BRP Johnson J30PL4SUA 2007 Manuals

Manuals and User Guides for BRP Johnson J30PL4SUA 2007. We have 1 BRP Johnson J30PL4SUA 2007 manual available for free PDF download: Service Manual

BRP Johnson J30PL4SUA 2007 Service Manual

BRP Johnson J30PL4SUA 2007 Service Manual (292 pages)

30 HP, 4 Stroke

Brand: BRP | Category: Outboard Motor | Size: 15.92 MB

Table of Contents

Safety Information

4
- Table of Contents
  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
- Product Reference and Illustrations
  15
- Symbols
  15
- Electrical
  15
- Values
  16
Service Specifications and Special Tools 1

17
- Service Specifications and Special Tools
  18
- Technical Data
  18
- Standard Torque Specifications
  20
  - Electrical / Ignition
    21
  - Fuel
    22
  - Gearcase
    22
- Special Tools
  23
  - Powerhead
    24
  - Universal
    26
- Shop Aids
  29
- Notes
  30
Table of Contents

31
- Installation and Predelivery
  31
- Boat Rigging
  
  32
  - Remote Controls
    32
  - Battery Installation
    34
  - Fuel System Requirements
    35
- Outboard Installation
  
  36
  - Hull Preparation
    36
  - Transom Measuring and Drilling
    37
  - Lifting the Outboard
    39
  - Steering Systems
    39
  - Outboard Mounting
    40
- Outboard Rigging
  
  41
- Fuel and Oil
  
  46
  - Fuel Requirements
    46
  - Oil Requirements
    47
- Running Checks
  
  47
  - Break-In (10 Hours)
    47
  - Fuel System
    48
  - Emergency Stop Switch
    48
  - Start-In-Gear Prevention
    48
  - Tachometer Pulse Setting
    49
  - Water Pump Overboard Indicator
    49
  - Operating Temperature
    49
- Propeller Selection
  
  50
  - Procedure
    50
  - Propeller Hardware Installation
    51
- Notes
  
  52
Installation and Predelivery Notes Notes

53
- Inspection and Maintenance Schedule
  54
- Anti-Corrosion Protection
  56
  - Sacrificial Anodes
    56
  - Metallic Component Protection
    57
  - Exterior Finish Protection
    57
- Engine Side Covers
  56
- Battery and Battery Connections
  57
- Carburetors
  58
  - General
    58
  - Synchronizing the Carburetor Throttle Valves
    58
  - Dashpot Adjustment
    61
- Engine Oil and Filter
  62
  - Checking the Engine Oil Level
    62
  - Changing the Engine Oil and Filter
    62
- Fuel System
  64
  - Hoses and Connections
    64
  - Fuel Filter
    64
- Gearcase
  65
  - Draining
    65
  - Inspection
    65
  - Filling
    65
  - Water Intake Screens
    65
- Idle Speed
  66
- Ignition Timing
  67
- Overboard Water Pressure Indicator
  67
- Lubrication Points
  68
- Spark Plugs
  69
- Valve Clearance
  70
  - Checking
    70
  - Adjusting
    70
Table of Contents

71
- Components
  
  72
  - Flywheel
    72
  - Charge Coil
    72
  - Crankshaft Position Vcsensor (Cps)
    72
  - Power Pack
    72
  - Emergency Stop Switch
    73
  - Ignition Coil
    73
- Operation
  
  74
- Troubleshooting
  
  75
- Ignition Tests
  
  76
- Caution Systems
  
  80
  - Operation
    80
  - Test Procedures
    81
- Removal and Installation
  
  82
  - Flywheel
    82
  - Charge Coil and Crankshaft Position Sensors
    83
  - Oil Pressure Switch
    84
Electrical

85
- Battery Charging System
  
  86
  - Operation
    86
  - Test Procedures
    87
  - Removal and Installation
    89
- Electric Starter System
  
  89
  - Schematics
    89
  - Troubleshooting
    90
  - Test Procedures
    92
- Starter Motor
  
  93
  - Removal
    93
  - Disassembly
    94
  - Inspection and Testing
    95
  - Assembly
    97
  - Installation
    99
- Notes
  
  100
Electrical Notes Notes

101
- Fuel Lines
  
  102
  - Removal and Installation
    102
  - Fuel Hose Connections
    102
- Carburetors
  
  103
  - Removal
    103
  - Disassembly
    105
  - Cleaning and Inspection
    106
  - Assembly
    107
  - Installation
    109
- Throttle Control
  
  111
  - Throttle Linkage Adjustments
    111
  - Throttle Cable Installation and Adjustment
    112
- Fuel Pump
  
  113
  - Removal
    113
  - Disassembly
    113
  - Inspection
    114
  - Assembly
    114
  - Installation
    115
- Operation
  
