Johnson J2R4SUC 2007 User manual

Printed in the United States.
© 2006 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II
are registered trademarks of Tyco International, Ltd.
† Amphenol is a registered trademark of The Amphenol Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† Frahm is a registered trademark of James G. Biddle Co.
† Gasoila is a registered trademark of The Federal Process Corporation.
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† Plastigage is a registered trademark of The Dana Corporation.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
† ThreeBond is a registered trademark of Three Bond Co., Ltd.
Bombardier logo is a registered trademark of Bombardier, Inc., used under license.
The following trademarks are the property of BRP US Inc. or its affiliates:
Carbon Guard™ Nut Lock™
DPL™ Lubricant QuikStart™
Evinrude ® S.A.F.E.™
Evinrude ® E-TEC ® S.L.O.W.™
Evinrude ® / Johnson ® XD30™ Outboard Oil Screw Lock™
Evinrude ® / Johnson ® XD50™ Outboard Oil SystemCheck™
Evinrude ® / Johnson ® XD100™ Outboard Oil Triple-Guard ® Grease
Extreme Pressure Grease™ Twist-Grip™
FasTrak™ 2+4 ® Fuel Conditioner
Gel-Seal II™ Ultra™ 4-Stroke Outboard Oil
Hi-Vis™ Gearcase Lubricant HPF XR™ Gearcase Lubricant
Johnson ® Ultra Lock™
Moly Lube™

SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained
technicians who are already familiar with the use
of Evinrude®/Johnson®Special Tools. This man-
ual is not a substitute for work experience. It is an
organized guide for reference, repair, and mainte-
nance of the outboard(s).
This manual uses the following signal words iden-
tifying important safety messages.
IMPORTANT: Identifies information that will
help prevent damage to machinery and appears
next to information that controls correct assembly
and operation of the product.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If
you have not had training related to common shop
safety practices, you should do so to protect your-
self, as well as the people around you.
It is understood that this manual may be trans-
lated into other languages. In the event of any dis-
crepancy, the English version shall prevail.
To reduce the risk of personal injury, safety warn-
ings 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 pro-
cedure. Human error is caused by many factors:
carelessness, fatigue, overload, preoccupation,
unfamiliarity with the product, and drugs and alco-
hol 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 dam-
age the outboard.
DANGER
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in
death or serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor
or moderate personal injury or property
damage. It also may be used to alert
against unsafe practices.

DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.

4
TABLE
OF
CONTENTS
SECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . 15
2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 27
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 IGNITION AND ELECTRICAL . . . . . . . . . . . . . . . . . . . . 53
5 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9 MANUAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10 WIRE/HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . 145
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S–1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index–1

INTRODUCTION
5
INTRODUCTION
CONTENTS
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TYPICAL PAGE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TYPICAL PAGE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TYPICAL PAGE – C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TYPICAL PAGE – D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6
INTRODUCTION
MODELS COVERED IN THIS MANUAL
MODELS COVERED IN
THIS MANUAL
This manual covers service information on
Johnson 2.5 HP 4-Stroke models. Use this man-
ual together with the proper Parts Catalog for part
numbers and for exploded views of the outboard,
which are a valuable aid to disassembly and reas-
sembly.
Identifying Model and Serial
Numbers
Outboard model and serial numbers are located
on the starboard midsection and on the power-
head.
Model Number Start Shaft Steer
J2R4SUC Rope 15 in. Tiller
Starboard Midsection
1. Model and serial number 005512
Powerhead
1. Serial number 005513
1
1

INTRODUCTION
MODEL DESIGNATION
7
MODEL DESIGNATION
PREFIX
STYLE:
J = Johnson
E = Evinrude
HORSEPOWER
MODEL YR:
I=1
N=2
T=3
R=4
O=5
D=6
U=7
C=8
E=9
S=0
Ex: SD = 2006
MODEL RUN
or SUFFIX
DESIGN FEATURES:
AP = Advanced Propulsion
B = Blue Paint
C = Counter Rotation
D = Evinrude E-TEC
E = Electric Start w/Remote Steering
F = Direct-Injection
G = Graphite Paint
H = High Output
J = Jet Drive
M = Military
P = Power Trim and Tilt
R = Rope Start w/Tiller Steering
S = Saltwater Edition
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
4-STROKE
BJ 2 R 4 SU C

