Page 3 † 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™...
Page 4: Table Of Contents
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 Always follow common shop safety practices. If technicians who are already familiar with the use you have not had training related to common shop safety practices, you should do so to protect your- of Evinrude...
Page 5 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.
Page 6: Table Of Contents
ABLE ONTENTS SECTION ........PAGE INTRODUCTION .
Page 7 INTRODUCTION INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL ..........6 .
Page 8: Models Covered In This Manual
INTRODUCTION MODELS COVERED IN THIS MANUAL MODELS COVERED IN Identifying Model and Serial Numbers THIS MANUAL Outboard model and serial numbers are located on the swivel bracket and on the powerhead. This manual covers service information on all 60° models. ®...
Page 9: Model Designation
INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: LENGTH: J = Johnson = 15” Std. E = Evinrude L = 20” Long Y = 22.5” Special MODEL RUN X = 25” X-long HORSEPOWER PREFIX or SUFFIX Z = 30” XX-long E 200 DP X SU MODEL YR: DESIGN FEATURES: I = 1...
Page 10: Typical Page - A
INTRODUCTION TYPICAL PAGE – A TYPICAL PAGE – A Subsection title indicates beginning of the subsection. Italic subheading above Service Chart indicates pertaining models. Bold letter indicates liquid product to be applied to a surface Pay attention to torque specifications. Some units appear as in.
Page 11: Typical Page - B
INTRODUCTION TYPICAL PAGE – B TYPICAL PAGE – B Section Title Section Title INSTALLATION AND PREDELIVERY OUTBOARD RIGGING PROCEDURE Subsection Title Section Title Cable, Hose, and Wire Routing If a water pressure gauge is to be used, install the water pressure hose fitting in the cylinder block. Route all hoses, control cables, and wiring Use Pipe Sealant with Teflon (P/N 910048) on the through a protective sleeve or conduit into the...
Page 12: Typical Page - C
INTRODUCTION TYPICAL PAGE – C TYPICAL PAGE – C POWERHEAD INSTALLATION INSTALLATION IMPORTANT: The motor mount, washer, and screw are serviced as an assembly. Do not disas- Title in italics indicates a procedure semble. V4 M ODELS concerning a Denotes necessary Install base gasket dry.
Page 13: Typical Page - D
INTRODUCTION TYPICAL PAGE – D TYPICAL PAGE – D OILING SYSTEM COMPONENTS Oil Pressure Switch Two pulse hoses connect the pump to pulse fit- tings on the front of the cylinder/crankcase. The oil pressure switch is located in the oil injec- •...
Page 14: Abbreviations Used In This Manual
INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft. lbs. foot pounds barometric pressure sensor horsepower...
Page 15: Engine Emissions Information
INTRODUCTION ENGINE EMISSIONS INFORMATION The owner/operator is not to, and should not allow ENGINE EMISSIONS anyone to, modify the outboard in any manner INFORMATION that would alter the horsepower or allow emis- sions levels to exceed their predetermined factory specifications. Maintenance, replacement, or repair of the emission control devices and systems may be Tampering with the fuel system to change horse-...
Page 16: Product Reference And Illustrations
AND ILLUSTRATIONS Throughout this service manual, symbols are used to interpret electrical troubleshooting results BRP US Inc. reserves the right to make changes or to assign values in drawings. at any time, without notice, in specifications and models and also to discontinue models. The right...
Page 17: Values
INTRODUCTION SYMBOLS When “Ω” follows a value on the meter face, the When “≥” precedes a value on the meter face, the procedure is measuring resistance. Ω is the sym- reading should be greater than, or equal to, the bol for ohm, the unit of measurement for resis- value shown.
Page 18: Notes
INTRODUCTION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 19 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA ..............18 STANDARD TORQUE SPECIFICATIONS .
Page 20: Service Specifications And Special Tools
SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA TECHNICAL DATA 150, 175, 200 Full Throttle 5500–6000 RPM 4850–5850 RPM Operating Range 150 HP: (111.9 kw) @ 5350 RPM Power 115 HP: (85.8 kw) @ 5750 RPM 175 HP: (130.5 kw) @ 5350 RPM 200 HP: (149.1 kw) @ 5350 RPM Idle RPM in Gear 550 ±...
Page 21 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA 150, 175, 200 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation Tachometer Setting 6 pulse (12 pole) Charging Isolator...
Page 22: Standard Torque Specifications
SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE SPECIFICATIONS Standard Torque Chart Size In. Lbs. Ft. Lbs. N·m No. 6 7–10 0.58–0.83 0.8–1.1 No. 8 15–22 1.25–1.83 1.7–2.5 No. 10 24–36 2–3 2.7–4.0 No. 12 36–48 3–4 4.0–5.4 1/4 in.
Page 23: Special Tools
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS Diagnostics 005444 002276 45583 Diagnostic Software P/N 763724 Bootstrap tool P/N 586551 Interface cable P/N 437955 Universal 44686 46215 Lifting tool P/N 342672 Flywheel service kit P/N 434649 005314 Flywheel puller adapter kit Includes P/N 5007181 adapter P/N 5007181 32885...
Page 24: Electrical / Ignition
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS 15345 45240 46879 Slide hammer P/N 432128 Temperature gun P/N 772018 Tilt tube nut wrench P/N 342680 33249 Tilt tube service kit P/N 434523 Electrical / Ignition DRC7265 49799 49793 Digital multimeter Peak reading voltmeter Analog multimeter P/N 501873 Ohms resolution 0.01 P/N 507972...
Page 25: Fuel/Oil Systems
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS 30387 49789 † 002277 Crimping pliers P/N 322696 Tachometer/timing light P/N 507980 connector tools Primary Lock Tool P/N 777077 Secondary Lock Tool P/N 777078 Release Tool P/N 351413 Lock Installer P/N 777079 Fuel/Oil Systems 005339 004560 002465...
Page 26: Powerhead
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Powerhead 005279 21596 41029 Alignment pin kit P/N 5007167 Rod cap alignment fixture Wrist pin bearing installer P/N 396749 P/N 336660 45303 000797 23668 Cylinder bore gauge P/N 771310 Torquing socket P/N 331638 Wrist pin pressing tool P/N 326356 DR1641...
Page 27: Gearcase
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Gearcase 002601 004315 32884 Universal Driveshaft Shimming Tool Gearcase Alignment Gauge Kit Driveshaft Puller P/N 390706 P/N 5005925 P/N 5006349 1. Lower Driveshaft Shimming Bolt (S2 gearcase) P/N352878 002805 005072 005074 Universal Pinion Bearing Remover Gauging Head, “S”...
Page 28 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS 23261 40372 15355 Driveshaft socket P/N 311875 Pinion nut starting tool P/N 342216 Prop shaft bearing installer P/N 432401 15356 000818 32973 Prop shaft adapter P/N 432398 Pinion bearing installer Prop shaft housing seal installer P/N 350958 P/N 336311 15358...
Page 29: Trim And Tilt
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Trim and Tilt 33023 33013 23694 Gauge and collar assembly Trim/tilt service kit P/N 390010 Tilt cylinder seal protector P/N 983975 P/N 326005 23665 33742A Hydraulic cylinder rod holder 1. Trim cylinder end cap 27340 1.
Page 30: Shop Aids
SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 Engine Tuner P/N 777185 Anti-Corrosion Spray P/N 777193 “6 in 1” Multi-Purpose Lubricant P/N 777192 D.P.L. Spray P/N 777183 Silicone spray P/N 775630 Oil - XD100™ P/N 777118 Oil - XD50™...
Page 31 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS HI-VIS™ Gearcase Lube P/N 775605 Triple-Guard® Grease P/N 508298 Extreme Pressure Grease™ P/N 508303 Moly Lube P/N 175356 Needle Bearing Grease, P/N 378642 Starter Bendix Lube P/N 337016 Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Biodegradeable TNT Fluid P/N 777186 P/N 775612...
Page 32 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS 2 + 4™ Fuel conditioner P/N 775613 Fuel System Cleaner P/N 777184 Carbon Guard™ P/N 775629 Gel-Seal and Gasket Remover P/N 771050 Gel·Seal II P/N 327361 Gasket Sealing Compound P/N 317201 † † Pipe Sealant with Teflon P/N 910048 Permatex No.
Page 33 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Locquic Primer P/N 772032 Adhesive 847 P/N 776964 Instant Bonding Adhesive P/N 509955 † Thermal Joint Compound P/N 322170 Gear Mark Compound P/N 772666...
Page 34: Notes
SERVICE SPECIFICATIONS AND SPECIAL TOOLS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 35: Installation And Predelivery
INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............34 .
Page 36: Boat Rigging
INSTALLATION AND PREDELIVERY BOAT RIGGING Additional remote control information: BOAT RIGGING Power trim/tilt switch(s) can be integral to the • remote control for outboards with power tilt and Remote Controls trim. Side-mount controls require a neutral lock fea- Control Selection •...
Page 37 INSTALLATION AND PREDELIVERY BOAT RIGGING Installation Guidelines SystemCheck™ Monitor Install the appropriate remote control following all The SystemCheck engine monitor alerts the oper- instructions provided with the remote control. ator of certain engine problems. Refer to the Operator’s Guide for detailed information related Make sure the following items are checked: to the various warning signals.
Page 38: Battery Installation
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Installation Connections Each outboard requires its own starting battery. Connect the battery positive (+) IMPORTANT: Select a battery that meets or exceeds the mini- cable to the battery positive (+) post FIRST. Con- mum requirements. nect the battery negative (–) cable to the battery negative (–) post LAST.
Page 39: Battery Switches And Multiple Batteries
INSTALLATION AND PREDELIVERY BOAT RIGGING Inadequate battery cables can Battery Cable Requirements IMPORTANT: affect the performance of an outboard’s high Evinrude/Johnson outboards are shipped with amperage start circuit and the cranking speed of stranded copper battery cables for typical installa- the outboard.
Page 40: Auxiliary Battery Charge Isolator
INSTALLATION AND PREDELIVERY BOAT RIGGING Use one battery switch for each outboard • installed. Use the appropriate sized wire and terminals for • all connections. Use AWG stranded copper wire. • Battery Switch Location Always locate battery switch(s) as close to the •...
Page 41: Battery And Switch Wiring Diagrams
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery and Switch Wiring Diagrams One outboard: Battery disconnect One outboard: One primary starting battery; one secondary battery BOTH PRIMARY PRIMARY SECONDARY 000135rev1 Two outboards: Two starting batteries for each outboard BOTH BOTH PRIMARY SECONDARY SECONDARY PRIMARY Positive (+) Battery cables...
Page 42 INSTALLATION AND PREDELIVERY BOAT RIGGING Two outboards: One primary starting battery for each outboard; one isolated accessory battery BOTH BOTH PRIMARY PRIMARY ACCESSORY Two outboards: One primary starting battery for each outboard; two isolated accessory batteries BOTH BOTH PRIMARY PRIMARY ACCESSORY ACCESSORY Positive (+) Battery cables...
Page 43: Fuel System Requirements
INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements Fuel System Primer Outboards require a priming system capable of Overview refilling the fuel system after periods of non-use. Fuel systems must meet minimum specifications to insure the proper delivery of fuel to the out- Primer Bulbs board.
Page 44 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.
Page 45: Oiling System Set-Up
INSTALLATION AND PREDELIVERY BOAT RIGGING Replacement hose must be designated for fuel Oiling System Set-Up • or oil use and approved for marine use. Location Extend wiring harness with 16 gauge AWG • wire. Consider the installation location IMPORTANT: Protect connections with heat shrink tube. •...
Page 46 INSTALLATION AND PREDELIVERY BOAT RIGGING Place floor bracket on center line between end 1.8 G ALLON lines. Use the inner bracket holes as guides to drill Place rods into floor bracket and secure floor two 5/32 in. (4 mm) pilot holes. bracket with lag bolts.
Page 47 INSTALLATION AND PREDELIVERY BOAT RIGGING Oil Tank Profiles 1.8 Gallon Tank 3 Gallon Tank P/N 176995 P/N 176996 Remote Oil Fill Kit (Optional) The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly.
Page 48: Cable And Hose Installation
INSTALLATION AND PREDELIVERY BOAT RIGGING Cable and Hose Installation Cable and Wire Harness Routing Before installation, identify all required wiring, WARNING cables, and hoses: Throttle and shift cables Improper installation and routing of out- • Modular Wiring System (MWS) harness •...
