Johnson 25 2004 Manuals

Manuals and User Guides for Johnson 25 2004. We have 1 Johnson 25 2004 manual available for free PDF download: Service Manual

Johnson 25 2004 Service Manual

Johnson 25 2004 Service Manual (347 pages)

Brand: Johnson | Category: Outboard Motor | Size: 55.73 MB

Table of Contents

Table of Contents

4
- Introduction
  6
- Installation and Predelivery
  7
  - Arrangement of this Manual
    7
  - Models Covered in this Manual
    7
  - Identifying Model and Serial Numbers
    7
  - Model Designation
    8
  - Model List
    8
  - Typical Page - a
    9
  - Typical Page - B
    10
  - Typical Page - C
    11
  - Typical Page - D
    12
  - Abbreviations Used in this Manual
    13
    
    Units of Measurement
    13
    
    List of Abbreviations
    13
  - Engine Emissions Information
    14
    
    Manufacturer's Responsibility
    14
    
    Dealer's Responsibility
    14
    
    Owner's Responsibility
    14
    
    Epa Emission Regulations
    14
  - Product Reference and Illustrations
    15
    
    Electrical
    15
    
    Values
    16
  - Notes
    17
Special Tools and Service Specifications

18
- Special Tools
  20
  - Electrical I Ignition
    20
  - Fuel
    21
  - Gearcase
    22
  - Powerhead
    24
  - Starter
    25
  - Universal
    25
- Shop Aids
  28
- Technical Data
  31
- Standard Torque Specifications
  33
Installation and Predeliverv

34
- Safety Information
  36
- PREINSTALLATION Considerations
  37
  - Maximum Capacity
    37
  - Mounting Surface
    37
  - Mounting Hardware
    37
- Transom Measuring and Drilling
  38
  - Inspect Transom Area
    38
  - Measure Transom
    38
  - Transom Drilling
    39
- Outboard Mounting
  40
  - Fastening the Outboard to the Transom
    40
- Steering System
  40
- Remote Controls
  41
  - Remote Control Selection
    41
- Outboard Rigging Procedure
  43
  - Control Cable Installation
    43
  - Cable, Hose, and Wire Routing
    46
- Battery and Cables
  48
  - Installing Battery
    48
  - Battery Cable Requirements
    48
- Fuel Requirements
  49
  - Minimum Octane
    49
  - Additives
    49
- Fuel System Requirements
  50
  - Overview
    50
  - Fuel Hose
    50
  - Fuel System Primer
    50
  - Fuel Filters
    51
  - Outboard Fuel System Requirements Chart
    51
- Initial Running Checks
  52
  - Break-In (10 Hours)
    53
  - Fuel System
    54
  - Emergency Stop Ikey Switch
    54
  - Remote Control Operation
    54
  - Start-In-Gear Prevention
    54
  - Tachometer Pulse Setting
    54
  - Water Pump Overboard Indicator
    54
  - Operating Temperature
    54
- Oil Requirements
  52
  - Engine Lubricant
    52
- Propeller Selection
  55
  - Procedure
    55
- Trim Tab Adjustment
  56
- Notes
  57
Maintenance

58
- Inspection and Maintenance Schedule
  59
- Safety Information
  62
- Anti-Corrosion Protection
  63
  - Sacrificial Anodes
    63
  - Testing Procedure - Continuity
    63
  - Metallic Component Protection
    63
  - Exterior Finishes
    63
- Cooling System
  64
  - Flushing
    64
  - Water Intake Screens
    65
  - Additional Maintenance
    65
- Lubrication
  66
  - Steering System
    66
  - Midsection
    66
  - Throttle and Shift Linkage
    67
  - Gearcase Lubricant
    68
  - Propeller Shaft
    68
  - Electric Starter
    69
- Battery and Battery Connections
  69
- Fuel System
  70
  - Fuel Filter
    70
  - Air Silencer
    70
  - Hoses and Connections
    70
- Spark Plugs
  70
- Synchronization and Linkage Adjustments - 9.9/15
  71
  - Preliminary Adjustments
    71
  - Cam Follower Pickup Point
    72
  - Wide Open Throttle Adjustment
    73
  - Maximum Spark Advance
    73
  - Idle Speed
    73
  - Shift Lever Detent
    74
- Synchronization and Linkage Adjustments - 25130
  74
  - Cam Follower Pickup Point
    74
  - Throttle Control Rod
    75
  - Maximum Spark Advance
    75
  - Idle Speed
    76
  - Throttle Cable Installation
    77
- 10-Hour Inspection
  77
- Clamp Screws and Mounting Bolts
  77
- Storage
  78
  - Fuel System Treatment
    78
  - Internal Engine Treatment
    78
  - Additional Recommendations
    78
- Pre-Season Service
  79
- Submerged Engines
  79
- Notes
  81
Electrical

