Johnson J15RSUA Outboard Motor Parts Manuals

Manuals and User Guides for Johnson J15RSUA Outboard Motor Parts. We have 1 Johnson J15RSUA Outboard Motor Parts manual available for free PDF download: Service Manual

Johnson J15RSUA Service Manual (229 pages)

9.9, 15 HP 2 Stroke

Brand: Johnson | Category: Outboard Motor | Size: 16 MB

Safety Information

4
- Table of Contents
  4
  - Safety Information
    4
  - Table of Contents
    6
- Introduction
  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
- Engine Emissions Information
  15
- Manufacturer's Responsibility
  15
- Dealer's Responsibility
  15
- Owner's Responsibility
  15
- Epa Emission Regulations
  15
- Product Reference and Illustrations
  16
- Symbols
  16
- Electrical
  16
- Values
  17
- Notes
  18
Service Specifications and Special Tools

19
- Technical Data
  
  20
- Standard Torque Specifications
  
  22
- Special Tools
  
  23
  - Electrical / Ignition
    23
  - Fuel
    24
  - Gearcase
    25
  - Powerhead
    26
  - Starter
    27
  - Universal
    27
- Shop Aids
  
  29
- Notes
  
  32
Table of Contents

33
- Installation and Predelivery
  33
- Boat Rigging
  
  34
  - Remote Controls
    34
  - Battery Installation
    35
  - Fuel System Requirements
    36
- Outboard Installation
  
  38
  - Hull Preparation
    38
  - Transom Measuring and Drilling
    39
  - Lifting the Outboard
    40
  - Steering Systems
    40
  - Outboard Mounting
    41
- Outboard Rigging
  
  42
  - Control Cable Installation
    42
  - Cable, Hose, and Wire Routing
    44
- Fuel and Oil Priming
  
  45
  - Fuel Requirements
    45
  - Fuel System Priming
    46
  - Oil Requirements
    46
  - Break-In Oiling
    46
- Before Start-Up
  
  47
  - Gearcase Lubricant
    47
- Running Checks
  
  47
  - Fuel System
    47
  - Emergency Stop / Key Switch
    47
  - Start-In-Gear Prevention
    48
  - Tachometer Pulse Setting
    48
  - Water Pump Overboard Indicator
    48
  - Operating Temperature
    48
  - Break-In
    48
- Propellers
  
  49
  - Propeller Selection
    49
  - Propeller Hardware Installation
    49
Maintenance

51
- Inspection and Maintenance Schedule
  
  52
- Anti-Corrosion Protection
  
  54
  - Metallic Component Protection
    54
  - Exterior Finishes
    54
- Cooling System
  
  55
  - Flushing
    55
  - Water Intake Screens
    56
- Lubrication
  
  56
  - Steering System
    56
  - Midsection
    57
  - Throttle and Shift Linkage
    57
  - Gearcase Lubricant
    58
  - Propeller Shaft
    58
  - Electric Starter
    59
- Battery and Battery Connections
  
  59
- Fuel System
  
  60
  - Fuel Filter
    60
  - Air Silencer
    60
  - Hoses and Connections
    60
- Spark Plugs
  
  60
- Synchronization and Linkage Adjustments
  
  61
  - Preliminary Adjustments
    61
  - Cam Follower Pickup Point
    62
  - Wide Open Throttle Adjustment
    63
  - Maximum Spark Advance
    63
  - Idle Speed
    63
  - Shift Lever Detent
    64
- 10-Hour Inspection
  
  64
- Storage
  
  65
  - Fuel System Treatment
    65
  - Internal Engine Treatment
    65
  - Additional Recommendations
    65
- Pre-Season Service
  
  66
  - Clamp Screws and Mounting Bolts
    66
  - Gearcase Lubricant
    66
  - Battery(S)
    66
  - Operational Checks
    66
  - Fuel System
    66
- Submerged Engines
  
