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2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual – PDF Download
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2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual
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Description
2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual
FILE DETAILS:
2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual
LANGUAGE:ENGLISH
PAGES:179
DOWNLOADABLE:YES
FILE TYPE:PDF
2007 JOHNSON EVINRUDE 2.5 HP 4-STROKE OUTBOARDS SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
- 2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual
- This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude®/Johnson® Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s).
- This manual uses the following signal words identifying important safety messages. Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. It is understood that this manual may be translated into other languages.
- In the event of any discrepancy, the English version shall prevail. To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual. DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs.
- Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.
- When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction. Torque wrench tightening specifications must be strictly followed.
- Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.
- If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.
TABLE OF CONTENTS:
2007 Johnson Evinrude 2.5 HP 4-Stroke Outboards Service Repair Workshop Manual
<— Return to Menu.............................................................. 0 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....................................... 17 TECHNICAL DATA............................................................. 18 STANDARD TORQUE SPECIFICATIONS............................................. 20 Tightening Torque - Important Fasteners................................ 20 Tightening Torque - General Bolt....................................... 21 SPECIAL TOOLS.............................................................. 22 Electrical / Ignition.................................................. 22 Fuel and Oil........................................................... 23 Gearcase............................................................... 23 Powerhead.............................................................. 24 Starter................................................................ 24 Universal.............................................................. 25 SHOP AIDS.................................................................. 26 INSTALLATION AND PREDELIVERY................................................... 29 HULL PREPARATION........................................................... 30 Maximum Capacity....................................................... 30 Mounting Surface....................................................... 30 Top Edge of Transom or Bracket......................................... 30 Transom Clearances..................................................... 30 Water Flow............................................................. 30 Mounting Hardware...................................................... 30 TRANSOM MEASURING AND DRILLING............................................. 31 Hull Centerline........................................................ 31 Transom Heights........................................................ 31 Lifting the Outboard................................................... 32 OUTBOARD MOUNTING.......................................................... 32 FUEL AND OIL............................................................... 33 Fuel Requirements...................................................... 33 Oil Requirements....................................................... 34 RUNNING CHECKS............................................................. 35 Break-In (10 Hours).................................................... 35 Fuel System............................................................ 36 Emergency Stop Switch.................................................. 36 Outboard Controls...................................................... 36 Start-In-Gear Prevention............................................... 36 Water Pump Overboard Indicator......................................... 36 Operating Temperature.................................................. 36 PROPELLER SELECTION........................................................ 37 Procedure.............................................................. 37 Propeller Hardware Installation........................................ 38 MAINTENANCE.................................................................... 39 INSPECTION AND MAINTENANCE SCHEDULE........................................ 40 10-HOUR INSPECTION......................................................... 42 ANTI-CORROSION PROTECTION.................................................. 42 Sacrificial Anodes..................................................... 42 Testing Procedure - Continuity......................................... 43 Metallic Component Protection.......................................... 43 Exterior Finishes...................................................... 43 COOLING SYSTEM............................................................. 44 Flushing............................................................... 44 Water Intake Screen.................................................... 44 Water Pump............................................................. 44 FUEL SYSTEM................................................................ 45 Breather and Fuel Line................................................. 45 Fuel Filter............................................................ 45 Carburetor............................................................. 45 LUBRICATION................................................................ 45 Engine Oil............................................................. 45 Gearcase Lubricant..................................................... 46 Linkages and Fittings.................................................. 47 SPARK PLUG................................................................. 48 VALVE CLEARANCE............................................................ 48 Measurement............................................................ 48 Adjustment............................................................. 49 IDLE SPEED................................................................. 50 IGNITION TIMING............................................................ 51 STORAGE.................................................................... 52 Fuel System Treatment.................................................. 52 Internal Engine Treatment.............................................. 52 Additional Recommendations............................................. 52 PRE-SEASON SERVICE......................................................... 53 Crankcase Oil.......................................................... 53 Gearcase Lubricant..................................................... 53 Operational Checks..................................................... 53 Fuel System............................................................ 53 SUBMERGED ENGINES.......................................................... 53 Engine Dropped Overboard (Not Running)................................. 53 Engine Dropped Overboard (Running)..................................... 54 Engine Dropped Overboard (In Salt Water)............................... 54 Prolonged Submersion (Fresh or Salt Water)............................. 54 IGNITION AND ELECTRICAL........................................................ 55 SERVICE CHART.............................................................. 56 OPERATION.................................................................. 57 TROUBLESHOOTING............................................................ 59 IGNITION TESTS............................................................. 60 Igniter Unit........................................................... 60 Spark Plug Cap......................................................... 60 Engine Stop Switch..................................................... 60 COMPONENT SERVICING........................................................ 61 Igniter Air Gap........................................................ 61 Removal................................................................ 