Page 49 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Hose Route the fuel supply hose with adequate slack to allow for the primer bulb to be held with the arrow pointing “up” during use. The fuel hose could be the only hose routed out- side of the protective sleeve or conduit.
Page 50 INSTALLATION AND PREDELIVERY BOAT RIGGING Oetiker Clamp Servicing Use Oetiker clamps for making hose connec- † tions. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging com- ponents, and provide solid, permanent connec- tions. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
Page 51 INSTALLATION AND PREDELIVERY BOAT RIGGING Clamp Installation Clamp Removal A constant stress should be applied to close the Method 1: Position Oetiker pincers across clamp ear clamps. This method ensures a positive stress ear and cut clamp. on the hose and does not result in excessive com- pression or expansion of the band material.
Page 52 INSTALLATION AND PREDELIVERY BOAT RIGGING Extend the control cables and lubricate them with Control Cable Identification Triple-Guard grease. Control cable function must be IMPORTANT: identified before rigging outboard. Identify each control cable: Put the control handle into NEUTRAL position. • The throttle cable casing guide will retract com- pletely and the shift cable casing guide will go to the midpoint of its travel.
Page 53: Outboard Installation
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Check transom strength and height. OUTBOARD • INSTALLATION WARNING DO NOT install an outboard on a curved or Hull Preparation irregular surface. Doing so can wear, bind, and damage components, causing loss of Maximum Capacity control.
Page 54: Transom Measuring And Drilling
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Brackets and Jack Plates Transom Measuring and Drilling When mounting an outboard on boats equipped Hull Centerline with transom brackets or jack plates, refer to the Locate the centerline of the boat transom as it manufacturer's recommendations.
Page 55 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION If the standard spacing does not allow full steering Transom Heights travel in a particular installation, it may be neces- Make sure the transom height is consistent with sary to increase the spacing. the height of the outboard to be installed. A 19 to 21 in.
Page 56 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION DO NOT assume that the top Transom Drilling Locations IMPORTANT: edge of the transom is straight. Position the drill All models use the standard ABYC 4-Bolt mount- fixture based on measurements aligning it to the ing pattern.
Page 57 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagrams This is not a template. IMPORTANT: 6 7/16" 6 7/16" (136.5mm) (136.5mm) 2" (50.8mm) (50.8mm) 90˚ 10 11 12 8" 8" (203.2mm) (203.2mm) 90˚ 4 15/16" 4 15/16" (125.4mm) (125.4mm) 000133m Quantity 1.
Page 58: Lifting The Outboard
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Lifting the Outboard Before Mounting Outboard to Transom Some rigging components that attach directly to Lifting Fixtures the outboard should be assembled before the out- board is mounted to the boat's transom. Steering WARNING system components and gearcase speedometer pickup hoses are the most common.
Page 59 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Manual Hydraulic Steering Drag Links Manual hydraulic steering systems use hydraulic Install cable wiper nut on tilt tube and connect fluid to transfer motion and load from the helm to drag link to the correct location on the steering the outboard.
Page 60: Outboard Mounting
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Assemble transom mounting plates on mounting Outboard Mounting bolts. Mounting Height Apply sealant around the mounting bolt holes on Boat performance depends on outboard mounting the outer surface of the transom. height. Install the mounting bolts through the transom Generally, the anti-ventilation plate of the gear- from the inside of the boat.
Page 61: Outboard Rigging
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Refer to the following diagram to ensure proper OUTBOARD RIGGING positioning of rigging components in grommet. CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.
Page 62: Control Cable Installation
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING board side of the powerhead. Secure all cables to Use long nose pliers to insert straight section of • anchor points with tie-straps. clip into linkage pin hole. DP0818 1. Straight section DP0817 2. Angled section Push the clip towards the hole while lifting on •...
Page 63 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Install trunnion cover and screw. Tighten retaining With throttle cable attached to the throttle linkage, screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). pull cable to remove slack and ensure that idle stop of the throttle linkage is against the crank- case.
Page 64: Electrical Harness Connections
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Route oil tank sending unit harness around the Electrical Harness Connections front to the port side. Secure all cables with tie Remove flywheel/harness connector cover. straps. 004954 Before installing electrical connectors, check that the seal is in place. Clean off any dirt from con- 004952 1.
Page 65: Water Pressure Gauge
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING SystemCheck connector with 6-Pin Connector Water Pressure Gauge Seal, P/N 586076. If a mechanical water pressure gauge is used, install the water pressure hose fitting in the cylin- der block. Use Pipe Sealant with Teflon, P/N 910048, on the threads of the hose fitting.
Page 66 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Connect the purple wire from the CANbus Ignition install the transducer lead in the engine wiring har- Harness to the CANbus Network Harness. This ness connector and secure in bracket. connection supplies power to the network when the keyswitch is on.
Page 67: Fuel And Oil Priming
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING When using alcohol-extended fuels, be aware of FUEL AND OIL PRIMING the following: The boat’s fuel system may have different • Fuel Requirements requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. WARNING Alcohol attracts and holds moisture that can •...
Page 68: Fuel System Priming
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe all fuel lines, both in the boat and on the Fuel System Priming outboard. Repair any fuel leaks. Vent Line Clamp In compliance with Code of Federal Regulations, WARNING 49 CFR §173.220, all outboards using a fuel Failure to check for fuel leaks could allow a vapor separator must be shipped with a vent line leak to go undetected, resulting in fire or...
Page 69: Oil Injection Rate
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Use the XD100 Outboard Oil Decal, P/N 352369, Oil Injection Rate to accurately inform the boat operator of the If the owner desires, the Engine Management XD100 outboard oil requirement. Module (EMM) on Evinrude E-TEC models can be programmed for the exclusive use of XD100, which will significantly reduce oil consumption.
Page 70: Systemcheck Low Oil Warning
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING SystemCheck Low Oil Warning Oil Distribution Manifold Priming Follow these steps for initial outboard set-up: Leave oil tank empty until low oil IMPORTANT: Squeeze the oil primer bulb to flow oil from the •...
Page 71 INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe oil flow through the oil distribution hoses. Small bubbles are acceptable. Large bubbles must be eliminated through a continued priming process. 004398 1. Oil distribution hose 2. Small bubbles 3. Large bubbles 004965 1.
Page 72: Before Start-Up
INSTALLATION AND PREDELIVERY BEFORE START-UP BEFORE START-UP Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run- Gearcase Lubricant ning outboard: Tilt the motor up and engage the tilt support. With outboard in vertical position, check the gear- •...
Page 73: Running Checks
INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS Fuel System Perform running checks of the fuel system by fol- lowing these steps: WARNING Squeeze fuel primer bulb until hard or activate • DO NOT run outboard without a water sup- electric primer. Observe all fuel hoses and con- nections.
Page 74: Tachometer Pulse Setting
INSTALLATION AND PREDELIVERY RUNNING CHECKS Tachometer Pulse Setting Operating Temperature Confirm accuracy of tachometer reading. An outboard run at idle speed should achieve a temperature based on the engine’s thermostatic Adjust dial on back of tachometer to required • setting (the outboard should not be running). control.
Page 75: Propellers
INSTALLATION AND PREDELIVERY PROPELLERS When selecting a propeller, consider the following: PROPELLERS Use an accurate tachometer to determine the • engine’s full-throttle RPM. Propeller Selection The outboard should be trimmed for top speed. • Select a propeller that suits the customer’s •...
Page 76: Propeller Hardware Installation
INSTALLATION AND PREDELIVERY PROPELLERS Propeller Hardware Installation WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.
Page 77: Final Adjustments
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Use the trim/tilt switch and trim the outboard IN all FINAL ADJUSTMENTS the way. Tilt Limit Switch Adjustment Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment WARNING tab DOWN to increase the maximum tilt position. If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in...
Page 78: Trim Sending Unit Adjustment
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Observe the trim gauge. If the needle does not Trim Sending Unit Adjustment show center position, tilt the outboard up and Tilt the outboard and engage the tilt support. adjust the sending unit by pivoting it up or down. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.
Page 79: Trim Tab Adjustment
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Trim Tab Adjustment WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to compensate for this steering torque.
Page 80: Dual-Outboard Alignment
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.
Page 81: Maintenance
MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 80 ANTI-CORROSION PROTECTION .
Page 82: Inspection And Maintenance Schedule
MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer. Outboards used for rental operations, commercial applications, or other high hour use IMPORTANT: applications require more frequent inspections and maintenance.
Page 83: Anti-Corrosion Protection
MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect meter leads between engine ground and PROTECTION anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.
Page 84: Cooling System
MAINTENANCE COOLING SYSTEM Thread garden hose into flushing port. COOLING SYSTEM Check the condition of cooling system compo- nents regularly. The outboard cooling system con- sists of: water intake screens; • water pump; • all internal water passages; • thermostats; •...
Page 85: Water Intake Screens
MAINTENANCE LUBRICATION LUBRICATION Water Intake Screens Inspect condition of water intake screens. Clean Steering System or replace as needed. Confirm function of overboard water pressure indi- WARNING cator. Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, mak- ing operator control difficult.
Page 86: Swivel Bracket And Trailering Bracket
MAINTENANCE LUBRICATION Swivel Bracket and Trailering Throttle and Shift Linkage Bracket Disconnect the battery cables at the battery. Lubricate the swivel bracket with Triple-Guard Remove cable trunnion cover. Carefully, remove grease. throttle and shift cables from trunnion block. Apply grease until the grease begins to flow from DO NOT disturb cable trunnion IMPORTANT: the upper or lower swivel bracket areas.
Page 87: Propeller Shaft
MAINTENANCE LUBRICATION Examine drained lubricant for excessive metal Propeller Shaft fragments and for any indication of water in oil Debris from the water can become lodged around (cloudy or milky appearance). Lubricant that is propeller shaft. Frequent inspection can minimize black in color with a burnt odor indicates worn, potential gearcase damage.
Page 88: Trim And Tilt
MAINTENANCE LUBRICATION Trim and Tilt Position outboard in FULL TILT (UP) position. Engage the tilt support bracket. DR22834 Three Piston Trim System 1. Fill cap • Single Piston System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring DR5071 1. Tilt support bracket level to the bottom of the fill plug threads.
Page 89: Battery And Battery Connections
MAINTENANCE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY FUEL AND OIL SYSTEMS CONNECTIONS Routine replacement of filters reduces the possi- bility of foreign material restricting the incoming Check battery connections frequently. Periodically fuel or oil supplies. remove battery to clean and service connections. Replacement filter elements are available through WARNING Evinrude/Johnson Genuine Parts.
Page 90: Oil Filters And Oil Reservoir
MAINTENANCE FUEL AND OIL SYSTEMS Oil Filters and Oil Reservoir Air Silencer Evinrude E-TEC 60° V outboards are equipped The air silencer on Evinrude outboards minimizes with two serviceable oil filters: one is located in the audible noise related to air flow into the engine. oil injection tank, and one is located in the oil sup- ply line before the oil lift pump.
Page 91: Spark Plugs
MAINTENANCE SPARK PLUGS Apply Triple-Guard grease to the gasket surface SPARK PLUGS of the spark plugs. Install all spark plugs and tighten them to a torque of 15 ft. lbs. (20 N·m). Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged If the mark is in unshaded area do not tighten any- spark plugs.
Page 92: Exhaust Pressure Fitting
MAINTENANCE EXHAUST PRESSURE FITTING With key ON, outboard NOT running, the exhaust EXHAUST PRESSURE pressure sensor reading should be close to zero. FITTING With the outboard running, make sure the exhaust pressure reading changes with throttle setting. The exhaust pressure fitting is threaded into the This reading will vary, based on actual outboard cylinder/crankcase assembly and protrudes into exhaust pressure conditions.
Page 93: Storage
MAINTENANCE STORAGE STORAGE Software Control Method Winterization can also be run using the Evinrude Diagnostics software program. With the outboard DO NOT start outboard without a IMPORTANT: running, start the process at the Settings/Adjust- water supply to the outboard’s cooling system. ments screen and follow the instructions.
Page 94: Additional Recommendations
MAINTENANCE PRE-SEASON SERVICE Additional Recommendations PRE-SEASON SERVICE Top off oil reservoir. • If the outboard was removed from the boat for inspect the fuel filter. If there is debris in the fuel • storage, make sure that it has been reinstalled filter, it must be replaced.
Page 95: Submerged Engines
MAINTENANCE SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL SUBMERGED ENGINES AND OIL PRIMING on p. 65. Make sure all oil injection hoses are clean and filled with oil. Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) Make sure high pressure fuel system does not hours of recovery.
