal Engine Treatment
Additional Recommendations
Pre-Season Service
Crankcase Oil
Gearcase Lubricant
Operational Checks
Fuel System
Submerged Engines
Engine Dropped Overboard (Not Running)
Engine Dropped Overboard (Running)
Engine Dropped Overboard (in Salt Water)
Prolonged Submersion (Fresh or Salt Water)
Electrical Electrical
Caution System
Self Test
Over-Revolution Caution System
Low Oil Pressure Caution System
Oil Pressure Caution System Tests
Oil Pressure Switch Service
Battery Charging System
Inspection
Removal and Installation
Electric Starter System
Operation
Troubleshooting
Inspection
Starter Motor Service
Notes
Ignition System
Service Chart
Operation
Troubleshooting
Ignition Tests
Condenser Charge Coil
Pulser Coil
Ignition Coil
Col UNIT
Spark Plug Cap
Engine Stop Switch
Component Servicing
Removal
Installation
Notes
Fuel System Fuel System
Carburetor Operation
Float System
Idlingitrolling
Low-MID Speed
MID-High Speed
Accelerator Pump
Auto-Enrichener System
Manual Starter System
Carburetor Service
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
Throttle Control
Installation/Adjustment
Fuel Pump
Removal
Disassembly
Inspection
Assembly
Installation
Notes
Powerhead
Specifications
Test Procedures
Compression Testing
Oil Pressure Test
Removal and Installation
Removal
Installation
Final Assembly Checks
Cylinder Head Assembly
Removal
Disassembly
Cleaning/Inspection
Assembly
Installation
Cylinder/Crankcase/Piston Assembly
Disassembly
Cleaning/Inspection
Reassembly
Cooling System
Operation
Cooling System Diagram
ENGINE LUBRICATION System
Engine Oil Lubrication Chart
Oil Passage Location
Notes
Midsection
Service Chart
Side Cover
Removal and Installation
Driveshaft Housing and Oil Pan
Disassembly
Cleaning and Inspection
Assembly
Stern Bracket
Disassembly
Inspection
Assembly
Steering Handle
Removal
Installation
Notes
Gearcase
Service Chart
Lubricant
Draining
Filling
Propeller
Inspection
Installation
Leak Test
Removal and Installation
Removal
Installation
Clutch Adjustment
Water Pump
Disassembly
Inspection
Assembly
Disassembly
Propeller Shaft Bearing Housing Components
Shift Rod Components
Pinion Bearing
Cleaning and Inspection
Assembly
Pinion Bearing
Shift Rod/Shift Cam Assembly
Propeller Shaft
Forward Gear
Pinion Gear and Driveshaft
Propeller Shaft Bearing Housing
Shimming Adjustments
Shimiwasher Positions
Forward Gear/Pinion Gear
Pinion Gear/Reverse Gear
Propeller Shaft Thrust Play
Notes
Manual Starter
Service Chart
Disassembly
Removal
Inspection
Assembly
Installation
Installation/Adjustment
Neutral Start Interlock
Safety
Marine Product5 and the 5Afety of People Who U5E Them
Outboard Shift Systems and Safety
Outboard Speed Control System and Safety
Outboard Steering Control System and Safety
Outboard Fuel, Electrical System, and Safety
Outboard Mounting System and Safety
Outboard Hydraulic Tiltitrim Shock Absorption System and Safety
Outboard Emergency Stop System and Safety
Summing up
Handling Outboards
Marine Product5 and the 5Afety of People Who Fix Them
Handling Lead/Acid Batteries
Gasoline - Handle with Care
Hazardous Products
Safety Awareness Test
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Quick Links
1
Models Covered in this Manual
2
Fuel and Oil
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Jah"SlflJn.
9.9 - 15 HP
4 Stroke Models
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
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Chapters
Introduction
6
Service Specifications and I
14
Installation and Predelivery •
26
Maintenance
44
Electrical Electrical
64
Ignition System
92
Fuel System Fuel System
106
Powerhead
126
Midsection
174
Gearcase
194
Manual Starter
216
Safety
236
Table of Contents
Troubleshooting
TROUBLESHOOTING
76
TROUBLESHOOTING
95
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