8
INTRODUCTION
TYPICAL PAGE – A
TYPICAL PAGE – A
Page Number
Bold letter indicates
liquid product to be
applied to a surface
Pay attention to
torque specifications.
Some units appear
as in. lbs. Use
appropriate torque.
Tightening torque for
a fastener.
Subsection title
indicatesbeginningof
the subsection.
Italic subheading
above Service Chart
indicates pertaining
models.
Indicates list
corresponding to
applicable letter in
exploded view of the
Service Chart.
Exploded view of
Service Chart assists
in identifying parts
and positions

INTRODUCTION
TYPICAL PAGE – B
9
TYPICAL PAGE – B
Section TitleSection Title
Section TitleSubsection Title
Model specific
illustrations
designated with
image captions
Products and
lubricants italicized
Products and
lubricants italicized

10
INTRODUCTION
TYPICAL PAGE – C
TYPICAL PAGE – C
Titleinitalicsindicates
a procedure
concerning a
particular model
Title indicates
from this point,
All Models
are concerned
Denotes necessary
step or information to
prevent damage or
control correct
procedure Title indicates the
procedure specific to
V4 Models is
finished. From this
point, this particular
procedure concerns
V6 Models.

INTRODUCTION
TYPICAL PAGE – D
11
TYPICAL PAGE – D
Typical illustration for
lower pulse hose of
V4 or V6 Models
Cross references
direct readers to
related topics
Cross references
direct readers to
related topics
Illustration
components
numbered to
correspond to
image
Section tabs allow for
quicker reference
when thumbing
through manual

12
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL
Units of Measurement List of Abbreviations
A Amperes
amp-hr Ampere hour
fl. oz. fluid ounce
ft. lbs. foot pounds
HP horsepower
in. inch
in. Hg inches of mercury
in. lbs. inch pounds
kPa kilopascals
ml milliliter
mm millimeter
N·m Newton meter
P/N part number
psi pounds per square inch
RPM revolutions per minute
°C degrees Celsius
°F degrees Fahrenheit
ms milliseconds
µs microseconds
ΩOhms
VVolts
VAC Volts Alternating Current
VDC Volts Direct Current
ABYC American Boat & Yacht Council
ATDC after top dead center
AT air temperature sensor
BPS barometric pressure sensor
BTDC before top dead center
CCA cold cranking amps
CPS crankshaft position sensor
DI Direct-Injection
ECU electronic control unit
EMM engine management module
ICOMIA International Council of Marine
Industry Associations
MCA marine cranking amps
MWS modular wiring system
NMEA National Marine Electronics Assoc.
NTC negative temperature coefficient
PDP power distribution panel
PTC positive temperature coefficient
ROM read only memory
S.A.F.E.™ speed adjusting failsafe electronics
SAC start assist circuit
SAE Society of Automotive Engineers
S.L.O.W.™ speed limiting operational warning
SYNC synchronization
TDC top dead center
TPS throttle position sensor
WOT wide open throttle
WTS water temperature sensor

13
INTRODUCTION
PRODUCT REFERENCE AND ILLUSTRATIONS
PRODUCT REFERENCE
AND ILLUSTRATIONS
BRP US Inc. reserves the right to make changes
at any time, without notice, in specifications and
models and also to discontinue models. The right
is also reserved to change any specifications or
parts, at any time, without incurring any obligation
to equip same on models manufactured prior to
date of such change. Specifications used are
based on the latest product information available
at the time of publication.
The continuing accuracy of this manual cannot be
guaranteed.
All photographs and illustrations used in this man-
ual may not depict actual models or equipment,
but are intended as representative views for refer-
ence only.
Certain features or systems discussed in this
manual might not be found on all models in all
marketing areas.
All service technicians must be familiar with nauti-
cal orientation. This manual often identifies parts
and procedures using these terms.
SYMBOLS
Throughout this service manual, symbols are
used to interpret electrical troubleshooting results
or to assign values in drawings.
Electrical
When “∞” shows on the meter face, no continuity,
or very high resistance, is indicated. The symbol is
referred to as infinity.
When “V” follows a value on the meter face, the
procedure is measuring voltage.
When “Ω” follows a value on the meter face, the
procedure is measuring resistance. Ωis the sym-
Nautical Orientation
DR4203
DR4204