Page 96: Notes
MAINTENANCE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 97: Engine Management Module (Emm)
ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............96 .
Page 98: Description
ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION DESCRIPTION EMM Connections EMM connections and wiring The Engine Management Module (EMM) is a IMPORTANT: water-cooled engine controller. It controls numer- must be clean and tight. Improper electrical con- ous outboard systems including alternator output nections can damage the EMM.
Page 99: Sensors And Functions
ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Sensor indicates less than -71°F (-57.4°C) or SENSORS AND greater than 314°F (156.9°C) a sensor circuit fault FUNCTIONS is detected and the EMM: Stores a service code 23 Sensor inputs and internal EMM controllers are Initiates EMM NO OIL/OVERHEAT LED used to control outboard operation.
Page 100: External Sensors
ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Barometric Pressure Sensor External Sensors Supplies the EMM with barometric pressure read- The EMM provides a 5 V DC signal for sensor cir- ing to compensate for changes in altitude and air cuits. It monitors all sensor voltage inputs and density.
Page 101 ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS If EITHER cylinder head temperature exceeds Oil Pressure Sensor 248°F (120°C), the EMM The oil pressure sensor monitors oil pressure in the oil distribution manifold. Activates SHUTDOWN Stores a service code 31 If the sensor fails to indicate pressure in the oil Flashes EMM NO OIL / OVERHEAT (LED 4) distribution manifold, the EMM: Flashes SystemCheck TEMP/HOT light...
Page 102 ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS If code 11 is present as both a Hard Fault and a Throttle Position Sensor Stored Fault, refer to Control Cable Installation The throttle position sensor is a rotary potentiome- on p. 60. ter connected to the throttle plate shaft.
Page 103: Internal Functions
ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Internal Functions Exhaust Valve (V4 Models) The EMM controls a valve that switches between ROM Verification two exhaust paths to provide optimum exhaust The EMM runs through a self-test of programming tuning under various running conditions. At slower every time it is turned ON.
Page 104: Emm Inputs And Outputs Diagram
ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM 1. Engine Management Module (EMM) 10. Engine Temperature Sensor(s) 19. Fuel Injector 2. Battery (12 volt) 11. Water in Fuel Sensor / Fuel Filter 20. Tachometer/SystemCheck Gauge 3.
Page 105: Warning System
ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING SHUTDOWN MODE SYSTEM Outboard “shutdown” will occur if specific faults are detected by the EMM. The EMM activates S.A.F.E. (Speed Adjusting Failsafe Electronics) and the dash-mounted Sys- Conditions that initiate shutdown temCheck gauge and horn to alert the operator of Code 29 Excessive EMM temperature abnormal operating conditions and to prevent...
Page 106: Emm Diagnostics
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS code 33 (engine shutdown, excessive no oil con- EMM DIAGNOSTICS dition). LED Indicators Running Mode The EMM has LED indicators located next to the LED 1 – Low charging output, “CHARGING electrical connectors that provide information FAULT.”...
Page 107: Diagnostic Software Program
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Code 45 – BP below expected range • Personal Com- Code 46 – BP above expected range Evinrude Diagnostics Soft- • puter (PC) based ware, Code 47 – AT sensor circuit fault • software P/N 763724 Code 48 –...
Page 108: Program Information
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Program Information Dynamic Information Refers to specific information viewed while the Static Information outboard is running. Dynamic information updates Refers to information viewed when the outboard is quickly and allows the viewer to monitor voltage NOT running.
Page 109: Static Tests
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS times the event occurred, operating hours of first Static Tests and last occurrence. Static Tests perform diagnostic testing of speci- fied components. 005143 Stored Faults Review Screen 005146 Static Tests Screen Hard Faults A hard fault is a code that currently exists. Hard Ignition Test faults become stored faults only if the outboard is Use the diagnostic software to test each ignition...
Page 110: Dynamic Tests
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Oil Injector Dynamic Tests Use the diagnostic software to test the oil injection Dynamic tests are performed with the outboard pump. Make sure the pump is wired correctly. If running. the pump activates, the EMM and oil injection cir- cuit are not at fault.
Page 111: Oil Control
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Initiate Break-in programming for Oil Control IMPORTANT: rebuilt powerheads. Oil Injection Ratio Timing Verification (Used with XD100 oil only) Evinrude E-TEC outboards can be programmed Use the Ignition Timing screen of the diagnostic to run a reduced oiling rate. This feature should software to check and adjust EMM timing.
Page 112: Tps Calibration
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS TPS Calibration Fuel Control Adjustment Use the diagnostic software Settings screen to tell The purpose of this feature is to help troubleshoot the EMM what the throttle position sensor voltage cylinder combustion. The Evinrude Diagnostics level is when the throttle plates begin to open.
Page 113: Reports
ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Reports Software Replacement Engine reports provide service records and can Software programs or “maps” are downloaded be used to document the running history of an out- into the EMM prior to factory testing of the out- board.
Page 114: Systemcheck Engine Monitor
ENGINE MANAGEMENT MODULE (EMM) SYSTEMCHECK ENGINE MONITOR The EMM activates the warning horn and the SystemCheck ENGINE appropriate gauge display as follows: MONITOR NO OIL indicates an oil delivery problem such • as an empty oil tank or damaged oil system The SystemCheck engine monitor warns the components.
Page 115: System Analysis
SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS ELECTRICAL CONNECTIONS ............114 GROUND CIRCUITS .
Page 116: Electrical Connections
SYSTEM ANALYSIS ELECTRICAL CONNECTIONS ELECTRICAL EMM J1-A Connector CONNECTIONS Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts to identify specific wiring details.
Page 117 SYSTEM ANALYSIS ELECTRICAL CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 1 Blue Injector, cylinder 2 Blue none Injector, cylinder 3 Green V4 Isolated B+ Red/Black Purple V6 Battery ground Black +55 V, in, ignition power...
Page 118: Ground Circuits
SYSTEM ANALYSIS GROUND CIRCUITS Ignition (pins 17, 18 and 24 of the EMM J1-B GROUND CIRCUITS • connector), injector and EMM battery grounds All ground circuits are essential to optimum out- on port and starboard cylinder head ground board performance. Make certain all ground con- screws.
Page 119: Emm Diagnostics
SYSTEM ANALYSIS EMM DIAGNOSTICS EMM DIAGNOSTICS Running Mode Light ON indicates system is MALFUNCTIONING. Access EMM information using the EMM’s LED LED 1 – Light ON, charging output malfunction • indicators and the diagnostic program. 12 V or 55 V circuit; or SAC overcurrent “CHARGING FAULT”...
Page 120: Diagnostic Procedures
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC PROCEDURES The key to effective troubleshooting is confirming the proper operation of each engine system. Causes of electrical failures may be difficult to iso- late. Check the integrity of all connections, grounds, and wiring prior to replacing a suspect component.
Page 121: Symptoms
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Symptoms Outboard runs: Use Evinrude Diagnostics Software program to • Outboard will not crank, starter does not perform Dynamic Tests. See Dynamic Tests on operate: p. 133. Check condition of battery and cables (main • Use the engine Monitor screen of the Evinrude •...
Page 122: Specialized Test Procedures
SYSTEM ANALYSIS SPECIALIZED TEST PROCEDURES Dynamic Tests can be used in conjunction with: SPECIALIZED TEST A timing light to determine how other cylinders • PROCEDURES are affected by one cylinder being “dropped”; or A voltmeter to check voltage changes on electri- •...
Page 123: Inductive Amp Meter Test
SYSTEM ANALYSIS SPECIALIZED TEST PROCEDURES Ignition System Output Inductive Amp Meter Test Use the timing light to monitor each ignition circuit Use an inductive amp meter to monitor battery for a consistent flash. Run outboard and observe charging and current flow. Identifying erratic strobe of the light.
Page 124: Voltage Testing
SYSTEM ANALYSIS START CIRCUIT Voltage Testing START CIRCUIT Use the engine Monitor screen of the Evinrude The start circuit provides the required current to Diagnostics Software program or a digital multim- the starter motor and associated electrical circuits. eter to check voltages. Identify all wiring and cir- cuits prior to performing any voltage tests.
Page 125: Starter Solenoid Activation
SYSTEM ANALYSIS START CIRCUIT Starter Solenoid Engine Wire Harness Starter solenoid and connections • Contains the following circuits: Starter solenoid switched ground (NEG), termi- • Red/purple output wire from fuse and provides • nal “B” 12 V to instrument harness Starter cable (solenoid to starter motor) •...
Page 126 SYSTEM ANALYSIS START CIRCUIT Key Switch, ON position Key Switch, START Position 12 V is applied to the “accessory” circuit. Key Switches 12 V to terminal “S” of key switch and switch ON: 12 V is applied to neutral safety switch. Switches 12 V to terminal “A”...
Page 127: Start Circuit Diagram
SYSTEM ANALYSIS START CIRCUIT Start Circuit Diagram 1. Marine battery 10. 26-pin J1-B EMM connector 2. RED wire (POS) 11. 34-pin J1-A EMM connector 3. BLACK wire (NEG) 12. Engine Management Module (EMM) 4. Starter solenoid 13. YELLOW/RED wire, start 5.
Page 128: Ignition And Electrical Circuits
SYSTEM ANALYSIS IGNITION AND ELECTRICAL CIRCUITS IGNITION AND Alternator Output/System Voltage System voltage from EMM (white/red) provides • ELECTRICAL CIRCUITS 55 VDC to the oil injection pump, the fuel injec- tors, and the ignition module of EMM. Following is a complete list of circuits required for ignition output: Capacitor Connected to 55 V circuit (white/red) to stabilize...
Page 129: Ignition Output
SYSTEM ANALYSIS IGNITION OUTPUT IGNITION OUTPUT Ignition Voltage Use the Evinrude Diagnostics Software program to check ignition voltage to the primary ignition cir- DANGER cuit(s). Check the EMM’s ignition voltage to the The electrical system presents a serious primary circuits of the ignition coils on the engine shock hazard.
Page 130: System Voltage
SYSTEM ANALYSIS IGNITION OUTPUT System Voltage Static Spark Test The ignition module of the EMM is powered by the Perform the static spark test using the Evinrude 55 V system. Diagnostics Software program and timing light. Use the engine Monitor screen of the Evinrude DO NOT use a spark checker tool IMPORTANT: Diagnostics Software program to check system...
Page 131: Running Ignition Tests
SYSTEM ANALYSIS IGNITION OUTPUT Results: Monitor Ignition Output with Timing Light Spark control on all cylinders and outboard • Use a timing light to monitor the spark signal runs, Refer to Running Ignition Tests on through each of the high tension spark plug wires. p.
Page 132: Ignition Primary Circuit Resistance Test
SYSTEM ANALYSIS IGNITION OUTPUT Ignition Primary Circuit Crankshaft Position Sensor (CPS) Resistance Test Test Disconnect the battery cables at the battery. Use the Evinrude Diagnostics Software program to check RPM reading. An RPM display higher Calibrate ohmmeter to low ohms scale. than zero indicates a CPS signal to the EMM.
Page 133: Fuel Delivery
SYSTEM ANALYSIS FUEL DELIVERY FUEL DELIVERY Results: Pressure test indicates 20 to 30 psi (138 to 207 kPa): WARNING Circulation pump output is good. Make sure fuel • system pressure does not fall below 15 psi (103 Protect against hazardous fuel spray. kPa) after outboard (pump) is OFF for five min- Before starting any fuel system service, utes.
Page 134: Vapor Separator Checks
SYSTEM ANALYSIS FUEL INJECTOR OPERATION Vapor Separator Checks FUEL INJECTOR Fuel Supply OPERATION The vapor separator must provide “solid” fuel to the fuel circulation pump. Make sure the vapor Static Tests separator receives the proper fuel supply from the Perform the Fuel Injector Static Test using the fuel lift pump.
Page 135: Dynamic Tests
SYSTEM ANALYSIS FUEL INJECTOR OPERATION Dynamic Tests Results: Steady light activation on all injector wires and Use the engine Monitor screen of the diagnostic consistent voltage readings: software program to monitor outboard system EMM injector control function is good. • voltage.
Page 136: Exhaust Valve
SYSTEM ANALYSIS EXHAUST VALVE (V4 MODELS) EXHAUST VALVE (V4 MODELS) The inner exhaust housing on Evinrude E-TEC V4 models is designed with an adjustable “tuning” length. Two modes of exhaust gas flow are accomplished through the use of an exhaust valve.
Page 137: Electrical And Ignition
ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............136 DASH CONNECTIONS, INSTRUMENT HARNESS .