  116
  - Carburetor
    116
  - Accelerator Pump System
    117
- Notes
  
  118
Powerhead

119
- Test Procedures
  
  120
  - Cylinder Compression Test
    120
  - Engine Oil Pressure Test
    121
- Removal and Installation
  
  122
  - Removal
    122
  - Installation
    127
- Timing Chain and Tensioner
  
  133
  - Removal
    133
  - Inspection
    135
  - Installation
    135
- Cylinder Head
  
  138
  - Removal
    138
  - Installation
    138
  - Disassembly
    139
  - Inspection and Servicing
    141
  - Assembly
    149
- Piston, Cylinder, and Crankshaft
  
  152
  - Removal
    152
  - Inspection and Servicing
    154
  - Installation
    166
- Thermostat
  
  171
  - Removal
    171
  - Inspection
    171
  - Installation
    171
- Operation
  
  172
  - Water Cooling System
    172
  - Engine Lubrication System
    173
- Notes
  
  174
Powerhead Notes Notes

175
- Cleaning and Inspection
  
  176
  - General
    176
  - Clamp Screw
    176
  - Exhaust Housing
    176
- Steering Handle
  
  177
  - Removal
    177
  - Installation
    178
- Tilt Assist Cylinder
  
  179
  - Removal
    179
  - Installation
    181
- Exhaust Housing and Oil Pan
  
  183
  - Removal
    183
  - Disassembly
    184
  - Assembly
    186
  - Installation
    189
- Stern Brackets, Steering Arm, and Swivel Bracket
  
  190
  - Removal
    190
  - Installation
    193
- Notes
  
  196
Midsection Notes Notes

197
- Gearcase
  197
- Components
  
  198
- Propeller
  
  200
  - Removal
    200
  - Inspection
    200
  - Installation
    200
- Trim Tab Adjustment
  
  201
- Lubricant
  
  202
  - Draining
    202
  - Inspection
    202
  - Filling
    202
- Removal and Installation
  
  203
  - Removal
    203
  - Installation
    204
- Leak Test
  
  203
- Water Pump
  
  206
  - Disassembly
    206
  - Inspection
    206
  - Assembly
    207
- Disassembly
  
  207
  - Pre-Disassembly Inspection
    207
  - Propeller Shaft Bearing Housing Removal
    208
  - Propeller Shaft Disassembly
    208
  - Pinion Gear and Driveshaft Removal
    209
  - Driveshaft Disassembly
    211
  - Shift Rod Removal
    211
  - Shift Rod Disassembly
    212
- Bearing and Seal Removal
  
  212
- Bearing and Seal Installation
  
  214
- Assembly
  
  217
  - Pre-Assembly Inspection
    217
  - Shift Rod Assembly
    217
  - Driveshaft Assembly
    218
  - Pinion Gear and Driveshaft Installation
    219
  - Propeller Shaft Assembly
    220
  - Propeller Shaft Bearing Housing Installation
    221
- Shimming and Gear Backlash Checks
  
  222
- Notes
  
  226
Gearcase Notes Notes

227
- System Wiring
  
  228
  - Wiring Diagram
    228
  - Testing the Ptt Motor Relay
    229
- Service Procedures
  
  230
  - Checking the Oil Level
    230
  - Bleeding the Air
    230
- Power Trim and Tilt (Ptt) Unit
  
  231
  - Removal
    231
  - Installation
    232
- Ptt Motor
  
  234
  - Removal
    234
  - Disassembly
    235
  - Inspection
    235
  - Assembly
    237
  - Installation
    237
- Operation
  
  239
  - Trim Tilt "Up" Circuit
    240
  - Trim/Tilt "Down" Circuit
    241
  - Shock Absorber Circuit
    242
  - Manual Release Circuit (Manual Valve)
    243
  - Thermal Valve
    244
Wire and Hose Routing

245
- Wire Routing
  
  246
  - 30 Tel
    247
  - 30 (PL) Remote
    248
  - 30 Tel
    249
  - 30 (PL) Remote
    249
  - 30 Tel
    250
  - 30 (PL) Remote
    250
  - 30 Tel
    251
  - Pl) Remote
    251
- Fuel / Water Hose Routing
  
  252
  - 30 Tel
    252
  - 30 (PL) Remote
    253
- Notes
  
  256
Wire and Hose Routing Notes Notes

257
- Marine Products and the Safety of People Who Use Them
  259
- Marine Products and the Safety of People Who Fix Them
  273
  - Handling Outboards
    273
  - Handling Lead/Acid Batteries
    277
  - Gasoline - Handle with Care
    278
  - Hazardous Products
    279
  - Safety Awareness Test
    280

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