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Outboard Motor
J15RLSUA
Johnson J15RLSUA User Manual
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74
ELECTRICAL
ELECTRIC ST
ARTER TESTS
9
+
8
7
6
5
1
4
3
2
TYPICAL
1.
Battery positive (+)
2.
Battery negative (-)
3.
Rectifier terminal ground
4.
S
tart switch connection
5.
Powerhead ground
6.
S
tart switch output lead
7.
S
tart button
8.
S
tarter terminal
9.
Pinion
DRC6305
75
77
Table of Contents
Safety Information
4
Table of Contents
4
Safety Information
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
Engine Emissions Information
15
Manufacturer's Responsibility
15
Dealer's Responsibility
15
Owner's Responsibility
15
Epa Emission Regulations
15
Product Reference and Illustrations
16
Symbols
16
Electrical
16
Values
17
Notes
18
Service Specifications and Special Tools
19
Technical Data
20
Standard Torque Specifications
22
Special Tools
23
Electrical / Ignition
23
Fuel
24
Gearcase
25
Powerhead
26
Starter
27
Universal
27
Shop Aids
29
Notes
32
Table of Contents
33
Default Chapter
33
Installation and Predelivery
33
Boat Rigging
34
Remote Controls
34
Battery Installation
35
Fuel System Requirements
36
Outboard Installation
38
Hull Preparation
38
Transom Measuring and Drilling
39
Lifting the Outboard
40
Steering Systems
40
Outboard Mounting
41
Outboard Rigging
42
Control Cable Installation
42
Cable, Hose, and Wire Routing
44
Fuel and Oil Priming
45
Fuel Requirements
45
Fuel System Priming
46
Oil Requirements
46
Break-In Oiling
46
Before Start-Up
47
Gearcase Lubricant
47
Running Checks
47
Fuel System
47
Emergency Stop / Key Switch
47
Start-In-Gear Prevention
48
Tachometer Pulse Setting
48
Water Pump Overboard Indicator
48
Operating Temperature
48
Break-In
48
Propellers
49
Propeller Selection
49
Propeller Hardware Installation
49
Maintenance
51
Inspection and Maintenance Schedule
52
Anti-Corrosion Protection
54
Metallic Component Protection
54
Exterior Finishes
54
Cooling System
55
Flushing
55
Water Intake Screens
56
Lubrication
56
Steering System
56
Midsection
57
Throttle and Shift Linkage
57
Gearcase Lubricant
58
Propeller Shaft
58
Electric Starter
59
Battery and Battery Connections
59
Fuel System
60
Fuel Filter
60
Air Silencer
60
Hoses and Connections
60
Spark Plugs
60
Synchronization and Linkage Adjustments
61
Preliminary Adjustments
61
Cam Follower Pickup Point
62
Wide Open Throttle Adjustment
63
Maximum Spark Advance
63
Idle Speed
63
Shift Lever Detent
64
10-Hour Inspection
64
Storage
65
Fuel System Treatment
65
Internal Engine Treatment
65
Additional Recommendations
65
Pre-Season Service
66
Clamp Screws and Mounting Bolts
66
Gearcase Lubricant
66
Battery(S)
66
Operational Checks
66
Fuel System
66
Submerged Engines
66
Engine Dropped Overboard (Not Running)
66
Engine Dropped Overboard (Running)
67
Engine Dropped Overboard (in Salt Water)
67
Prolonged Submersion (Fresh or Salt Water)
67
Notes
68
Maintenance Notes Notes
69
Default Chapter
69
Electrical
69
Charging System Components
70
Flywheel
70
Stator
70
Rectifier
70
Charging System Tests
71
Charging System Check Chart
71
Running Alternator Output Test
71
Stator Resistance Tests
72
Rectifier Resistance Tests
72
Tachometer Circuit Test
73
Electric Starter Tests
74
Start Switch Test
74
Start Circuit Voltage Test
74
Voltage Drop Tests
77
Starter Solenoid Test
78
No Load Current Draw Test
79
Electric Starter Servicing
79
Removal
79
Disassembly
79
Cleaning and Inspection
80
Assembly
81
Installation
82
Accessory Components
83
Removal
83
Installation
84
Connector Servicing
84
Amphenol Connectors
84
Notes
86
Electrical Notes Notes
87
Default Chapter
87
Ignition
87
Components
88
Flywheel
88
Charge Coil
88
Sensor Coil
88
Power Pack
88
Stop Button
89
Key Switch
89
Ignition Coil
89
Troubleshooting
90
