brp Johnson 4HP Manuals

Manuals and User Guides for brp Johnson 4HP. We have 1 brp Johnson 4HP manual available for free PDF download: Service Manual

brp Johnson 4HP Service Manual

brp Johnson 4HP Service Manual (185 pages)

2007

Brand: brp | Category: Outboard Motor | Size: 9.32 MB

Table of Contents

General Information

7
- Table of Contents
  7
- Warning / Caution / Note
  8
- General Precautions
  8
- Identification Number Location
  10
  - Model, Prefix, Serial Number
    10
  - Engine Serial Number
    10
- Fuel and Oil
  10
  - Gasoline Recommendation
    10
  - Engine Oil
    10
- Engine Break-In
  11
  - Warm-Up Recommendation
    11
  - Throttle Recommendation
    11
- Propellers
  12
- Specifications
  13
- Tightening Torque
  21
- Special Tools
  23
- Notes
  26
Periodic Maintenance

27
- Periodic Maintenance Schedule
  28
  - Periodic Maintenance Chart
    28
- Maintenance and Tune-Up Procedures
  29
- Gear Oil
  32
- Lubrication
  33
- Cooling System Flushing
  34
- Spark Plug
  35
  - Spark Plug Gap
    35
  - Condition of Electrode / Insulator
    35
- Valve Clearance
  36
  - Checking and Adjusting Valve Clearance
    36
- Idle Speed
  38
- Carburetor
  39
- Ignition Timing
  39
- Breather Hose and Fuel Line
  40
- Fuel Filter
  40
- Water Pump / Water Pump Impeller
  40
- Anodes
  41
- Bolts and Nuts
  41
- Propeller / Nut / Cotter Pin
  41
- Cylinder Compression
  42
Ignition and Electrical

43
- Ignition System
  
  44
  - Outline
    44
- Ignition Troubleshooting
  
  45
- Inspection
  
  46
  - Ignition Secondary Coil Resistance
    46
  - Spark Plug Cap
    46
  - Engine Stop Switch
    47
- Removal / Installation
  
  48
  - Removal
    48
  - Installation
    49
- Notes
  
  50
Fuel System

51
- Precaution on Fuel System Service
  
  52
  - General Precaution
    52
- Fuel Line
  
  52
  - Removal / Installation
    52
  - Fuel Leakage Check Procedure
    53
  - Fuel Hose Connection
    53
- Carburetors
  
  54
  - Removal / Installation
    54
  - Disassembly
    56
  - Cleaning and Inspection
    57
  - Reassembly
    58
- Fuel Pump
  
  60
  - Removal / Installation
    60
  - Disassembly / Reassembly
    61
  - Inspection
    62
- Fuel Tank and Fuel Cock
  
  63
  - Removal / Installation
    63
  - Disassembly / Reassembly
    64
  - Inspection
    65
- Notes
  
  66
Manual Starter

67
- Removal
  68
- Disassembly
  69
- Reassembly
  71
- Inspection
  72
- Installation
  72
- Neutral Start Interlock (Nsi)
  73
- Notes
  74
Powerhead

75
- Removal
  76
- Installation
  79
- Disassembly
  81
- Cylinder / Piston / Crankshaft / Conrod / Camshaft
  83
- Inspection and Servicing
  85
  - Cylinder Head
    85
- Valve / Valve Guide
  86
  - Valve Seat Servicing
    90
  - Valve Guide Replacement
    91
- Valve Spring
  92
- Camshaft
  93
- Cylinder / Piston / Piston Ring
  95
- Piston Pin / Conrod / Crankshaft
  100
- Oil Seal / Bearing
  104
- Thermostat
  106
- Reassembly
  107
  - Piston to Conrod
    107
  - Piston Ring to Piston
    108
  - Crankshaft and Piston to Cylinder
    109
  - Conrod Cap
    109
  - Camshaft to Cylinder
    110
  - Crankcase to Cylinder
    110
  - Cylinder Head / Valve
    111
  - Cylinder Head to Cylinder
    112
  - Pivot Nut / Rocker Arm / Valve Clearance
    112
  - Cylinder Head Cover
    113
  - Intake Manifold / Thermostat
    113
  - Oil Pump / Oil Filter
    113
- Operation
  114
  - Water Cooling System
    114
  - Engine Lubrication System
    115
- Notes
  116
Midsection

117
- Tiller Handle
  
  118
  - Removal / Installation
    118
  - Installation
    119
- Disassembly / Reassembly
  
  119
  - Disassembly
    119
  - Reassembly
    120
- Clutch Lever / Rod
  
  121
  - Removal
    121
  - Installation
    122
- Steering Bracket / Driveshaft Housing / Swivel Bracket / Clamp Bracket
  
  123
  - Disassembly
    123
  - Inspection
    126
  - Driveshaft Housing / Steering Bracket
    126
  - Clamp Bracket / Swivel Bracket
    126
  - Mount / Bushing
    126
  - Water Tube
    126
  - Reassembly
    127
  - Swivel Bracket / Clamp Bracket
    128
  - Driveshaft Housing / Steering Bracket
    128
  - Lubrication
    129
- Notes
  
  130
Gearcase

131
- Removal and Disassembly
  132
  - Disassembly of Propeller Shaft Components
    135
- Gear
  136
- Gearcase
  136
- Inspection
  136
- Propeller
  136
- Propeller Shaft Bearing Housing
  137
- Propeller Shaft Components
  137
- Driveshaft
  138
- Driveshaft Support Housing
  138
- Shift Rod and Shift Cam
  138
- Water Pump and Related Items
  138
- Reassembly and Installation
  139
- Driveshaft / Driveshaft Support Housing
  141
- Forward Gear
  141
- Pinion Gear
  141
- Shift Rod Assembly
  142
- Water Pump and Related Items
  142
- Propeller Shaft Components
  143
- Leakage Check
  144
- Propeller
  144
- Lower Unit Installation
  
  145
  - Gear Oil
    145
  - Clutch Adjustment
    146
    
    Forward Gear / Pinion Gear Shim Adjustment
    148
- Lower Unit Gears-Shimming and Adjustment
  
  148
Wire / Hose Routing

153
- Wire and Hose Routing
  154
  - Hp Models
    155
  - 5/6 Hp Models
    156
- Wiring Diagram
  157
- Optional Electrical Parts Installation
  158
- Cable / Wire Routing
  159
- Notes
  160
Wire / Hose Routing Notes Notes

161
- Marine Products and the Safety of People Who Use Them
  163
- Marine Products and the Safety of People Who Fix Them
  177
  - Handling Outboards
    177
  - Handling Lead/Acid Batteries
    181
  - Gasoline - Handle with Care
    182
  - Hazardous Products
    183
  - Safety Awareness Test
    184

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