82
- Safety
  84
  - Safety Information
    84
  - General
    85
  - Charging System Components
    85
    
    Flywheel
    85
    
    Rectifier
    85
  - Charging System Tests
    86
    
    Charging System Check Chart
    86
    
    Running Alternator Output Test
    86
    
    Stator Resistance Tests
    87
    
    Rectifier Resistance Tests
    88
    
    Ac Lighting Coil Resistance Tests
    89
  - Tachometer Circuit Test
    90
  - Electric Starter Tests
    91
    
    Start Switch Test
    91
    
    Start Circuit Voltage Test
    91
    
    Voltage Drop Tests
    97
    
    Starter Solenoid Test
    98
    
    No Load Current Draw Test
    99
  - Water Temperature Switch Test
    100
  - Electric Starter Servicing
    101
    
    Removal
    101
    
    Disassembly
    101
    
    Cleaning and Inspection
    103
    
    Installation
    107
  - Accessory Components
    108
    
    General
    108
    
    Removal
    108
    
    Installation
    109
  - Connector Servicing
    110
    
    Amphenol Terminal Removal
    110
    
    Amphenol Terminal Installation
    111
Ignition

112
- Safety Information
  114
- Components
  115
  - Flywheel
    115
  - Charge Coil
    115
  - Sensor Coil
    115
  - Power Pack
    115
  - Stop Button
    116
  - Key Switch
    116
  - Ignition Coil
    117
  - Peak-Reading Voltmeters
    118
  - Ignition Module Load Adapter
    118
  - Ignition Coil Terminal Extenders
    119
  - Amphenol Connector Adapter
    119
  - Flywheel Holding Tool
    119
- Troubleshooting
  120
  - Flywheel Indexing
    120
- Ignition System Tests
  121
  - Total Ignition Output Test
    121
  - Stop Circuit Tests
    121
  - Charge Coil Test
    123
  - Sensor Coil Test
    125
  - Power Pack Cranking Output
    125
  - Power Pack Running Output
    126
  - Ignition Coil Tests
    126
- S.l.o. W. Warning System Tests
  128
  - Function Test
    128
  - Blocking Diode Test
    128
- Flywheel Servicing
  129
  - Removal
    129
  - Installation
    130
- Spark Plugs
  129
- Ignition Plate Servicing
  131
  - Removal
    131
  - Installation
    132
- Charge Coil and Sensor Coil
  134
  - Removal
    134
  - Installation
    135
- Ignition Coil
  136
  - Removal
    136
  - Installation
    136
- Notes
  137
Fuel System

138
- Safety Information
  140
- Components
  141
  - Primer Solenoid
    141
  - Primer Pump
    141
  - Fuel Pump
    141
  - Primer/Fuel Pump
    141
  - Carburetor
    142
  - Intake Manifold
    142
- Fuel System Trouble Check Chart
  143
- Fuel System Tests
  144
  - Primer Solenoid Tests
    144
  - Primer Pump Tests
    145
  - Fuel Pump Pressure Test
    146
- Primer Solenoid
  147
  - Removal
    147
  - Disassembly
    147
  - Assembly
    147
  - Installation
    147
- Primer Pump
  148
  - Disassembly
    148
  - Cleaning and Inspection
    148
  - Assembly
    149
- Fuel Pump
  150
  - General
    150
  - Disassembly
    150
  - Cleaning
    151
  - Assembly
    151
- Carburetor Emissions Compliance
  151
  - Removal
    151
  - 25/30 Models Carburetor
    153
  - Disassembly
    154
  - Cleaning and Inspection
    155
  - Assembly
    157
- Carburetor Mixture Adjustment
  162
- Intake Manifold
  164
  - Inspection
    165
  - Disassembly
    166
  - Assembly
    167
  - Installation
    169
Powerhead