Page 138: Service Chart
ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 12-16 In. lbs. (1.5-2 N·m) 60-84 In. lbs. (7-9.5 N·m) 24-26 Ft. lbs. (33-35 N·m) 12-16 In. lbs. 48 In. lbs. (1.5-2 N·m) (5.5 N·m) See Text 24-36 In. lbs. (2.7-4.1 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In.
Page 139 ELECTRICAL AND IGNITION SERVICE CHART 60-84 in. lbs (6.8-9.5 N·m) 60-84 In. lbs. (7-10 N·m) 60-84 In. lbs. (7-10 N·m) 168-192 in. lbs (19.0-21.7 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 004100 Liquid Neoprene...
Page 140: Dash Connections, Instrument Harness
ELECTRICAL AND IGNITION DASH CONNECTIONS, INSTRUMENT HARNESS DASH CONNECTIONS, INSTRUMENT HARNESS 3-pin connector – Connect to trim switch located in the handle of the remote control or to trim switch mounted on the boat dash. 6-pin connector – Connect to a pre-wired remote control or to a dash-mounted key switch.
Page 141: Sensor Resistance Tests
ELECTRICAL AND IGNITION SENSOR RESISTANCE TESTS (1.85 mm). The acceptable clearance is 0.036 to SENSOR RESISTANCE 0.110 in. (1 to 2.8 mm). TESTS All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the appropriate circuit in the EMM.
Page 142: Capacitor Test
ELECTRICAL AND IGNITION CAPACITOR TEST Air Temperature Sensor (AT) Test STEP 2 Connect red meter lead to terminal “A” and black Use an ohmmeter to measure resistance. meter lead to terminal “C.” Rotate the sensor lever AT Sensor Resistance through its range of travel. Resistance reading 9000 to 11000 Ω...
Page 143: Ignition Coil Tests
ELECTRICAL AND IGNITION IGNITION COIL TESTS IGNITION COIL TESTS STATOR TESTS The stator consists of 3 windings (6 poles each) Primary Winding Resistance Test on a 7 inch diameter core and generates an out- Connect ohmmeter between coil primary terminal put voltage of 55 VAC (1700 watts maximum).
Page 144: Charging System Tests
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM STEP 2 To check for a grounded condition, connect one TESTS meter lead to ground wire and alternately connect the other meter lead to each stator wire. Meter 12 V Charging Circuit should read no continuity.
Page 145 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Following the manufacturer’s directions, connect Start the outboard and run it at approximately the variable load tester (carbon pile) across the 5000 RPM. Use the variable load tester to draw battery terminals. Stevens model LB-85 and the battery down at a rate equivalent to the sta- Snap-On model MT540D are examples of testers tor’s full output.
Page 146 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS STEP 3 STEP 2 With outboard running at 1000 RPM, voltage on With the key switch OFF, check battery voltage at white/red wires should increase to 55 V. auxiliary battery, then check voltage at auxiliary battery connection.
Page 147: Systemcheck Circuit Tests
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS instrument harness terminal 1 (purple wire) and SystemCheck CIRCUIT terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...
Page 148 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test gauge. The tan wire of engine harness and the MWS har- ness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head.
Page 149: Remote Control Switch Tests
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL LOW OIL Circuit Test Turn the key switch ON. Using a jumper wire, con- SWITCH TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW Key Switch Test OIL light should turn on after 40 seconds.
Page 150: Neutral Start Circuit Test
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Circuit Test Neutral Start Switch Test Use an ohmmeter or continuity light to test the Use an ohmmeter or a continuity light to test neu- continuity of the circuit while positioning the tral start switch operation.
Page 151: Emergency Stop Switch Test
ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT Emergency Stop Switch Test This switch can be incorporated into the key TESTS switch or installed as a separate switch. Either style effectively connects the “M” terminals of the Check voltage at the battery. Use this reading as a key switch.
Page 152: Electric Starter Tests
ELECTRICAL AND IGNITION ELECTRIC STARTER TESTS ELECTRIC STARTER STEP 2 Apply B+ to terminal “A” of solenoid and ground TESTS (NEG) to terminal “B” of solenoid. Measure resis- tance between the starter positive (+) cable termi- Starter Solenoid Test nal and the positive battery (+) cable terminal. The solenoid must close with an audible click.
Page 153: Tilt/Trim Relay Test
ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST Use an inductive ammeter or connect a 0 to 100 TILT/TRIM RELAY TEST amp ammeter in series with a heavy jumper between the battery positive (+) terminal and the The tilt and trim (TNT) module contains the cir- starter positive (+) terminal.
Page 154: Test Procedure
ELECTRICAL AND IGNITION EXHAUST VALVE RELAY TESTS Test Procedure EXHAUST VALVE RELAY Make sure red and black wires are connected to TESTS 12 V battery power supply. Set voltmeter to 12 VDC scale. Connect test leads The exhaust valve control module contains the cir- to terminals “A”...
Page 155: Emm Servicing
ELECTRICAL AND IGNITION EMM SERVICING EMM SERVICING Removal Disconnect exhaust pressure hose and cooling hoses from EMM. Disconnect J1-A and J1-B connectors. Remove two EMM retaining screws. Lift EMM up and to the port side. 005429 Exhaust Valve Relay Module Diagram 1.
Page 156: Installation
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Installation FLYWHEEL AND STATOR SERVICING If a new EMM is being installed, IMPORTANT: refer to EMM Transfer on p. 111. Weak flywheel magnets IMPORTANT: Install J2 connector cause low ignition voltage and affect outboard per- Align slots in starboard side of EMM case with iso- formance.
Page 157 ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Lift the electrical harness base out of the way. Use two 3/8-24x2 in. screws from the adaptor kit to attach the tool to the flywheel. Two holes are tapped in the flywheel for the tool. 005379 Use Flywheel Holder, P/N 771311, or equivalent, 005369...
Page 158: Stator Service
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING wheel onto crankshaft. Remove tools from the fly- Stator Service wheel and crankshaft. Remove six allen head screws to remove stator. 005383 005382 1. Stator screws CAUTION To install stator, position stator on cylinder block. Apply Nut Lock to screw threads.
Page 159: Timing Adjustments
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Install the electrical harness base and secure with TIMING ADJUSTMENTS four screws. Torque screws to 60 to 84 in. lbs (7 to 9.5 N·m). Timing Pointer The timing pointer must be adjusted to indicate “top dead center” (TDC) of the number 1 piston. This reference to the position of the number 1 pis- ton is used to synchronize the electronic timing controlled by the EMM with the mechanical posi-...
Page 160 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Rotate the flywheel clockwise to 30° ATDC. Rotate the flywheel in a clockwise direction until the piston contacts the tool. Mark the flywheel directly across from the pointer. Label this mark “B.” Rotate flywheel counterclockwise slightly to release tool and remove it from spark plug hole.
Page 161: Timing Verification
ELECTRICAL AND IGNITION TPS CALIBRATION TPS CALIBRATION Timing Verification Use the Evinrude Diagnostics Software program Use the Evinrude Diagnostics Software program to synchronize the mechanical timing of the out- to tell the EMM what the throttle position sensor board with the electronic timing control function of voltage level is when the throttle plates begin to the EMM.
Page 162: Spark Plugs
ELECTRICAL AND IGNITION SPARK PLUGS Apply Triple-Guard grease to the gasket surface SPARK PLUGS of the spark plugs. Install all spark plugs and tighten them to a torque of 15 ft. lbs. (20 N·m). Inspection Spark plugs should be removed and examined If the mark is in unshaded area do not tighten any- periodically.
Page 163: Electric Starter Servicing
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the screws, lock washers, and pinion ELECTRIC STARTER housing. SERVICING Removal Do not clean the starter drive IMPORTANT: while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator.
Page 164 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Hit the socket with a mallet to lower the spacer Remove pinion and plastic weather cover from and expose the retaining ring under the spacer. pinion shaft. 30368 Remove the driven gear and thrust washer. 30371 30367 30360...
Page 165 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the two thru-bolts. Mark the end cap ori- Note the alignment marks by the positive terminal entation, and remove the cap. stud. Hold the armature in place, and slide the frame away from the gear housing. 30365 Gently tap the starter frame with a rubber mallet to loosen it.
Page 166: Cleaning And Inspection
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING matter which could contribute to failure of wind- Cleaning and Inspection ings. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. 24058 TYPICAL Check permanent magnets. Make sure they 30349 strongly attract any steel or iron object held inside frame.
Page 167: Assembly
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Align the starter frame and make sure the long Assembly alignment mark matches the mark next to the pos- itive terminal stud on the gear housing. If removed, apply Locquic Primer IMPORTANT: and Screw Lock to the brush card screws before Push the armature down firmly and slide the installing.
Page 168 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Install the two thru-bolts. Tighten to a torque of 50 Guard grease. Install the thrust washer and driven to 65 in. lbs. (5.6 to 7.3 N·m). gear. 30362 30363 Install the weather cover. Lightly coat the drive gear with Triple-Guard grease, and install it on the armature shaft.
Page 169: Installation
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Lightly coat the pinion shaft splines (helix) with To test the assembly and operation of the starter, Starter Bendix Lube. Lower the pinion into place refer to No Load Current Draw Test on p. 150. without displacing the driven gear or thrust Installation washer.
Page 170: Connector Servicing
ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire. CONNECTOR SERVICING DEUTSCH Connectors recom- IMPORTANT: Electrical Grease mended. Incorrect grease application can cause electrical or warning system problems. 42329 1. Terminal latch (receptacle) 2. Terminal latch (plug) To disconnect the connector, press the latch and pull the connectors apart.
Page 171 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors Always use the appropriate meter IMPORTANT: test probes and adapters when testing compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. † UPERSEAL Disconnect Lift latch. Pull connectors apart. 002447 1.
Page 172 ELECTRICAL AND IGNITION CONNECTOR SERVICING † † UPER OWER IMER ERIES The J1-A and J1-B connectors of the EMM are The J2 connector of the EMM is a AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOTH latches and pull connector from Use a screw driver to open latch.
Page 173 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back side of the terminal engages a terminal with seal into connector housing until shoulder in the connector housing to hold the ter- seated.
Page 174 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Install wire gasket on wires and feed wires through the correct terminal position of the con- nector housing. Terminal is crimped onto wire and then pulled back into connector housing until lock- ing tab engages and terminal is seated. 002304 Crimping Terminals Strip insulation back 3/16 in.
Page 175 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............174 COMPONENTS .
Page 176: Service Chart
FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 60-80 in. lbs. (7-9 N·m) 60-84 In. lbs. (7-10 N·m) 60-84 In. lbs. (7-10 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant Pipe Thread Sealing Compound 004940 Permatex #2...
Page 177 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Bond seals to air silencer IMPORTANT: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 96-120 in. lbs. (11-13.5 N·m) Start at center and use a spiral torque pattern 60-80 in.
Page 178 FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Torque in 3 stages 60-84 in. lbs. (6.8-9.5 N·m) 120 in. lbs. (14 N·m) 24-26 Ft. lbs. 24-36 in. lbs (33-35 N·m) (2.7-4 N·m) S = Supply R = Return Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...
Page 179: Components
FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The Evinrude E-TEC direct injection system con- high-pressure components of the fuel system from sists of the following components: water and contaminants. Refer to INSPECTION Fuel Lift Pump •...
Page 180: Vapor Separator
FUEL SYSTEM COMPONENTS Vapor Separator Venting The fuel vapor vent regulates fuel vapor pressure The vapor separator: in the fuel system. Serves as a water-cooled fuel reservoir to accu- • mulate incoming fuel from the fuel lift pump and from the fuel return manifold; Contains a float controlling the venting of fuel •...
Page 181: Fuel Circulation Pump
FUEL SYSTEM COMPONENTS Pressure Regulator Fuel Manifolds The fuel pressure regulator helps maintain consis- The fuel supply and return manifolds route fuel tent fuel pressure in the fuel system. through the high pressure side of the fuel system. Fuel returning from the injectors enters the fuel Fuel Supply Manifold chamber of the vapor separator through a pres- The fuel supply manifold supplies pressurized fuel...
Page 182: Fuel Injectors
FUEL SYSTEM COMPONENTS Fuel Injectors Injector Fuel Supply Fuel is supplied to the injectors by the fuel circula- Fuel injectors are fuel metering (55 V), electric tion pump and the fuel supply manifold. solenoids bolted directly to the cylinder head. The EMM supplies 55 V and controls the activation of Each injector has internal fuel passages.
