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Johnson BJ25RL4SUC
BRP Johnson BJ25RL4SUC Manuals
Manuals and User Guides for BRP Johnson BJ25RL4SUC. We have
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BRP Johnson BJ25RL4SUC manual available for free PDF download: Service Manual
BRP Johnson BJ25RL4SUC 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
Engine Dropped Overboard (Not Running)
64
Engine Dropped Overboard (Running)
65
Engine Dropped Overboard (in Salt Water)
65
Prolonged Submersion (Fresh or Salt Water)
65
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
Outboard Shift Systems and Safety
240
Outboard Speed Control System and Safety
241
Outboard Steering Control System and Safety
242
Outboard Fuel, Electrical System, and Safety
244
Outboard Mounting System and Safety
247
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
249
Outboard Emergency Stop System and Safety
250
Summing up
252
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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