170
- Torque Chart
  171
- Safety Information
  172
- General
  173
  - Cylinder Compression Testing
    173
  - Retaining Ring Pliers
    173
  - Taper Pin Tool
    173
- Engine Temperature Check
  174
- Upper Crankcase Seal
  175
  - General
    175
  - Removal
    175
  - Installation
    175
- Shift Linkage
  176
  - Removal
    176
  - Installation
    177
  - Adjustment
    178
  - Startswitch
    178
- Neutral Start Protection
  179
  - Manual Starter
    179
  - Electric Starter
    179
- Removal - 25130
  181
- Removal - 9.9/15
  181
- Disassembly - 9.9/15
  185
- Disassembly - 25/30
  189
- Cleaning
  194
- Inspection
  195
  - All Models
    195
  - Models
    196
  - 25/30 Models
    197
- Assembly - 9.9/15
  199
- Assembly - 25/30
  205
- Installation - 9.9/15
  214
- Installation - 25130
  215
- Powerhead Views - 9.9/15
  218
  - Port/Starboard View, Manual Start
    218
  - Rear View, Manual Start
    219
- Powerhead Views - 25/30
  220
  - Port/Starboard View, Manual Start
    220
  - Rear View, Manual Start
    221
  - Port/Starboard View, Tiller Electric Start
    222
  - Rear View, Tiller Electric Start
    223
  - PORT/STARBOARD VIEW, REMOTE Electric
    224
  - Rear View, Remote Electric
    225
Midsection

226
- Torque Chart
  227
- Safety Information
  228
- Steering Handle - Tiller Models
  229
  - Removal
    229
  - Disassembly
    231
  - Inspection
    232
  - Assembly
    233
  - Installation
    235
- Exhaust Housing
  238
  - Disassembly
    238
  - Cleaning and Inspection
    242
  - General
    242
  - Assembly
    243
- Swivel Bracket
  247
  - Disassembly
    247
  - Assembly
    249
- Adjustments
  253
  - Tilt Friction Adjustment
    253
  - Steering Friction Adjustment
    253
  - Idle Speed Adjustment
    253
  - Throttlefriction Adjustment
    253
Gearcase

254
- Service Chart
  255
- Safety Information
  258
- Propeller
  259
  - Inspection
    259
  - Installation
    259
- Lubricant
  260
  - Draining
    260
  - Inspection
    260
  - Filling
    260
- Leak Test Procedure
  261
- Removal and Installation
  261
  - Removal
    261
  - Installation
    263
- Water Pump
  266
  - Inspection
    267
  - Assembl V
    267
  - 25/30 Models Water Pump Assembly
    268
- Disassembly - 9.9/15
  270
- Bearing and Seal Removal
  274
  - Driveshaft Seals
    274
  - Driveshaft Bearing
    274
  - Pinion Bearings
    275
  - Forward Bearing
    275
  - Shift Rod Bushing and O-Ring
    276
  - Prop Shaft Bearing Housing Seals and O-Ring
    276
  - Prop Shaft Bearing Housing Bearings
    277
- Cleaning and Inspection
  278
- Seal and Bearing Installation
  279
  - Prop Shaft Bearing Housing Bearings
    279
  - Propeller Shaft Bearing Housing Seals and O-Ring
    280
  - Shift Rod Bushing and O-Ring
    281
  - Forward Bearing
    281
  - Pinion Bearings
    282
  - Driveshaft Bearing
    282
  - Driveshaft Seals
    283
- Assembly - 9.9/15
  284
- Notes
  291
Manual Starter

292
- Safety Information
  294
- General
  295
- Removal
  295
- Torque Chart
  295
- Disassembly
  297
- Rope Replacement
  297
- Cleaning and Inspection
  299
- Assembly
  300
- Installation
  304
Table of Contents

306
- Marine Products and the Safety of People Who Use Them
  308
- Marine Products and the Safety of People Who Fix Them
  322
  - Handling Outboards
    322
  - Handling Lead/Acid Batteries
    326
  - Gasoline - Handle with Care
    327
  - Hazardous Products
    328
  - Safety Awareness Test
    329

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