Page 183: Fuel System Hose Routing
FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING V4 M ODELS Fuel Supply Fuel Return 005194 V6 M ODELS Fuel Supply Fuel Return 004943 Fuel supply from boat fuel system Electric fuel circulation pump (20 to 35 psi) Fuel lift pump (2 to 8 psi) Fuel supply manifold Pulse hose(s) from cylinder/crankcase...
Page 184: Direct Injection Electrical Circuits
FUEL SYSTEM DIRECT INJECTION ELECTRICAL CIRCUITS Requirements for injector activation: DIRECT INJECTION 55 V system voltage from the EMM and through • ELECTRICAL CIRCUITS the individual circuits; and Switched ground connection provided by the • The outboard’s 55 V alternator circuit supplies the EMM.
Page 185: Injector / Circulation Pump Circuits Diagram
FUEL SYSTEM DIRECT INJECTION ELECTRICAL CIRCUITS Injector / Circulation Pump Circuits Diagram 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3...
Page 186: Fuel Component Tests
FUEL SYSTEM FUEL COMPONENT TESTS FUEL COMPONENT Fuel Injectors Pressure Test TESTS This test requires Injector Test Fitting kit, P/N 5005844. DANGER Disconnect the battery cables at the battery. Contact with a rotating propeller is likely to result in serious injury or death. Assure Relieve fuel system pressure.
Page 187: Fuel Supply
FUEL SYSTEM FUEL COMPONENT TESTS fuel pump uses 12 V circuit and the injectors use Fuel Supply 55 V circuit. Fuel System Pressure Test Relieve fuel system pressure. See Relieving Fuel System Pressure on p. 189. After relieving fuel system pressure, install a 0 to 60 psi (0 to 415 kPa) Fuel Pressure Gauge, P/N 5007100 or equivalent, to the upper fuel pres- sure test fitting.
Page 188 FUEL SYSTEM FUEL COMPONENT TESTS High pressure Apply pressure to check regulator operation. The pressure should open check valve at approxi- Suspect restricted filter or fuel return fitting of • mately 15 psi (103 kPa). vapor sperator, damaged pressure regulator in vapor separator, or restricted fuel return mani- fold.
Page 189 FUEL SYSTEM FUEL COMPONENT TESTS Circulation Pump Resistance Test Results: Disconnect the battery cables at the battery. Normal pressure Perform the Lift Pump Vacuum Test on • Use a digital multimeter to measure the fuel pump p. 187. Make certain no air leaks or restrictions circuit and coil resistance.
Page 190 FUEL SYSTEM FUEL COMPONENT TESTS START outboard and run at FULL THROTTLE for Anti-Siphon Valve Test at least two minutes. Monitor clear vinyl hose for Remove anti-siphon valve from fuel tank. Install the presence of air. Air bubbles indicate a faulty adapter fittings and a 36 in.
Page 191: Fuel Component Servicing
FUEL SYSTEM FUEL COMPONENT SERVICING of high pressure fuel pump/vapor separator FUEL COMPONENT assembly. SERVICING WARNING 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.
Page 192: In-Line Fuel Filter
FUEL SYSTEM FUEL COMPONENT SERVICING In-Line Fuel Filter Optional Fuel Filter Accessory kit, P/N 5007045, is available to add a Removal water-separating cannister fuel filter to Evinrude Disconnect the battery cables at the battery. E-TEC 60° V outboards. Remove filter carefully to prevent spilling con- Removal tents.
Page 193: Fuel Lift Pump
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Vapor Separator The fuel lift pump is serviceable as a complete Removal assembly. Refer to parts catalog for service parts. Disconnect the battery cables at the battery. Removal Relieve fuel system pressure. Refer to Relieving Disconnect the battery cables at the battery.
Page 194: Fuel Manifolds
FUEL SYSTEM FUEL COMPONENT SERVICING Disconnect fuel manifold fittings from fuel injector Fuel Manifolds ports, then remove the manifold assembly(s). Removal Installation Disconnect the battery cables at the battery. Check condition of sealing O-rings on fuel mani- Relieve fuel system pressure. Refer to Relieving fold fittings.
Page 195: Fuel Injectors
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injectors Removal Disconnect the battery cables at the battery. Mark fuel injector(s) to indicate cylinder loca- tion(s). Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189. Fuel injector(s) must be installed IMPORTANT: in the correct cylinder location(s).
Page 196 FUEL SYSTEM FUEL COMPONENT SERVICING Crush Ring Replacement Injector crush rings must be IMPORTANT: replaced if injector is installed in a different head or cylinder location. Use Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, compo- nents to remove injector from mounting cup.
Page 197 FUEL SYSTEM FUEL COMPONENT SERVICING supplied with all replacement injectors on 3.5 in. through mounting flange of injector and thread floppy disk. into cylinder head. 002316 Tighten screws in stages, starting with the lower screw. 004160 First torque is 5 ft. lbs. (7 N·m) •...
Page 198: Intake Manifold
FUEL SYSTEM INTAKE MANIFOLD Remove oil distribution hoses from oil pump/mani- INTAKE MANIFOLD fold and reed plate bracket. Refer to OIL COMPO- NENT SERVICING on p. 222. Removal Disconnect vapor separator vent hose, throttle Remove oil recirculation hose from starboard side position sensor connector, and throttle link arm.
Page 199: Inspection
FUEL SYSTEM INTAKE MANIFOLD Use caution to prevent damaging reed valve Assembly assemblies. Remove old adhesive from reed valve retaining screws. Prime the threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate and install screws. Final torque is 30 to 42 in.
Page 200 FUEL SYSTEM INTAKE MANIFOLD Position gasket on throttle body. Install throttle Install oil filter and oil and fuel supply hoses. body, with oil pump bracket on reed plate and install screws. Tighten the center screws first and expand out- ward. Final torque is 96 to 120 in. lbs. (11 to 13.5 N·m).
Page 201: Oiling System
OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............200 COMPONENTS .
Page 202: Service Chart
OILING SYSTEM SERVICE CHART SERVICE CHART Engine Oil Programming Labels *IMPORTANT* *IMPORTANT* XD 100 XD 30 This outboard has is outboard has been programmed been programmed for use of ® for use of Evinrude ® /Johnson rude ® /Johnson ® (Blue) XD 50 TCW3RL OIL...
Page 203: Components
OILING SYSTEM COMPONENTS COMPONENTS Oil Pick-up Components Pickup hose • The oiling system consists of the following compo- Sending unit, LOW OIL warning, and oil pickup • nents: Filter • Oil tank • Primer bulb and supply hose • Oil injection pump and manifold assembly •...
Page 204: Oil Pressure Sensor
OILING SYSTEM COMPONENTS Oil Pressure Sensor Electrical Circuit (55 V) The oil pressure sensor reacts to changes in oil The oil injector is powered by the 55 V electrical manifold pressure. The EMM supplies and moni- circuit. The EMM controls injection pump opera- tors electrical current to the sensor.
Page 205: Oil Injection Pump Diagram
OILING SYSTEM COMPONENTS Oil Injection Pump Diagram 004296r 1. Oil supply hose 2. Inlet check valve 3. Oil injection pump 4. Injection pump check valve 5. Oil distribution manifold 6. Filter (screen type) 7. Oil pressure sensor 8. Oil distribution hoses to individual cylinders 9.
Page 206: Oiling System Electrical Diagram
OILING SYSTEM COMPONENTS Oiling System Electrical Diagram J1-B J1-A Oil Injection Pump 55 V Circuit (WHITE/RED) Grounds, NEG (BLACK) EMM to Oil Solenoid (BLUE) Oil Pressure Sensor, +5 V analog (RED) Oil Pressure Sensor Signal (TAN/WHITE) Capacitor 005358...
Page 207: Systemcheck, I-Command And Emm Oiling System Warnings
OILING SYSTEM COMPONENTS SystemCheck, I-Command and Cylinder and Crankcase EMM Oiling System Warnings The primary oil distribution manifold provides crankcase lubrication through oil distribution Evinrude outboards can be monitored by System- hoses and pressed-in fittings at the front of the Check or Evinrude E-TEC 115-250 HP outboards crankcase, port side.
Page 208: Oil Supply And Distribution Diagrams - V6
OILING SYSTEM COMPONENTS Oil Supply and Distribution Diagrams – V6 Oil Injector / Hose Routing Diagram 150-200HP/60ºV6- Evinrude E-TEC Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3, #4, #5 and #6 crankcase fittings Primary Oil Manifold 1.
Page 209 OILING SYSTEM COMPONENTS Port Side View Starboard Side View 005356...
Page 210: Oil Supply And Distribution Diagrams - V4
OILING SYSTEM COMPONENTS Oil Supply and Distribution Diagrams – V4 Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3 and #4 crankcase fittings Primary Oil Manifold 1. Cylinder 4 2. Cylinder 1 3. Cylinder 2 4.
Page 211 OILING SYSTEM COMPONENTS Port Side View Starboard Side View 005354...
Page 212: Oil Recirculation System
OILING SYSTEM COMPONENTS Oil Recirculation System Crankcase / Main Bearing Recirculation The movement of oil through the main bearings is External hoses fittings, internal cylin- controlled by internal passages, external fittings der/crankcase passages, and intake manifold pas- and hoses, and check valves. sages are used to “recirculate”...
Page 213: Recirculation Hose Routings And Check Valve Diagrams - V6
OILING SYSTEM COMPONENTS Recirculation Hose Routings and Check Valve Diagrams – V6 Port Side View Oil from auxiliary oil manifold Starboard Side View Check valves 005353...
Page 214 OILING SYSTEM COMPONENTS Direction of flow* Check valves - Main bearings to cylinders Direction of flow* Check valves - Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards cylinders 005352...
Page 215: Recirculation Hose Routings And Check Valve Diagrams - V4
OILING SYSTEM COMPONENTS Recirculation Hose Routings and Check Valve Diagrams – V4 Port Side View Oil from auxiliary oil manifold Starboard Side View Check valve 005351...
Page 216 OILING SYSTEM COMPONENTS Direction of flow* Check valves - Main bearings to cylinders Direction of flow* Check valves - Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards cylinders 005350...
Page 217: Priming
OILING SYSTEM PRIMING PRIMING Oil Distribution Manifold Priming Follow these steps for initial outboard set-up: Position outboard in lowest trim/tilt position. • WARNING Squeeze the oil primer bulb to flow oil from the • To prevent injury from contact with rotat- hose connection, through the filter, to the oil ing propeller, always remove the propeller pump.
Page 218 OILING SYSTEM PRIMING Observe oil flow through all oil distribution hoses. Small bubbles are acceptable. Large bubbles must be eliminated through a continued priming process. 004398 1. Oil distribution hose 2. Small bubbles 005348 3. Large bubbles 1. Crankcase oil distribution hoses (port side) Make sure that oil flows through the rear oil distri- All clear “blue”...
Page 219: Oiling Rates
OILING SYSTEM OILING RATES OILING RATES XD100 Outboard Oil Decal Evinrude/Johnson XD100 oil decals are available EMM programming controls the rate of oil injec- to label boats equipped with Evinrude E-TEC out- tion. Use engine diagnostics software to access boards that have been programmed for the this EMM feature.
Page 220: Oiling System Tests
OILING SYSTEM OILING SYSTEM TESTS OILING SYSTEM TESTS Oil Injection Pump Voltage Test Acceptable voltage readings: Always perform visual inspections Key switch ON: approximately 30 V IMPORTANT: • to identify oiling system leaks. Make sure the oil Outboard running: 55 V •...
Page 221: Oil Injection Pump Circuit Resistance Test
OILING SYSTEM OILING SYSTEM TESTS pin 2 (blue wire) of oil injection pump connector. Oil Injection Pump Circuit Key switch must be ON. Resistance Test The oil injection pump circuit includes the engine wire harness, the injection pump winding and con- nector, and the oil injection control circuit of the EMM.
Page 222: Oil Supply Vacuum Test
OILING SYSTEM OILING SYSTEM TESTS Attach a vacuum tester to the outboard side of oil Oil Supply Vacuum Test supply hose and draw 7 in. Hg (24 kPa) vacuum on the hose for at least five minutes. Repair or WARNING replace any leaking components.
Page 223: Oil Injection Fittings Flow Test
OILING SYSTEM OILING SYSTEM TESTS Static Test Oil Injection Fittings Flow Test Remove oil distribution hose from fitting at crank- case. Squeeze oil supply primer bulb to provide oil WARNING to injection pump. To prevent accidental starting while ser- vicing, disconnect battery cables at the battery.
