BRP Johnson J25R4SUR User Manual

Details the outboard models covered in this service manual.

Explains the meaning of letters and numbers in the model designation.

Provides specifications for engine, electrical, cooling, ignition, and gearcase.

Lists torque values for important fasteners and general bolts.

Lists special tools required for various service procedures.

Procedures for rigging the outboard, including controls and battery.

Steps for installing the outboard onto the boat transom.

Procedures for initial engine checks and break-in.

Guide to selecting the correct propeller for optimal performance.

Comprehensive schedule for routine inspection and maintenance tasks.

Methods to protect the outboard from corrosion.

Maintenance of the cooling system, including flushing.

Maintenance of the fuel system, including lines and filters.

Procedures for checking and changing engine oil and filter.

Measuring and adjusting valve clearance.

Procedures for preparing the outboard for storage.

Explains caution systems for over-revolution, low oil, and overheat warnings.

Testing and servicing the battery charging system components.

Operation, troubleshooting, and service of the electric starter system.

Diagnosing and resolving ignition system problems.

Procedures for testing ignition system components like coils and sensors.

Removal and installation of ignition system components.

Explains the operation of the carburetor systems.

Procedures for carburetor disassembly, cleaning, and assembly.

Removal, inspection, and installation of the fuel pump.

Service procedures for the intake manifold.

Installation and adjustment of throttle controls for tiller and remote models.

Technical specifications for cylinder head, camshaft, valves, and guides.

Procedures for compression and oil pressure testing.

Steps for removing and installing the powerhead.

Procedures for cylinder head removal, disassembly, cleaning, and assembly.

Disassembly, cleaning, inspection, and assembly of crankshaft, pistons, and camshaft.

Procedures for thermostat removal, inspection, and installation.

Removal and installation procedures for the side cover.

Removal, disassembly, cleaning, and assembly of driveshaft housing and oil pan.

Disassembly and assembly procedures for the stern bracket.

Removal and installation procedures for the steering handle.

Inspection and installation of the propeller.

Procedures for draining, inspecting, and filling gearcase lubricant.

Steps for testing the gearcase for leaks.

Procedures for removing and installing the gearcase.

Disassembly and assembly of the water pump.

Cleaning and inspection of gearcase components for wear and damage.

Adjusting shims for proper gear contact and backlash.

Steps for removing the manual starter assembly.

Steps for disassembling the manual starter.

Inspecting manual starter components for wear or damage.

Steps for assembling the manual starter components.

Steps for installing the manual starter.

Installation and adjustment of the neutral start interlock system.

Wiring diagrams for different outboard models.

Proper routing of electrical wires on the engine.

Proper routing of fuel and water hoses.

General safety guidelines for boaters and users.

Safety considerations for outboard shift systems.

Safety considerations for outboard speed control systems.

Safety considerations for outboard steering systems.

Safety precautions for fuel and electrical systems.

Guidelines for safe handling and storage of gasoline.

Safety precautions for mounting the outboard.

Safety of the emergency stop system and lanyard use.

Safety guidelines for technicians working on marine products.

Hazards associated with exhaust fumes and ventilation requirements.

Safety precautions when working near the propeller.

Safety procedures for handling and charging lead-acid batteries.