  66
- Notes
  
  68
Maintenance Notes Notes

69
- Electrical
  69
- Charging System Components
  
  70
  - Flywheel
    70
  - Stator
    70
  - Rectifier
    70
- Charging System Tests
  
  71
- Tachometer Circuit Test
  
  73
- Electric Starter Tests
  
  74
  - Start Switch Test
    74
  - Start Circuit Voltage Test
    74
  - Voltage Drop Tests
    77
  - Starter Solenoid Test
    78
  - No Load Current Draw Test
    79
- Electric Starter Servicing
  
  79
  - Removal
    79
  - Disassembly
    79
  - Cleaning and Inspection
    80
  - Assembly
    81
  - Installation
    82
- Accessory Components
  
  83
  - Removal
    83
  - Installation
    84
- Connector Servicing
  
  84
  - Amphenol Connectors
    84
- Notes
  
  86
Electrical Notes Notes

87
- Ignition
  87
- Components
  
  88
  - Flywheel
    88
  - Charge Coil
    88
  - Sensor Coil
    88
  - Power Pack
    88
  - Stop Button
    89
  - Key Switch
    89
  - Ignition Coil
    89
- Troubleshooting
  
  90
  - Flywheel Indexing
    90
- Ignition System Tests
  
  91
  - Total Ignition Output Test
    91
  - Stop Circuit Tests
    91
  - Charge Coil Test
    93
  - Sensor Coil Test
    94
  - Power Pack Cranking Output
    96
  - Power Pack Running Output
    96
  - Ignition Coil Tests
    97
- Flywheel Servicing
  
  99
  - Removal
    99
  - Installation
    100
- Spark Plugs
  
  99
- Ignition Plate Servicing
  
  101
  - Removal
    101
  - Installation
    101
- Charge Coil and Sensor Coil
  
  102
  - Removal
    102
  - Installation
    103
- Ignition Coil
  
  104
  - Removal
    104
  - Installation
    104
Fuel System

105
- Fuel System Trouble Check Chart
  
  106
- Components
  
  107
  - Fuel Pump
    107
  - Carburetor
    107
  - Intake Manifold
    107
- Fuel Pump Pressure Test
  
  108
- Fuel Pump Service
  
  108
  - Disassembly
    108
  - Cleaning
    108
  - Assembly
    109
- Carburetor Service
  
  109
  - Emissions Compliance
    109
  - Removal
    109
  - Disassembly
    110
  - Cleaning and Inspection
    111
  - Assembly
    113
  - Installation
    115
- Carburetor Mixture Adjustment
  
  116
- Intake Manifold
  
  117
  - Removal
    117
  - Inspection
    117
  - Disassembly
    118
  - Assembly
    118
  - Installation
    119
- Notes
  
  120
Fuel System Notes Notes

121
- Powerhead
  121
- Torque Chart
  122
- General
  123
  - Cylinder Compression Testing
    123
  - Retaining Ring Pliers
    123
  - Taper Pin Tool
    123
- Engine Temperature Check
  124
- Upper Crankcase Seal
  125
  - General
    125
  - Removal
    125
  - Installation
    125
- Shift Linkage
  126
  - Removal
    126
  - Installation
    127
  - Start Switch
    128
- Neutral Start Protection
  129
  - Manual Starter
    129
  - Electric Starter
    129
- Removal
  130
- Disassembly
  131
- Cleaning
  135
- Inspection
  136
- Assembly
  138
- Installation
  145
- Powerhead Views
  147
  - Port/Starboard View, Manual Start
    147
  - Rear View, Manual Start
    148
Powerhead Powerhead Views Rear View, Manual Start

149
- Torque Chart
  
  150
- Steering Handle
  
  151
  - Removal
    151
  - Disassembly
    152
  - Inspection
    153
  - Assembly
    153
  - Installation
    155
- Exhaust Housing
  
  157
  - Disassembly
    157
  - Cleaning and Inspection
    158
  - Assembly
    159
- Swivel Bracket
  
