BRP Johnson BJ25EL4SUC Manuals

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BRP Johnson BJ25EL4SUC Service Manual

BRP Johnson BJ25EL4SUC Service Manual (265 pages)

4 Stroke

Brand: BRP | Category: Engine | Size: 20.38 MB

Table of Contents

Safety Information

4
- Table of Contents
  4
  - Table of Contents
    7
- Models Covered in this Manual
  8
- Identifying Model and Serial Numbers
  8
- Model Designation
  9
- Typical Page - a
  10
- Typical Page - B
  11
- Typical Page - C
  12
- Typical Page - D
  13
- Abbreviations Used in this Manual
  14
- Units of Measurement
  14
- List of Abbreviations
  14
- Product Reference and Illustrations
  15
- Symbols
  15
- Electrical
  15
- Values
  16
Service Specifications and Special Tools

17
- Technical Data
  
  18
- Standard Torque Specifications
  
  20
  - Tightening Torque - Important Fasteners
    20
  - Tightening Torque - General Bolt
    21
- Special Tools
  
  22
  - Electrical / Ignition
    22
  - Fuel and Oil
    23
  - Gearcase
    23
  - Powerhead
    24
  - Starter
    25
  - Universal
    25
- Shop Aids
  
  26
Installation and Predelivery

29
- Boat Rigging
  
  30
  - Remote Controls
    30
  - Battery Installation
    31
  - Fuel System Requirements
    32
- Outboard Installation
  
  33
  - Hull Preparation
    33
  - Transom Measuring and Drilling
    34
  - Lifting the Outboard
    36
  - Steering Systems
    36
  - Outboard Mounting
    37
- Outboard Rigging
  
  38
  - Control Cable Identification
    38
  - Control Cable Installation
    39
- Fuel and Oil
  
  41
  - Fuel Requirements
    41
  - Oil Requirements
    42
- Running Checks
  
  43
  - Break-In (10 Hours)
    43
  - Fuel System
    44
  - Emergency Stop Switch
    44
  - Outboard Controls
    44
  - Start-In-Gear Prevention
    44
  - Tachometer Pulse Setting
    44
  - Water Pump Overboard Indicator
    44
  - Operating Temperature
    44
- Propeller Selection
  
  45
  - Procedure
    45
  - Propeller Hardware Installation
    46
  - Trim Tab Adjustment
    47
- Notes
  
  48
Maintenance

49
- Inspection and Maintenance Schedule
  
  50
- Anti-Corrosion Protection
  
  52
  - Sacrificial Anodes
    52
  - Testing Procedure - Continuity
    53
  - Bonding Wires
    53
  - Metallic Component Protection
    53
  - Exterior Finishes
    53
- Cooling System
  
  54
  - Flushing
    54
  - Water Intake Screen
    54
  - Water Pump
    54
- Fuel System
  
  55
  - Breather and Fuel Line
    55
  - Fuel Filter
    55
- Battery
  
  56
- Lubrication
  
  56
  - Engine Oil
    56
  - Engine Oil Filter
    57
  - Gearcase Lubricant
    58
  - Linkages and Fittings
    59
- Spark Plugs
  
  60
- Valve Clearance
  
  60
  - Measurement
    60
  - Adjustment
    61
- Idle Speed
  
  62
- Ignition Timing
  
  62
- Storage
  
  63
  - Fuel System Treatment
    63
  - Internal Engine Treatment
    63
  - Additional Recommendations
    63
- Pre-Season Service
  
  64
  - Crankcase Oil
    64
  - Gearcase Lubricant
    64
  - Operational Checks
    64
  - Fuel System
    64
- Submerged Engines
  
  64
- Notes
  
  66
Electrical

67
- Caution System
  
  68
  - Self Test
    68
  - Over-Revolution Caution System
    68
  - Low Oil Pressure Caution System
    69
  - Overheat Caution System
    69
  - Oil Pressure Caution System Tests
    69
  - Oil Pressure Switch Service
    70
  - Temperature Sensor Tests
    71
- Battery Charging System
  
  72
  - Inspection
    73
  - Removal and Installation
    75
- Electric Starter System
  
  76
  - Operation
    76
  - Troubleshooting
    78
  - Inspection
    79
  - Starter Motor Service
    81
Ignition System

93
- Service Chart
  
  94
- Operation
  
  95
- Troubleshooting
  
  96
- Ignition Tests
  
  97
  - Power Source Coil (Stator)
    97
  - Crankshaft Position Sensor
    98
  - Ignition Coil
    99
  - CDI Unit
    100
  - Spark Plug Cap
    100
  - Engine Stop Switch
    100
- Component Servicing
  
