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2995 Johnson
BRP 2995 Johnson User Manual
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Jah"SlflJn.
9.9
-
15
HP
4
Stroke
Models
2
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
Control Cable Identification
34
Cable, Hose, and Wire Routing
35
Control Cable Installation
35
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
Engine Dropped Overboard (Not Running)
62
Engine Dropped Overboard (Running)
63
Engine Dropped Overboard (in Salt Water)
63
Prolonged Submersion (Fresh or Salt Water)
63
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
Marine Product5 and the 5Afety of People Who U5E Them
238
Outboard Shift Systems and Safety
239
Outboard Speed Control System and Safety
240
Outboard Steering Control System and Safety
241
Outboard Fuel, Electrical System, and Safety
243
Outboard Mounting System and Safety
246
Outboard Hydraulic Tiltitrim Shock Absorption System and Safety
248
Outboard Emergency Stop System and Safety
249
Summing up
251
Handling Outboards
252
Marine Product5 and the 5Afety of People Who Fix Them
252
Handling Lead/Acid Batteries
256
Gasoline - Handle with Care
257
Hazardous Products
258
Safety Awareness Test
259
4
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BRP 2995 Johnson Specifications
General
Engine Type
2-Stroke
Starting System
Manual
Maximum Power
9.9 hp
Gear Shift
Forward
Shaft Length
15 inches
Oil Tank Capacity
N/A (premix)
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