Page 224: Oil Component Servicing
OILING SYSTEM OIL COMPONENT SERVICING Once hose is removed from the manifold, make OIL COMPONENT sure hose support is in the end of the hose. SERVICING WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery. Access to certain oil distribution IMPORTANT: hoses requires removal of various engine compo-...
Page 225: Oil Injection Pump
OILING SYSTEM OIL COMPONENT SERVICING Connect oil hoses to crankcase fittings and fasten Oil Injection Pump with tie straps. Removal Disconnect the battery cables at the battery. Remove engine cover and air silencer. Remove the oil supply hose from the fitting (inlet) of the oil injection pump.
Page 226 OILING SYSTEM OIL COMPONENT SERVICING Reconnect the electrical connector. Use oil primer bulb to purge oil IMPORTANT: supply hose before reconnecting hose to oil pump. Reconnect oil supply hose to the inlet fitting of oil pump. Fasten with Oetiker clamp. 005346 TYPICAL 1.
Page 227: Cooling System
COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........226 ENGINE TEMPERATURE CHECK .
Page 228: Hose Routing And Water Flow Diagrams
COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V4 M ODELS Hose Routing & Water Flow Diagram 115HP/60°V4 Water intake screens Water pump 1. Water intake screens Water tube 2. Water pump 3. Water tube Adapter housing 4.
Page 229 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V6 M ODELS Hose Routing & Water Flow Diagram 150-200 HP/60°V6 Water intake screens 1. Water intake screens Water pump 2. Water pump Water tube 3. Water tube Adapter housing 4.
Page 230: Engine Temperature Check
COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use the Evinrude Diagnostics Software program. CHECK Observe temperature displays for port and star- board temperature sensors. The engine temperatures listed IMPORTANT: below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). CAUTION When servicing the propeller, always shift the outboard to NEUTRAL, turn the key...
Page 231: Idle Operating Temperature Troubleshooting (Below Range)
COOLING SYSTEM ENGINE TEMPERATURE CHECK Pressure Relief Valve The pressure relief valve should be closed at IDLE speed. Water should not flow past the plunger and seal. Check for damage or debris that could prevent the valve from closing completely. Replace pres- sure relief valve if necessary.
Page 232: Components
COOLING SYSTEM COMPONENTS COMPONENTS General Description All models use a two-stage cooling system design. The cooling system is dependent on water pump pressure and controlled by thermostat and pressure valve operation. Restricted or inadequate water IMPORTANT: flow through the outboard reduces cooling system performance and may lead to severe powerhead damage.
Page 233: Adapter/Inner Exhaust Housing
COOLING SYSTEM COMPONENTS Overcooling: Debris may prevent the valve from Adapter/Inner Exhaust Housing closing completely. Adapts the cylinder/crankcase assembly (pow- • erhead) to the exhaust housing and the water tube. Provides water passages which route incoming • and outgoing cooling water. Provides exhaust passages which connect to •...
Page 234: Operation
COOLING SYSTEM OPERATION At higher speeds, water pressure increases. The OPERATION pressure valve opens, or lifts off the seat, at approximately 2500 RPM. Water flows through Cylinder Block / Cylinder Head the pressure valve and bypasses the thermostats. Cooling Hoses route the water flow from the pressure The flow of water through the cylinder block and valve to the vertical water passages below the cylinder heads is controlled by two thermostats...
Page 235: Thermostat Servicing
COOLING SYSTEM THERMOSTAT SERVICING THERMOSTAT PRESSURE RELIEF SERVICING VALVE SERVICING Pressure relief valve assembly should be serviced Disassembly at the same time as the thermostats. Remove the thermostat cover and O-ring from each cylinder head. Remove each thermostat. Disassembly Remove the EMM. Refer to EMM SERVICING on p.
Page 236: Inspection
COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING Remove the pressure valve components. Inspection Inspect all components for cracks, heat damage, or signs of corrosion. Replace damaged compo- nents. Clean all debris from pressure relief valve components. Assembly Assembly is essentially the reverse of disassem- bly.
Page 237 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............236 GENERAL .
Page 238: Service Chart
POWERHEAD SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (14-16 N·m) 168-192 In. lbs. (19-21.7 N·m) 40-50 In. lbs. (5-6 N·m) 60-84 In. lbs. (7-9.5 N·m) IMPORTANT See - Spark Plug Indexing Procedure 15-30 Ft. lbs. 40-50 In.
Page 239 POWERHEAD SERVICE CHART 48 In. lbs. (5.5 N·m) Must use Rod Alignment Tool. 30-32 Ft. lbs. (41-43 N·m) Triple-Guard Grease Gasket Sealing Compound Red Ultra Lock Needle Bearing Grease Outboard Engine Lubricant 005229 DSS135...
Page 240: General
POWERHEAD GENERAL GENERAL Retaining Ring Pliers Cylinder Compression Testing Start and run outboard until it achieves operating temperature, then shut OFF. Disconnect crankshaft position sensor (CPS) con- nector. Remove all spark plugs. Advance throttle linkage to WOT. Install compression tester’s hose attachment into spark plug hole (14 mm threads).
Page 241: Removal
POWERHEAD REMOVAL Remove flywheel cover and rear shroud. REMOVAL WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189. To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
Page 242 POWERHEAD REMOVAL Disconnect power trim connectors. ODELS Disconnect water overflow hose from vapor sepa- rator. Remove clamps and muffler assembly from rear of powerhead. 005254 1. Tilt limit switch connector 2. Sending unit connector 005243 1. Overflow indicator hose 2. Muffler clamps Remove the four small powerhead screws, seven large powerhead screws, and the upper mount screws.
Page 243: Disassembly
POWERHEAD DISASSEMBLY Allen 1/4 in. hexagonal wrench. Attach suitable DISASSEMBLY chain hoist to lifting tool. General To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p.
Page 244: Crankcase
POWERHEAD DISASSEMBLY Remove shoulder screw from shift arm and retain- Loosen in stages and remove the main bearing ing screw from shift rod lever. Slide entire shift screws. linkage assembly from crankcase. 005313 1. Main bearing screws (6 on V4; 8 on V6) 005294 1.
Page 245: Cylinder Head
POWERHEAD DISASSEMBLY Carefully remove the crankcase from the cylinder Connecting Rods and Pistons block to avoid damaging the crankshaft seal rings. Use a permanent marker to identify each connect- ing rod cap, connecting rod, and piston by cylinder number. Number 1 is closest to the flywheel. 005304 Cylinder Head 005292...
Page 246 POWERHEAD DISASSEMBLY Using one hand to support the piston, remove the Use Retaining Ring Pliers, or equivalent, to rod cap screws with your other hand. Remove remove wrist pin retaining rings. Discard retaining each piston and rod assembly. rings. WARNING Wear safety glasses to avoid injury.
Page 247: Crankshaft
POWERHEAD DISASSEMBLY If the lower crankshaft is to be resealed or the Crankshaft lower bearing replaced, remove the lower bearing seal housing. WARNING Wear safety glasses to avoid injury. Carefully lift crankshaft straight up and remove from crankcase. 005280 Remove the housing O-ring. Discard O-ring. 005285 Remove upper seal from crankshaft.
Page 248 POWERHEAD DISASSEMBLY Remove O-ring from crankshaft sleeve and Using an appropriate bearing separator, support inspect it. Replace the O-ring if it is not in good the bearing, place separator flats against the condition. bearing, and press off the crankshaft. 29019 24383 Inspect the crankshaft sleeve and replace if nec- Remove and inspect crankcase seal rings.
Page 249: Cleaning
POWERHEAD CLEANING Use Gel Seal and Gasket Remover to remove all CLEANING traces of gaskets, adhesives, and Gel-Seal II™ sealant from the cylinder block and crankcase. Before inspecting or assembling IMPORTANT: powerhead, all internal components must be completely clean and free of contaminants. Remove any carbon accumulation from exhaust port areas.
Page 250: Inspection
POWERHEAD INSPECTION INSPECTION Crankshaft Measure the diameter of each crankpin and main For powerhead dimensions, refer to TECHNICAL bearing journal. The lower main bearing journal DATA on p. 18. would only be measured if the bearing was removed for another reason. Before any inspection process IMPORTANT: can begin, all internal components must be com-...
Page 251: Cylinder Bore
POWERHEAD INSPECTION If any cylinder is outside these Cylinder Bore IMPORTANT: tolerances, it must be bored oversize. It is permis- Use Cylinder Bore Gauge, P/N 771310, to inspect sible to have one or more oversize pistons in an each cylinder bore for an out-of-round, oversize, engine.
Page 252: Bearings
POWERHEAD ASSEMBLY or just below the surface of piston. Rings must ASSEMBLY move freely in piston ring groove. Proceed slowly. Make no forced IMPORTANT: assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant. Use new wrist pin retaining rings, IMPORTANT: gaskets, seals, and O-rings during assembly.
Page 253 POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installa- facing down. The seal lip faces the bottom of the tion, thread Slide Hammer, P/N 391008, into crankshaft. installer and pull it off. Inspect sleeve after installation. IMPORTANT: Sleeve must not be used if surface is damaged. Using retaining ring pliers, install bearing retaining ring with sharp edge facing away from bearing.
Page 254: Pistons And Connecting Rods
POWERHEAD ASSEMBLY Align bearings with Wrist Pin Bearing Tool, Pistons and Connecting Rods P/N 336660. It is very important that the pis- IMPORTANT: tons in this engine are oriented correctly. New pistons are stamped “PORT” or “STBD,” and “EXH.” These markings should be oriented to the exhaust side (center) of the block.
Page 255 POWERHEAD ASSEMBLY Install wrist pin through piston and connecting rod, Installing Pistons pushing bearing tool out through the piston. When all pistons and connecting rods are assem- bled, install piston ring sets. Be sure rings are Use Wrist Pin Cone, P/N 318600, and Driver, installed in the cylinder used to test ring end gap.
Page 256: Cylinder Head
POWERHEAD ASSEMBLY Slide piston and rod assembly into the correct cyl- If it has been removed, apply soapy water to water inder, as marked during disassembly. Guide con- dam and insert into block. necting rod through cylinder block to avoid scratching cylinder wall.
Page 257: Crankshaft And Connecting Rods
POWERHEAD ASSEMBLY screws in stages to 168 to 192 in. lbs. (19 to 21.7 Thoroughly clean upper seal area of the crank- N·m). shaft. Install new upper seal on crankshaft. Do not apply sealer to outside diameter of the seal. 005289 1.
Page 258 POWERHEAD ASSEMBLY Lubricate each crankpin and bearing assembly Be sure alignment dot on rod cap IMPORTANT: with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dots face fly- up to crankshaft and install bearing halves. wheel.
Page 259 POWERHEAD ASSEMBLY Secure restraining jaw “C” and forcing jaw “D” to Tighten the forcing screw to a torque of 14 to 16 • frame. in. lbs. (1.6 to 1.8 N·m). 21591c Restraining Jaw “C” 005297 1. Forcing screw 2. Adjustment stop 3.
Page 260: Crankcase
POWERHEAD ASSEMBLY Test at least three corners of the rod and cap joint Gel-Seal II has a shelf life of at IMPORTANT: with a pick. Joint must be smooth with no step. least one year when stored at room temperature. Test the Gel-Seal II or replace it if the age of the tube cannot be determined.
Page 261: General
POWERHEAD ASSEMBLY Torque main bearing screws in stages to 31 to 35 Test that the crankshaft spins freely without bind- ft. lbs. (42 to 47.5 N·m). Begin with the center ing. screws and work outward in a spiral pattern. After powerhead been IMPORTANT:...
Page 262 POWERHEAD ASSEMBLY Apply Nut Lock to threads of throttle lever screw. Install ignition coils and fuel injectors. Refer to Fuel Injectors on p. 193. Insert spring into cavity of throttle lever. Install lever, screw, and washer on crankcase and hook All injectors must be reinstalled in IMPORTANT: spring on rib as shown.
Page 263: Upper Mount Servicing
POWERHEAD UPPER MOUNT SERVICING Dislodge mount assemblies and remove. UPPER MOUNT SERVICING Removal Remove mount retainer screw. 005312 Inspect mounts and replace if necessary. The motor mount, washer, and IMPORTANT: screw are serviced as an assembly. Do not disas- 005309 semble.
Page 264: Installation
POWERHEAD INSTALLATION Installation INSTALLATION Place mount assemblies in position, with flats fac- Apply Permatex No. 2 to both sides of a new base ing away from each other. gasket around the exhaust ports only. Install gas- ket on adapter. To ensure proper sealing, mating Apply Moly Lube to all sides of retainer and install surfaces must be clean.