  101
  - Removal
    101
  - Installation
    103
- Notes
  
  104
Fuel System

105
- Carburetor Operation
  
  106
  - Float System
    106
  - Idling/Trolling
    106
  - Low-MID Speed
    107
  - MID-High Speed
    107
  - Accelerator Pump
    108
  - Auto-Enrichener System
    109
  - Manual Starter System
    110
- Carburetor Service
  
  111
  - Removal
    111
  - Disassembly
    112
  - Cleaning and Inspection
    114
  - Assembly
    116
  - Installation
    118
- Fuel Pump
  
  119
  - Removal
    119
  - Inspection
    119
  - Installation
    119
- Intake Manifold Service
  
  120
  - Removal
    120
  - Installation
    121
- Throttle Control
  
  122
  - Installation/Adjustment
    122
- Notes
  
  124
Powerhead

125
- Specifications
  
  126
- Test Procedures
  
  130
  - Compression Testing
    130
  - Oil Pressure Test
    131
- Removal and Installation
  
  132
  - Removal
    132
  - Installation
    135
- Oil Pump
  
  137
  - Disassembly
    137
  - Inspection
    137
  - Assembly
    137
- Cylinder Head
  
  138
  - Removal
    138
  - Disassembly
    140
  - Cleaning/Inspection
    141
  - Assembly
    145
  - Installation
    148
- Crankshaft, Pistons and Camshaft
  
  151
  - Disassembly
    151
  - Cleaning/Inspection
    153
  - Assembly
    161
- Thermostat Service
  
  168
  - Removal
    168
  - Inspection
    169
  - Installation
    169
- Cooling System Diagram
  
  170
- Engine Lubrication Diagram
  
  171
- Notes
  
  172
Midsection

173
- Service Chart
  
  174
- Driveshaft Housing and Oil Pan
  
  179
  - Removal
    179
  - Disassembly
    181
  - Cleaning and Inspection
    182
  - Assembly
    183
- Side Cover
  
  179
  - Removal and Installation
    179
- Stern Bracket
  
  186
  - Disassembly
    186
  - Inspection
    190
  - Assembly
    190
- Steering Handle
  
  195
  - Removal
    195
  - Installation
    196
Gearcase

197
- Service Chart
  
  198
- Propeller
  
  200
  - Inspection
    200
  - Installation
    200
- Lubricant
  
  200
  - Draining
    200
  - Filling
    201
- Leak Test
  
  201
- Removal and Installation
  
  202
  - Removal
    202
  - Installation
    203
  - Clutch Adjustment
    203
- Water Pump
  
  204
  - Disassembly
    204
  - Inspection
    204
  - Assembly
    205
- Disassembly
  
  206
  - Propeller Shaft Bearing Housing Components
    208
  - Shift Rod Components
    209
  - Pinion Bearing
    209
- Cleaning and Inspection
  
  210
- Assembly
  
  211
  - Pinion Bearing
    211
  - Forward Gear
    211
  - Pinion Gear and Driveshaft
    212
  - Driveshaft Oil Seal Housing
    212
  - Shift Rod/Shift Cam Assembly
    213
  - Propeller Shaft
    214
  - Propeller Shaft Bearing Housing
    214
- Shimming Adjustments
  
  216
  - Shim/Washer Positions
    216
  - Forward Gear/Pinion Gear
    216
  - Driveshaft Thrust Play
    216
  - Gear Tooth Contact Pattern
    217
  - Pinion Gear/Reverse Gear
    217
  - Propeller Shaft Thrust Play
    218
Manual Starter

219
- Service Chart
  220
- Removal
  221
- Disassembly
  222
- Inspection
  223
- Assembly
  224
- Installation
  225
- Installation/Adjustment
  226
- Neutral Start Interlock (Nsi)
  226
Wire/Hose Routing

227
- Wiring Diagrams
  
  228
  - Rope Start Models
    228
  - Tiller Electric Models
    229
  - Remote Electric Models
    230
- Wire Routing
  
  231
- Fuel/Water Hose Routing
  
  235
Safety

237
- Marine Products and the Safety of People Who Use Them
  239
- Marine Products and the Safety of People Who Fix Them
  253
  - Handling Outboards
    253
  - Handling Lead/Acid Batteries
    257
  - Gasoline - Handle with Care
    258
  - Hazardous Products
    259
  - Safety Awareness Test
    260

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