14
INTRODUCTION
SYMBOLS
bol for ohm, the unit of measurement for resis-
tance.
Values
When “≤” precedes a value on the meter face, the
reading should be less than, or equal to, the value
shown.
When “≥” precedes a value on the meter face, the
reading should be greater than, or equal to, the
value shown.
DR4205
DR4206
DR4207

SERVICE SPECIFICATIONS AND SPECIAL TOOLS
15
1
SERVICE SPECIFICATIONS AND
SPECIAL TOOLS
TABLE OF CONTENTS
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TIGHTENING TORQUE – IMPORTANT FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TIGHTENING TORQUE – GENERAL BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ELECTRICAL / IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

16
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TECHNICAL DATA
TECHNICAL DATA
ENGINE
HP 2.5
Full Throttle
Operating Range RPM 5250-5750
Power 2.5 HP (1.8 kw) @ 5500 RPM
Idle RPM in Gear 1800 to 2000
Weight 30.1 lbs. (14 kg)
Lubrication Evinrude/Johnson Ultra 4-Stroke outboard oil
Refer to Oil Requirements on p. 32.
Engine Type 4-Stroke OHV 1-cylinder
Displacement 4.2 cu. in. (68 cm3)
Bore 1.89 in. (48 mm)
Stroke 1.50 in. (38 mm)
Compression ratio 9.0:1
FUEL SYSTEM
Carburetion One single-throat carburetor, float feed
Main Jet #70
Pilot Jet #32
Starting Enrichment Manual
Float Level Setting 10 ± 2 mm
Preferred Fuel Regular unleaded, plus grade unleaded, premium unleaded gasolines
Acceptable Fuel Any of the above gasolines with 10% Ethanol or 5% Methanol with 5% co-solvents
Minimum Octane 87 AKI (R+M)/2 or 90 RON
Additives
2+4®Fuel Conditioner, Fuel System Cleaner, Carbon Guard
Use only Evinrude/Johnson recommended fuel additives.
The use of other additives may result in engine damage.
See Fuel Requirements on p. 31 for additional information.

SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TECHNICAL DATA
17
1
HP 2.5
COOLING
Thermostat opens 118 to 126°F (48 to 52°C)
IGNITION
Type Transistorized
RPM Limit 6500 RPM
Spark Plugs NGK†CR6HSA @ 0.030 in. (0.76 mm)
Gap: 0.024 to 0.028 in. (0.6 to 0.7 mm)
Ignition Timing 30° BTDC
GEARCASE
Gear Ratio 13:28 (2.15:1)
Lubricant HPF XR Gearcase Lube
Capacity 2.0 fl. oz. (60 ml)

18
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
STANDARD TORQUE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS
Tightening Torque – Important Fasteners
ITEM THREAD
DIAM. TIGHTENING TORQUE
N·m kg-ft lb-ft
Cylinder head cover bolt 5 mm 7 0.7 5.0
Cylinder head bolt 6 mm 13 1.3 9.5
Crankcase bolt 6 mm 11 1.1 8.0
Connecting rod cap bolt 5 mm 7 0.7 5.0
Valve adjusting lock nut 5 mm 7 0.7 5.0
Intake pipe bolt 6 mm 11 1.1 8.0
Carburetor mounting bolt 6 mm 10 1.0 7.0
Flywheel nut 10 mm 45 4.5 32.5
Igniter unit bolt 6 mm 10 1.0 7.0
Engine oil drain plug 10 mm 10 1.0 7.0
Powerhead mounting bolt 6 mm 10 1.0 7.0
Tiller handle pivot bolt 8 mm 17 1.7 12.5
Lower cover bolt 6 mm 8 0.8 6.0
Swivel shaft nut 8 mm 10 1.0 7.0
Gearcase bolt 6 mm 8 0.8 6.0
Water pump case bolt 6 mm 5 0.5 3.5
Propeller shaft bearing housing bolt 6 mm 8 0.8 6.0