Page 265 POWERHEAD INSTALLATION Install pins from Alignment Pin Kit, P/N 5007167, With alignment pins in place, loosely install as shown. Tighten pins until fully seated. remaining powerhead screws and upper mount screws. 005274 005277 1. Large powerhead screws 2. Small powerhead screws 3.
Page 266 POWERHEAD INSTALLATION Position the shift rod in the shift rod lever. Install ODELS the retaining screw and washer. Torque screw to Connect the power trim connectors. 60 to 84 in. lbs. (7 to 9.5 N·m). 005254 1. Tilt limit switch connector 005253 2.
Page 267 POWERHEAD INSTALLATION Install rear shroud and flywheel cover. Connect trim/tilt switch connector. 005248 005246 Install the lower engine covers and tighten the Perform the following procedures IMPORTANT: screws. before returning outboard to service: Index all spark plugs. Refer to Spark Plug •...
Page 268: Powerhead Views
POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS V4 Starboard – Hose Routings 005249...
Page 269: V4 Port - Hose Routings
POWERHEAD POWERHEAD VIEWS V4 Port – Hose Routings 005250 02406...
Page 270: V4 Starboard
POWERHEAD POWERHEAD VIEWS V4 Starboard 005225...
Page 271: V4 Port
POWERHEAD POWERHEAD VIEWS V4 Port 005224 02406...
Page 272: V4 Front
POWERHEAD POWERHEAD VIEWS V4 Front 005226...
Page 273: V4 Rear
POWERHEAD POWERHEAD VIEWS V4 Rear 005227...
Page 274: Top - Hose Routings
POWERHEAD POWERHEAD VIEWS Top – Hose Routings 005245...
Page 275: V4 - V6 Top
POWERHEAD POWERHEAD VIEWS V4 – V6 Top 005228...
Page 276: V6 Starboard - Hose Routings
POWERHEAD POWERHEAD VIEWS V6 Starboard – Hose Routings 005324...
Page 277: V6 Port - Hose Routings
POWERHEAD POWERHEAD VIEWS V6 Port – Hose Routings 005325...
Page 278: V6 Starboard
POWERHEAD POWERHEAD VIEWS V6 Starboard 005256...
Page 279: V6 Port
POWERHEAD POWERHEAD VIEWS V6 Port 005257...
Page 280: V6 Front
POWERHEAD POWERHEAD VIEWS V6 Front 005252...
Page 281: V6 Rear
POWERHEAD POWERHEAD VIEWS V6 Rear 005251...
Page 282: Notes
POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 283: Midsection
MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............282 TILT TUBE .
Page 284: Service Chart
MIDSECTION SERVICE CHART SERVICE CHART 8-12 In. lbs. 40-50 In. lbs. (0.9-1.5 N·m) (4.5-5.7 N·m) 110-130 Ft. lbs. (149-176 N·m) 10-16 In. lbs. (1.1-1.8 N·m) 30-50 In. lbs. (3.5-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.7 N·m) 28-30 Ft.
Page 285 MIDSECTION SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. 216-240 In. lbs. (7-9.5 N·m) (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 20-22 Ft. lbs. (27-30 N·m) 156-180 In. lbs. (18-20 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube...
Page 286 MIDSECTION SERVICE CHART...
Page 287: Tilt Tube
MIDSECTION TILT TUBE Remove the nut from the starboard side. TILT TUBE The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist.
Page 288: Installation
MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of thread are WARNING engaged. Replace locknut if definite resistance is not felt. Torque starboard tilt tube nut to 50 to 54 ft. lbs. (68 to 73 N·m), then loosen nut 1/8 to 1/4 turn.
Page 289: Exhaust Housing
MIDSECTION EXHAUST HOUSING Remove the exhaust housing. EXHAUST HOUSING Removal Before removing the midsection: The gearcase must be removed. Refer to Gear- • case REMOVAL AND INSTALLATION on p. 308. The powerhead must be removed. Refer to • Powerhead REMOVAL on p. 239. Remove and discard four lower mount screws.
Page 290: Disassembly
MIDSECTION EXHAUST HOUSING Remove the water tube. Inspect water tube grom- Disassembly met and replace if necessary. V4 M ODELS Remove three screws and exhaust valve actuator. 005210 1. Water tube grommet 005206 1. Actuator screws V4 M ODELS Remove circlip and washers from exhaust valve ODELS shaft on starboard side of inner exhaust housing.
Page 291: Cleaning And Inspection
MIDSECTION EXHAUST HOUSING Inspect the water tube for obstructions or kinks, Cleaning and Inspection which may restrict water flow. WARNING Assembly Wear safety glasses to avoid personal V4 M ODELS injury, and set compressed air to less than Assemble linkage to exhaust valve shaft as 25 psi (172 kPa).
Page 292 MIDSECTION EXHAUST HOUSING Place exhaust valves in inner exhaust housing. Secure shaft with spring washer, flat washer, and circlip. 005215 005211 1. Circlip Push valves into housing until they drop into 2. Spring washer notch. ODELS Apply Adhesive 847 to the bottom flange of the inner exhaust housing.
Page 293 MIDSECTION EXHAUST HOUSING Clean and degrease the adapter housing and 216 to 240 in. lbs. (24.5 to 27 N·m) and rear screw outer exhaust housing mating surfaces with to 60 to 84 in. lbs. (7 to 9.5 N·m). Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing.
Page 294: Installation
MIDSECTION EXHAUST HOUSING Rotate and push actuator into position. Apply Tri- V4 M ODELS ple-Guard grease to screw threads and install Check that exhaust valve linkage is oriented as screws and washers. Tighten screws to 60 to 84 shown. “OUT” marking on lever must be visible. in.
Page 295: Stern Bracket
MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer. It STERN BRACKET may be necessary to tap the steering shaft out using a wood dowel and mallet. Removal Before servicing the stern bracket: The gearcase must be removed. Refer to Gear- •...
Page 296 MIDSECTION STERN BRACKET Remove the anode. Remove the tilt limit switch and retainer from the swivel bracket. 30762 1. Anode 30758 1. Tilt limit switch Remove the swivel bracket. Inspect and, if neces- 2. Retainer sary, replace the tilt tube bushings. Disconnect the trail lock spring and remove it from the swivel bracket.
Page 297: Assembly
MIDSECTION STERN BRACKET Remove the two trim rod rollers from the swivel Assembly bracket. Before proceeding, make sure all IMPORTANT: components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evi- dence of deterioration.
Page 298 MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel bracket. Torque to 216 to 240 in. lbs. (25 to 27 bracket. Torque screws to 40 to 50 in. lbs. (4.5 to N·m).
Page 299 MIDSECTION STERN BRACKET Install the steering shaft keeper. Apply Locquic Coat the bushings and seal lips with Triple- • Primer and Nut Lock to the splines of the steering Guard grease. shaft and lower mount bracket. 30765 / 30764 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.
Page 300: Exhaust Relief Muffler Assembly
MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY The overboard indicator and flush port in the EXHAUST RELIEF exhaust relief grommet connect to the vapor sepa- MUFFLER ASSEMBLY rator with a hose. This hose is not connected to the muffler assembly. The exhaust relief muffler is located at the rear of the powerhead and concealed by the lower motor covers.
Page 301 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............300 GEARCASE TYPES .
Page 302: Service Chart
GEARCASE SERVICE CHART SERVICE CHART V4 20 “S2”–T ODELS EARCASE 120-144 In. lbs. (13.6-16.3 N·m) 60-84 In. lbs. 24-36 In. lbs. (6.8-9.5 N·m) (2.7-4.1 N·m) 60-84 In. lbs. (6.8-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) See Water Pump Assembly instructions 37-41 Ft.
Page 303 GEARCASE SERVICE CHART V6 20 “O”–T ODELS EARCASE 60-84 In. lbs. (6.8-9.5 N·m) 120-144 In. lbs. (13.6-16.3 N·m) 60-84 In. lbs. 24-36 In. lbs. (6.8-9.5 N·m) (2.7-4.1 N·m) 26-28 Ft. lbs. (35-38 N·m) See Water Pump Assembly instructions 45-50 Ft. lbs. (61-68 N·m) 60-84 In.
Page 304 GEARCASE SERVICE CHART “L”-T ERFORMANCE ODELS EARCASE 60-84 In. lbs. (6.8-9.5 N·m) 120-144 In. lbs. (13.6-16.3 N·m) 60-84 In. lbs. (6.8-9.5 N·m) 24-36 In. lbs. (2.7-4.1 N·m) 40-50 Ft. lbs. 26-28 Ft. lbs. (54-68 N·m) (35-38 N·m) See Water Pump Assembly instructions 40-50 Ft.
Page 305 GEARCASE SERVICE CHART V4/V6 25 “M”– ODELS TANDARD OTATION TYPE EARCASE 10-12 Ft. lbs. (13.6-16.3 N•m) 60-84 In. lbs. (6.8-9.5 N•m) 60-84 In. lbs. (6.8-9.5 N•m) 24-36 In. lbs. (2.7-4.1 N•m) 18 In. lbs. (2.0 N•m) Then 10-12 In. Lbs (Then 1.1-1.4 N•m) See Water Pump Assembly instructions...
Page 306 GEARCASE SERVICE CHART V6 C “M”-T OUNTER OTATION EARCASE 10-12 Ft. lbs. (14-16 N•m) 60-84 In. lbs. 24-36 In. lbs. (6.8-9.5 N•m) (2.7-4.1 N•m) 60-84 In. lbs. (6.8-9.5 N•m) 18 In. lbs. (2.0 N•m) Then 10-12 In. Lbs (1.1-1.4N•m) See Water Pump Assembly instructions 40-50 Ft.
Page 307: Gearcase Types
GEARCASE GEARCASE TYPES GEARCASE TYPES Outboard Model Housing Type Comparative Information Gear Ratio V4 20 in. “S” standard gearset 13:26 (.500) Similar Housings V4 20 in. “S2” unique shafts, “large” gearset 13:26 (.500) V4 25 in special gear ratio, uses V6 style prop 12:27 (.444) “O”...
Page 308: Propeller
GEARCASE PROPELLER PROPELLER SHIFT INTERRUPT SWITCH Inspection Carefully examine propeller and outboard for the The shift interrupt switch signal is IMPORTANT: following: not utilized on 60°V4 or 60°V6 Evinrude ETEC Damaged blades and signs of propeller cavita- • models. Low idle speeds do not require shift inter- tion (burned paint, etc.) rupt function.
Page 309: Lubricant
GEARCASE LUBRICANT Overheated lubricant will have a black color and LUBRICANT burned odor. Draining Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of WARNING failure. Gearcase lubricant may be under pressure Filling and/or hot. If plug is removed from a Secure the gearcase in a vertical position.
Page 310: Leak Test
GEARCASE LEAK TEST LEAK TEST REMOVAL AND INSTALLATION Drain lubricant before testing. STEP 1 Removal Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant WARNING level hole. To prevent accidental starting while ser- Pressurize 3 to 6 psi (21 to 42 kPa). vicing, twist and remove all spark plug leads.
Page 311 GEARCASE REMOVAL AND INSTALLATION Remove the forward screw with the washer, and Installation remove middle screw. WARNING 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.
Page 312 GEARCASE REMOVAL AND INSTALLATION Apply Gel-Seal II to gearcase mating surface pads Apply Gasket Sealing Compound to threads of the on exhaust housing. Slide the gearcase into gearcase retaining screws. Torque the screws: place, making sure: 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N·m) •...
Page 313: Water Pump
GEARCASE WATER PUMP lbs. (47 to 54 N·m). For adjustment, refer to Trim WATER PUMP Tab Adjustment on p. 77. Disassembly Rotate the driveshaft counterclockwise to unlock the impeller cam. Remove the four impeller hous- ing screws. COA3663 1. Trim tab screw 2.
Page 314 GEARCASE WATER PUMP Install the water tube grommet with the inside Assembly taper facing up. Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs. Do not allow any adhesive to get IMPORTANT: into the air bleed groove in the impeller housing.
Page 315 GEARCASE WATER PUMP Run a thin bead of Adhesive 847 in the seal impeller, and slide water pump down over cam. groove, and install the special shaped O-ring seal. Be sure impeller cam does not fall out of position. CO2995 1.