61 Installation........................................................... 62 FUEL SYSTEM.................................................................... 63 SERVICE CHART.............................................................. 64 REMOVAL.................................................................... 66 CARBURETOR................................................................. 67 Disassembly............................................................ 67 Cleaning and Inspection................................................ 68 Reassembly............................................................. 69 INSTALLATION............................................................... 70 Leakage Check.......................................................... 71 Throttle Adjustment.................................................... 71 FUEL TANK.................................................................. 72 Removal................................................................ 72 Inspection............................................................. 72 Installation........................................................... 73 NOTES...................................................................... 74 Technician’s Notes..................................................... 74 Related Documents...................................................... 74 POWERHEAD...................................................................... 75 SPECIFICATIONS............................................................. 76 COMPRESSION TESTING........................................................ 78 REMOVAL.................................................................... 79 CYLINDER HEAD.............................................................. 80 Disassembly............................................................ 80 Cleaning and Inspection................................................ 82 Assembly............................................................... 86 Installation........................................................... 88 CYLINDER/CRANKCASE/ PISTON................................................. 89 Disassembly............................................................ 89 Inspection............................................................. 91 Assembly............................................................... 98 THERMOSTAT.................................................................103 Removal................................................................103 Inspection.............................................................103 Installation...........................................................104 INSTALLATION...............................................................105 Flywheel...............................................................106 Igniter Unit...........................................................106 Final Assembly Check...................................................106 WATER COOLING SYSTEM.......................................................107 ENGINE LUBRICATION SYSTEM..................................................108 MIDSECTION.....................................................................109 SERVICE CHART..............................................................110 SERVICE CHART..............................................................111 REMOVAL....................................................................112 Clamp Bracket..........................................................113 Swivel Bracket.........................................................113 Tiller Handle..........................................................114 INSPECTION.................................................................116 ASSEMBLY...................................................................117 Swivel Bracket.........................................................117 Clamp Bracket..........................................................118 Lubrication............................................................119 Tiller Handle..........................................................119 GEARCASE.......................................................................121 SERVICE CHART..............................................................122 SERVICE CHART..............................................................123 PROPELLER..................................................................124 Inspection.............................................................124 Installation...........................................................124 LUBRICANT..................................................................124 Draining...............................................................124 Inspection.............................................................125 Filling................................................................125 LEAK TEST..................................................................125 REMOVAL....................................................................126 Propeller Shaft........................................................128 Water Pump.............................................................129 INSPECTION.................................................................129 ASSEMBLY...................................................................133 Lubrication............................................................133 Propeller Shaft........................................................134 Water Pump.............................................................135 Shift Rod..............................................................136 INSTALLATION...............................................................137 GEAR SHIMMING AND ADJUSTMENT...............................................137 Forward Gear/Pinion Gear...............................................138 Propeller Shaft Thrust Play............................................139 NOTES......................................................................140 Technician’s Notes.....................................................140 Related Documents......................................................140 MANUAL STARTER.................................................................141 SERVICE CHART..............................................................142 REMOVAL....................................................................143 DISASSEMBLY................................................................144 INSPECTION.................................................................145 ASSEMBLY AND INSTALLATION..................................................145 WIRE/HOSE ROUTING..............................................................147 WIRING DIAGRAM.............................................................148 WIRE ROUTING...............................................................149 FUEL HOSE ROUTING..........................................................150 SAFETY.........................................................................151 TABLE OF CONTENTS..........................................................151 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM......................153 Outboard Shift Systems and Safety......................................154 Outboard Speed Control System and Safety...............................155 Outboard Steering Control System and Safety............................156 Outboard Fuel, Electrical System, and Safety...........................158 Outboard Mounting System and Safety....................................161 If weakened, parts could fail later on the water, when not expected....162 Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety........163 Outboard Emergency Stop System and Safety..............................164 Summing up.............................................................166 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM......................167 Handling Outboards.....................................................167 Handling Lead/Acid Batteries...........................................171 Gasoline - Handle With Care!...........................................172 Hazardous Products.....................................................173 Safety Awareness Test..................................................174 INDEX..........................................................................175
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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