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Johnson J30TEL4SUA 2007
BRP Johnson J30TEL4SUA 2007 User Manual
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2
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
Default Chapter
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
Mws Harness Installation
41
Control Cable Identification
42
Control Cable Installation
43
Water Pressure Gauge Connection
45
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
Ignition Coil Resistance Test
76
Charge Coil Tests
77
Crankshaft Position Sensor (Cps) Coil Tests
78
Power Pack Cranking Output Test
79
Emergency Stop Switch Continuity Test
79
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
Default Chapter
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
Checking the Forward Gear-To-Pinion Gear Backlash
222
Checking the Tooth Contact Pattern
223
Checking the Driveshaft Thrust Play
224
Checking the Propeller Shaft Thrust Play
225
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
Outboard Shift Systems and Safety
260
Outboard Speed Control System and Safety
261
Outboard Steering Control System and Safety
262
Outboard Fuel, Electrical System, and Safety
264
Outboard Mounting System and Safety
267
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
269
Outboard Emergency Stop System and Safety
270
Summing up
272
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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BRP Johnson J30TEL4SUA 2007 Specifications
General
Brand
BRP
Model
Johnson J30TEL4SUA 2007
Category
Outboard Motor
Language
English
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