BRP Johnson J10TBL4S0B Manuals

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BRP Johnson J10TBL4S0B Service Manual

BRP Johnson J10TBL4S0B Service Manual (264 pages)

9.9-15 HP 4 Stroke Outboard Motors

Brand: BRP | Category: Outboard Motor | Size: 38.25 MB

Table of Contents

Introduction

6
- Table of Contents
  6
- Models Covered in this Manual
  7
  - Identifying Model and Serial Numbers
    7
- Typical Page - a
  9
- Typical Page - B
  10
- Typical Page - D
  10
- Typical Page - C
  11
- Symbols
  13
  - Values
    13
Service Specifications and I

14
- Technical Data
  15
- TORQUE Specifications
  17
  - Tightening Torque -Important Fastners
    17
  - Tightening Torque - General Bolt
    18
- Special Tools
  19
  - Electrical I Ignition
    19
  - Fuel and Oil
    20
  - Gearcase
    20
  - Powerhead
    21
  - Starter
    21
  - Universal
    22
- Shop Aids
  23
Installation and Predelivery •

26
- Boat Rigging
  27
  - Remote Controls
    27
  - Battery Installation
    28
  - Fuel System Requirements
    29
- Outboard Installation
  30
  - Hull Preparation
    30
  - Transom Measuring and Drilling
    31
  - Lifting the Outboard
    32
  - Steering Systems
    32
  - Outboard Mounting
    33
- Outboard Rigging
  34
- Fuel and Oil
  38
  - Fuel Requirements
    38
  - Minimum Octane
    38
  - Additives
    38
  - Oil Requirements
    39
- Initial Running Checks
  39
  - Break-In (10 Hours)
    39
  - Fuel System
    40
  - Emergency Stop Switch
    40
  - Outboard Controls
    40
  - Start-In-Gear Prevention
    40
  - Tachometer Pulse Setting
    41
  - Water Pump Overboard Indicator
    41
  - Operating Temperature
    41
- Propeller Selection
  42
  - Procedure
    42
  - Propeller Hardware Installation
    43
Maintenance

44
- Inspection and Maintenance Schedule
  45
- 10-Hour Inspection
  47
- Anti-Corrosion Protection
  47
  - Sacrificial Anodes
    47
  - Testing Procedure Continuity
    48
  - Bonding Wires
    48
  - Metallic Component Protection
    48
  - Exterior Finishes
    48
- Cooling System
  49
  - Flushing
    49
  - Water Intake Screen
    49
  - Water Pump
    49
- Battery
  50
- Fuel System
  50
  - Breather and Fuel Line
    50
  - Fuel Filter
    50
- Lubrication
  51
  - Engine Oil
    51
  - Engine Oil Filter
    52
  - Gearcase Lubricant
    53
  - Linkages and Fittings
    54
- Spark Plugs
  55
- Valve Clearance
  55
  - Measurement
    55
  - Adjustment
    56
- Timing Belt
  57
- Idle Speed
  60
- Ignition Timing
  60
- Storage
  61
  - Fuel System Treatment
    61
  - Internal Engine Treatment
    61
  - Additional Recommendations
    61
- Pre-Season Service
  62
  - Crankcase Oil
    62
  - Gearcase Lubricant
    62
  - Operational Checks
    62
  - Fuel System
    62
- Submerged Engines
  62
Electrical Electrical

64
- Caution System
  65
  - Self Test
    65
  - Over-Revolution Caution System
    65
  - Low Oil Pressure Caution System
    66
  - Oil Pressure Caution System Tests
    67
  - Oil Pressure Switch Service
    68
- Battery Charging System
  69
  - Inspection
    70
  - Removal and Installation
    73
- Electric Starter System
  74
  - Operation
    74
  - Troubleshooting
    76
  - Inspection
    77
  - Starter Motor Service
    78
- Notes
  91
Ignition System

92
- Service Chart
  93
- Operation
  94
- Troubleshooting
  95
- Ignition Tests
  96
  - Condenser Charge Coil
    96
  - Pulser Coil
    97
  - Ignition Coil
    98
  - Col UNIT
    99
  - Spark Plug Cap
    99
  - Engine Stop Switch
    99
- Component Servicing
  100
  - Removal
    100
  - Installation
    103
- Notes
  105
Fuel System Fuel System

106
- Carburetor Operation
  107
  - Float System
    107
  - Idlingitrolling
    107
  - Low-MID Speed
    108
  - MID-High Speed
    108
  - Accelerator Pump
    109
  - Auto-Enrichener System
    110
  - Manual Starter System
    111
- Carburetor Service
  112
  - Removal
    112
  - Disassembly
    113
  - Cleaning and Inspection
    115
  - Assembly
    117
  - Installation
    119
- Throttle Control
  120
  - Installation/Adjustment
    120
- Fuel Pump
  122
  - Removal
    122
  - Disassembly
    122
  - Inspection
    123
  - Assembly
    124
  - Installation
    124
- Notes
  125
Powerhead

126
- Specifications
  127
- Test Procedures
  131
  - Compression Testing
    131
  - Oil Pressure Test
    132
- Removal and Installation
  133
  - Removal
    133
  - Installation
    136
  - Final Assembly Checks
    138
- Cylinder Head Assembly
  139
  - Removal
    139
  - Disassembly
    139
  - Cleaning/Inspection
    141
  - Assembly
    147
  - Installation
    151
- Cylinder/Crankcase/Piston Assembly
  152
  - Disassembly
    152
  - Cleaning/Inspection
    154
  - Reassembly
    163
- Cooling System
  169
  - Operation
    169
  - Cooling System Diagram
    170
- ENGINE LUBRICATION System
  171
  - Engine Oil Lubrication Chart
    171
  - Oil Passage Location
    172
- Notes
  173
Midsection

174
- Service Chart
  175
- Side Cover
  179
  - Removal and Installation
    179
- Driveshaft Housing and Oil Pan
  180
  - Disassembly
    181
  - Cleaning and Inspection
    182
  - Assembly
    183
- Stern Bracket
  185
  - Disassembly
    185
  - Inspection
    187
  - Assembly
    187
- Steering Handle
  191
  - Removal
    191
  - Installation
    192
- Notes
  193
Gearcase

194
- Service Chart
  195
- Lubricant
  197
  - Draining
    197
  - Filling
    198
- Propeller
  197
  - Inspection
    197
  - Installation
    197
- Leak Test
  198
- Removal and Installation
  199
  - Removal
    199
  - Installation
    200
  - Clutch Adjustment
    200
- Water Pump
  201
  - Disassembly
    201
  - Inspection
    202
  - Assembly
    202
- Disassembly
  204
  - Propeller Shaft Bearing Housing Components
    205
  - Shift Rod Components
    206
  - Pinion Bearing
    207
- Cleaning and Inspection
  207
- Assembly
  208
  - Pinion Bearing
    208
  - Shift Rod/Shift Cam Assembly
    209
  - Propeller Shaft
    209
  - Forward Gear
    210
  - Pinion Gear and Driveshaft
    210
  - Propeller Shaft Bearing Housing
    211
- Shimming Adjustments
  212
  - Shimiwasher Positions
    212
  - Forward Gear/Pinion Gear
    213
  - Pinion Gear/Reverse Gear
    214
  - Propeller Shaft Thrust Play
    214
- Notes
  215
Manual Starter

216
- Service Chart
  217
- Disassembly
  218
- Removal
  218
- Inspection
  220
- Assembly
  221
- Installation
  222
- Installation/Adjustment
  223
- Neutral Start Interlock
  223
Safety

236

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