Flywheel Indexing
90
Ignition System Tests
91
Total Ignition Output Test
91
Stop Circuit Tests
91
Charge Coil Test
93
Sensor Coil Test
94
Power Pack Cranking Output
96
Power Pack Running Output
96
Ignition Coil Tests
97
Flywheel Servicing
99
Removal
99
Installation
100
Spark Plugs
99
Ignition Plate Servicing
101
Removal
101
Installation
101
Charge Coil and Sensor Coil
102
Removal
102
Installation
103
Ignition Coil
104
Removal
104
Installation
104
Fuel System
105
Fuel System Trouble Check Chart
106
Components
107
Fuel Pump
107
Carburetor
107
Intake Manifold
107
Fuel Pump Pressure Test
108
Fuel Pump Service
108
Disassembly
108
Cleaning
108
Assembly
109
Carburetor Service
109
Emissions Compliance
109
Removal
109
Disassembly
110
Cleaning and Inspection
111
Assembly
113
Installation
115
Carburetor Mixture Adjustment
116
Intake Manifold
117
Removal
117
Inspection
117
Disassembly
118
Assembly
118
Installation
119
Notes
120
Fuel System Notes Notes
121
Powerhead
121
Torque Chart
122
General
123
Cylinder Compression Testing
123
Retaining Ring Pliers
123
Taper Pin Tool
123
Engine Temperature Check
124
Upper Crankcase Seal
125
General
125
Removal
125
Installation
125
Shift Linkage
126
Removal
126
Installation
127
Start Switch
128
Neutral Start Protection
129
Manual Starter
129
Electric Starter
129
Removal
130
Disassembly
131
Cleaning
135
Inspection
136
Assembly
138
Installation
145
Powerhead Views
147
Port/Starboard View, Manual Start
147
Rear View, Manual Start
148
Powerhead Powerhead Views Rear View, Manual Start
149
Torque Chart
150
Steering Handle
151
Removal
151
Disassembly
152
Inspection
153
Assembly
153
Installation
155
Exhaust Housing
157
Disassembly
157
Cleaning and Inspection
158
Assembly
159
Swivel Bracket
161
Disassembly
161
Assembly
162
Adjustments
164
Tilt Friction Adjustment
164
Steering Friction Adjustment
164
Idle Speed Adjustment
164
Throttle Friction Adjustment
164
Table of Contents
165
Service Chart
166
Lubricant
167
Draining
167
Inspection
168
Filling
168
Propeller
167
Inspection
167
Leak Test
168
Removal and Installation
169
Removal
169
Installation
170
Water Pump
171
Disassembly
171
Inspection
171
Assembly
171
Disassembly
173
Bearing and Seal Removal
174
Driveshaft Seals
174
Driveshaft Bearing
174
Pinion Bearings
175
Forward Bearing
175
Shift Rod Bushing and O-Ring
175
Prop Shaft Bearing Housing Seals and O-Ring
176
Prop Shaft Bearing Housing Bearings
176
Cleaning and Inspection
177
Seal and Bearing Installation
178
Propeller Shaft Bearing Housing Bearings
178
Propeller Shaft Bearing Housing Seals and O-Ring
178
Shift Rod Bushing and O-Ring
178
Forward Bearing
179
Pinion Bearings
179
Driveshaft Bearing
180
Driveshaft Seals
180
Assembly
181
Notes
184
Manual Starter
185
General
186
Starter Rope Length
186
Torque Chart
186
Removal
186
Rope Replacement
187
Safety
187
Disassembly
188
Assembly
189
Cleaning and Inspection
189
Installation
192
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
193
Marine Products and the Safety of People Who Use Them
195
Outboard Shift Systems and Safety
196
Outboard Speed Control System and Safety
197
Outboard Steering Control System and Safety
198
Outboard Fuel, Electrical System, and Safety
200
Outboard Mounting System and Safety
203
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
205
Outboard Emergency Stop System and Safety
206
Summing up
208
Marine Products and the Safety of People Who Fix Them
209
Handling Outboards
209
Handling Lead/Acid Batteries
213
Gasoline - Handle with Care
214
Hazardous Products
215
Safety Awareness Test
216
Index
217
4
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Johnson J15RLSUA Specifications
General
Brand
Johnson
Model
J15RLSUA
Category
Outboard Motor
Language
English
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