  161
  - Disassembly
    161
  - Assembly
    162
- Adjustments
  
  164
  - Tilt Friction Adjustment
    164
  - Steering Friction Adjustment
    164
  - Idle Speed Adjustment
    164
  - Throttle Friction Adjustment
    164
Table of Contents

165
- Service Chart
  
  166
- Lubricant
  
  167
  - Draining
    167
  - Inspection
    168
  - Filling
    168
- Propeller
  
  167
  - Inspection
    167
- Leak Test
  
  168
- Removal and Installation
  
  169
  - Removal
    169
  - Installation
    170
- Water Pump
  
  171
  - Disassembly
    171
  - Inspection
    171
  - Assembly
    171
- Disassembly
  
  173
- Bearing and Seal Removal
  
  174
  - Driveshaft Seals
    174
  - Driveshaft Bearing
    174
  - Pinion Bearings
    175
  - Forward Bearing
    175
  - Shift Rod Bushing and O-Ring
    175
  - Prop Shaft Bearing Housing Seals and O-Ring
    176
  - Prop Shaft Bearing Housing Bearings
    176
- Cleaning and Inspection
  
  177
- Seal and Bearing Installation
  
  178
  - Propeller Shaft Bearing Housing Bearings
    178
  - Propeller Shaft Bearing Housing Seals and O-Ring
    178
  - Shift Rod Bushing and O-Ring
    178
  - Forward Bearing
    179
  - Pinion Bearings
    179
  - Driveshaft Bearing
    180
  - Driveshaft Seals
    180
- Assembly
  
  181
- Notes
  
  184
Manual Starter

185
- General
  186
  - Starter Rope Length
    186
  - Torque Chart
    186
- Removal
  186
- Rope Replacement
  187
  - Safety
    187
- Disassembly
  188
- Assembly
  189
- Cleaning and Inspection
  189
- Installation
  192
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety

193
- Marine Products and the Safety of People Who Use Them
  195
- Marine Products and the Safety of People Who Fix Them
  209
  - Handling Outboards
    209
  - Handling Lead/Acid Batteries
    213
  - Gasoline - Handle with Care
    214
  - Hazardous Products
    215
  - Safety Awareness Test
    216
  - Index
    217

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Johnson J15RSUA Outboard Motor Parts Manuals

Johnson J15RSUA Service Manual (229 pages)

Table of Contents

Safety Information

Service Specifications and Special Tools

Technical Data

Standard Torque Specifications

Special Tools

Shop Aids

Notes

Table of Contents

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil Priming

Before Start-Up

Running Checks

Propellers

Maintenance

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Lubrication

Battery and Battery Connections

Fuel System

Spark Plugs

Synchronization and Linkage Adjustments

10-Hour Inspection

Storage

Pre-Season Service

Submerged Engines

Notes

Maintenance Notes Notes

Charging System Components

Charging System Tests

Tachometer Circuit Test

Electric Starter Tests

Electric Starter Servicing

Accessory Components

Connector Servicing

Notes

Electrical Notes Notes

Components

Troubleshooting

Ignition System Tests

Flywheel Servicing

Spark Plugs

Ignition Plate Servicing

Charge Coil and Sensor Coil

Ignition Coil

Fuel System

Fuel System Trouble Check Chart

Components

Fuel Pump Pressure Test

Fuel Pump Service

Carburetor Service

Carburetor Mixture Adjustment

Intake Manifold

Notes

Fuel System Notes Notes

Powerhead Powerhead Views Rear View, Manual Start

Torque Chart

Steering Handle

Exhaust Housing

Swivel Bracket

Adjustments

Table of Contents

Service Chart

Lubricant

Propeller

Leak Test

Removal and Installation

Water Pump

Disassembly

Bearing and Seal Removal

Cleaning and Inspection

Seal and Bearing Installation

Assembly

Notes

Manual Starter