To begin with, a downloadable Johnson outboard repair manual, also termed factory service manual, refers to a digitally delivered book of repair instructions provided by the outboard motor manufacture. The handbook is intended to guide the mechanic in the process of fixing or restoring a boat motor to working order. Johnson outboard repair manuals cover every aspect of repair and it’s divided into several main sections. Below is a breakdown of information generally found in a Johnson outboard repair manual.
Table of Contents
A table of contents is the part of the repair manual that list the main chapters and it’s located at the beginning of the manual. Typical Johnson outboard repair manuals contain the following chapters:
- Service Specifications
- Ignition System
- Fuel System
- Manual Starter (If Equipped)
- Electric Starter (If Equipped)
- Tilt And Steering
- Wire/House Routing
Nowadays there are paperback manuals and downloadable versions. Downloadable repair manuals are often more helpful because the table of contents contain clickable chapters and subchapters that navigate the user to the selected repair procedures with the click of the mouse.
The Johnson outboard repair manual introduction describes important information about the text that the reader should know about before proceeding to use the manual. The introduction will contain models covered in the manual, how to identify model and serial numbers, model designation, as well as information on how to use the repair manual.
Service specifications describe or identify precise technical data and descriptions of the outboard motor. Some of the service specifications might include torque specifications, special tools required to perform a repair job properly, and shop aids.
A Johnson outboard maintenance section describes the process of maintaining the motor based on manufacture specifications. Maintenance information often includes:
- Inspection and Maintenance Schedules
- Anti-Corrosion Protection
- Cooling System Maintenance
- Fuel System Maintenance
- Battery Maintenance
- Lubrication Maintenance
- Spark Plug Maintenance
- Valve Clearance Maintenance
- Timing Belt Maintenance
- Pre-Season Service
- Submerged Engines
- Repair Procedures
All Johnson outboard repair manuals contain step-by-step repair procedures so that the mechanic can establish the official way of servicing the outboard motor and restoring it to manufacture specifications. Depending on what’s being repaired, information might include:
- Part Removal Procedures
- Part Disassembly Procedures
- Part Inspection Procedures
- Part Cleaning Procedures
- Part Repair Procedures
- Part Assembly Procedures
- Part Installation Procedures
- Part Testing Procedures (If Applicable)
In most cases, repair procedures are accompanied with pictures, illustrations and labeled part breakdown diagrams to help the mechanic complete the repair job successfully.
Wiring And Hose Routing Diagrams
Complete hose routing and wiring diagrams are provided. Writing diagrams are usually black and white illustrations of specific parts and list wire colors and functions. Hose routing diagrams show intended route which are especially helpful for mechanics performing complete engine overhaul.
The troubleshooting section of the Johnson outboard repair manual is critical for solving serious problems. Especially when the cause of the problem is not fully understood. Troubleshooting guides help the mechanic trace and correct faults in the Johnson outboards mechanical or electrical system. Using a troubleshooting guide can be a fast and effective way of pinpointing a malfunction.