Page 316: Shift Rod Adjustment
GEARCASE SHIFT ROD ADJUSTMENT SHIFT ROD DISASSEMBLY ADJUSTMENT WARNING Check the shift rod height from the shift rod hole to Wear safety glasses to avoid personal the surface of the gearcase using Universal Shift injury, and set compressed air pressure to Rod Height Gauge, P/N 389997.
Page 317: Propeller Shaft Bearing Housing Removal
GEARCASE DISASSEMBLY Hydrostatic Seal Grooves — Must be in good • Propeller Shaft Bearing condition to help prevent propeller ventilation. Housing Removal This procedure is for standard IMPORTANT: rotation gearcases only. For counter rotation gear- cases, refer to COUNTER ROTATION on p. 341. Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.
Page 318: Pinion Gear And Driveshaft Removal
GEARCASE DISASSEMBLY Assemble components and pull the bearing hous- Use the required tools to remove the pinion screw ing from the gearcase. Remove the thrust washer, and gear from the lower driveshaft. thrust bearing, and reverse gear from gearcase. 005406 1.
Page 319 GEARCASE DISASSEMBLY Remove shims, thrust washer, and thrust bearing Make sure Lower Driveshaft IMPORTANT: with the lower driveshaft. Wrench is fully seated in head of pinion screw. Use a long 3/4 in. combination wrench to hold lower Driveshaft Spline Tool and a 1/2” drive wrench to turn the Lower Driveshaft Wrench in a counterclockwise direction.
Page 320 GEARCASE DISASSEMBLY The bearing housing, shims, thrust bearing, and “O,” “L,” “M” T EARCASES thrust washer will come out with the driveshaft. Position the shift rod to move the clutch dog as far forward as possible. This will assist in the removal of the pinion nut.
Page 321 GEARCASE DISASSEMBLY If upper driveshaft becomes separated from lower (Special) Driveshaft Removal Procedures driveshaft, Lower Driveshaft Puller, “O,” “L,” “M” T EARCASES P/N 342681, to remove. Install puller into lower The driveshaft to pinion taper is a locking taper. If driveshaft and turn 90°...
Page 322: Driveshaft Service
GEARCASE DISASSEMBLY Driveshaft Service “S2” T EARCASE Removal To separate the upper driveshaft IMPORTANT: from the lower driveshaft, the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft. Remove the four driveshaft bearing housing screws with washers and bearing housing. 005424 Force upper driveshaft into lower driveshaft.
Page 323 GEARCASE DISASSEMBLY Install new seals in driveshaft bearing housing. Installation Refer to Driveshaft Bearing Housing on p. 326. To install upper driveshaft into lower driveshaft, Using Driveshaft Seal Protector, P/N 318674, position new retainers (circlip type) on upper slide the driveshaft bearing housing onto the driveshaft as shown.
Page 324 GEARCASE DISASSEMBLY Install the upper driveshaft into the lower drive- “O,” “L,” “M” T EARCASES shaft, aligning the holes in the driveshaft retainer Refer to DISASSEMBLY on p. 314 for driveshaft and the lower driveshaft. removal. To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin.
Page 325: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE GEARCASE HOUSING INSPECTION GEARCASE HOUSING Shift Housing, Gear and Propeller Shaft Removal INSPECTION Push down on the shift rod. This will move the detent lever downward to clear the inside of the Thoroughly clean gearcase housing to remove all gearcase when the shaft assembly is pulled out.
Page 326: Bearing And Seal Removal
GEARCASE BEARING AND SEAL REMOVAL Remove the gear, thrust bearing, and thrust BEARING AND SEAL washer from the shift housing. REMOVAL Shift Housing WARNING Wear safety glasses to avoid injury. The shift housing and forward IMPORTANT: gear bearing are serviced as an assembly. If either are worn or damaged, replace the complete assembly.
Page 327: Pinion Gear Bearing
GEARCASE BEARING AND SEAL REMOVAL Wrap the housing with a shop cloth to catch ball “S” T EARCASES and spring. Rotate the shifter detent 90° in either Use a mallet to drive the bearing from the hous- direction, then pull the detent out of the housing. ing.
Page 328: Driveshaft Bearing Housing
GEARCASE BEARING AND SEAL REMOVAL Driveshaft Bearing Housing Propeller Shaft Bearing Housing The driveshaft bearing is not serviceable. Replace Rear Seal Removal the bearing housing assembly if the bearing is Remove seals using Puller Bridge, P/N 432127, worn or damaged. Also, inspect the driveshaft and Small Puller Jaws, P/N 432131.
Page 329: Bearing And Seal Installation
GEARCASE BEARING AND SEAL INSTALLATION Inspect the bearing housing anode. Replace BEARING AND SEAL anode if it is reduced to two-thirds of original size. INSTALLATION Shift Housing Clean and inspect all components IMPORTANT: before beginning assembly procedures. Replace any damaged components. Lightly coat the detent ball and spring with Needle Bearing grease.
Page 330 GEARCASE BEARING AND SEAL INSTALLATION Thoroughly grease 25 needle bearings with Nee- Position the shift lever arms into the recesses of dle Bearing grease and place in the bearing case the shift cradle. Pull shifter detent back up to (except “S” Type). NEUTRAL position to hold the cradle and shaft in place.
Page 331: Pinion Gear Bearing
GEARCASE BEARING AND SEAL INSTALLATION Align holes in the clutch dog with slot in the pro- Pinion Gear Bearing peller shaft. Install the clutch dog on the shaft with Assemble the following components of Pinion “PROP END” facing rear of the shaft. Bearing Remover and Installer, P/N 391257, as shown: The clutch dog is not symmetri-...
Page 332: Driveshaft Bearing Housing
GEARCASE BEARING AND SEAL INSTALLATION Apply Needle Bearing grease to the needle bear- Driveshaft Bearing Housing ings and insert them into the bearing case (except Lightly apply Gasket Sealing Compound to a new “S” Type). O-ring. Install the O-ring in top groove of the bear- ing housing.
Page 333: Propeller Shaft Bearing Housing
GEARCASE BEARING AND SEAL INSTALLATION Propeller Shaft Bearing Rear Seal Installation Install new seals back to back in bearing housing Housing using Seal Installation Tool. Apply Gasket Sealing Bearing Installation Compound to metal casings of the seals before installing. Oil, then install new bearings in bearing housing. Install inner seal with lip facing toward the bearing Place the lettered end of the bearing case on the housing, then outer seal with lip facing away from...
Page 334: Driveshaft Shimming
GEARCASE DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING “O,” “L,” “M” T EARCASES Degrease pinion and driveshaft IMPORTANT: If new pinion gear is needed, IMPORTANT: tapers prior to assembly. Check tapers for any replace gear set before shimming. damage or material transfer. Replace any dam- aged components before proceeding.
Page 335 GEARCASE DRIVESHAFT SHIMMING with end of threads. Tighten locking ring on pre- Check the squareness of the pinion to the drive- load screw. shaft by holding the shim gauge bar against the bearing housing (between the screw holes) while rotating just the driveshaft and pinion assem- bly and measuring the clearance between the shim gauge bar and the pinion.
Page 336: Assembly
GEARCASE ASSEMBLY ASSEMBLY Shift Rod Housing Installation Lubricate a new shift rod cover O-ring with Triple- Water Intake Screens Guard grease. Install the O-ring into the shift rod cover. Install water intake screens. Torque screws to 60 to 84 in. lbs. (7 to 9.5 N·m). Make sure O-ring is fully seated IMPORTANT: in groove around shift rod cover’s full circumfer-...
Page 337: Pinion Gear And Driveshaft Installation
GEARCASE ASSEMBLY on the gearcase. Thread the shift rod into the Pinion Gear and Driveshaft shifter detent about four turns. Installation Refer to DRIVESHAFT SHIMMING on p. 332 “S2” T EARCASE Position the driveshaft thrust bearing, thrust washer, and correct shim(s) on driveshaft as shown.
Page 338 GEARCASE ASSEMBLY Install pinion gear in gearcase housing Temporarily install bearing hous- IMPORTANT: ing for support during pinion torque procedure. 005420 005426 Install driveshaft with thrust bearing, thrust washer, and correct shim(s) in gearcase housing. Insert Lower Driveshaft Spline Tool, P/N 5007052, Position pinion on lower driveshaft.
Page 339 GEARCASE ASSEMBLY Use a long 3/4 in. combination wrench to hold Hold lower retainer and align upper driveshaft with Driveshaft Spline Tool and a 1/2” drive torque lower driveshaft. Force upper driveshaft down wrench to turn the Lower Driveshaft Wrench in a until seated.
Page 340 GEARCASE ASSEMBLY Install new seals in driveshaft bearing housing. “O,” “L,” “M” T EARCASES Refer to Driveshaft Bearing Housing on p. 326. Refer to DRIVESHAFT SHIMMING on p. 332 Using Driveshaft Seal Protector, P/N 318674, before proceeding. slide the driveshaft bearing housing onto the Position the driveshaft thrust bearing, thrust driveshaft.
Page 341 GEARCASE ASSEMBLY Washer must be snapped into recess of pinion Install washers on the driveshaft bearing housing gear. screws. Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N·m). DSC02293 1.
Page 342: Propeller Shaft Bearing Housing And Gear Installation
GEARCASE ASSEMBLY Propeller Shaft Bearing Housing and Gear Installation Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the reverse gear assembly onto the propeller shaft until it engages the pinion gear. 001989 1. Retainer tab screws “O,”...
Page 343: Counter Rotation
GEARCASE COUNTER ROTATION To remove the propeller shaft, bearing housing COUNTER ROTATION and forward gear from a counter rotation gear- case, thread Propeller Shaft Adapter, P/N 432398, Counter rotation model gear- IMPORTANT: onto Slide Hammer, P/N 432128, until it seats. cases use unique components and require differ- Thread adapter completely onto propeller shaft ent service procedures.
Page 344: Shift Housing Service
GEARCASE COUNTER ROTATION shaft assembly. Remove propeller shaft assembly Push the pin out of the clutch dog. Remove all from the gearcase. components. COA3561 1. Pin Remove the gear, thrust bearing, and thrust washer from the shift housing. 14038 Counter Rotation Models 1.
Page 345 GEARCASE COUNTER ROTATION shifter detent accordingly to assist in removal of Assembly components. Clean and inspect all components IMPORTANT: before beginning assembly procedures. Replace any damaged components. Lightly coat the detent ball and spring with Needle Bearing grease. Insert the spring in the housing, then the ball.
Page 346 GEARCASE COUNTER ROTATION Thoroughly grease 25 needle bearings with Nee- Position the shift lever arms into the recesses of dle Bearing grease and place in the bearing case. the shift cradle. Pull shifter detent back up to NEUTRAL to hold the cradle and shaft in place. 001219 4520 Inspect clutch shaft detent balls, retainer and...
Page 347: Propeller Shaft Bearing Housing And Forward Gear
GEARCASE COUNTER ROTATION end of the pin, MAKING SURE NONE OF THE Bearing and washer must be IMPORTANT: COILS OVERLAP OR ARE LOOSE. installed in the correct order. COB3101 DSC02297 1. Retaining spring 1. Thrust bearing 2. Thrust washer Propeller Shaft Bearing Align holes in the clutch dog with slot in the pro- Housing and Forward Gear peller shaft.
Page 348 GEARCASE COUNTER ROTATION Remove gear housing retaining ring. Remove the thrust bearing. DSC02486 1. Retaining ring 31963 Remove the set screws and remove the flange. Remove the bearing housing from the forward gear. 31965 Remove the shim from either the flange or forward gear.
Page 349 GEARCASE COUNTER ROTATION Remove the forward gear bearing only if it needs Install the thrust bearing on the forward gear. to be replaced. If removal of the bearing is neces- sary, use Large Puller Jaws, P/N 432129, and Puller Bridge, P/N 432127, with an appropriate base.
Page 350 GEARCASE COUNTER ROTATION Install set screws and torque to 144 to 168 in. lbs. (16.3 to 19 N·m). Use no thread sealant. 31968 Remove the 0.030 in. (0.7 mm) of shims from the 31967 assembly. Reassemble the gear assembly using a Anchor a dial indicator gauge to a flat, level sur- combination of shims to achieve the required face.
Page 351 GEARCASE COUNTER ROTATION For seal and bearing service, refer to Propeller Install gear housing retaining ring as shown. Shaft Bearing Housing Seals and Bearings on p. 350. Assembly Apply Needle Bearing grease to the thrust bear- ing. Position bearing around shoulder on the pro- peller shaft.
Page 352: Propeller Shaft Bearing Housing Seals And Bearings
GEARCASE COUNTER ROTATION port the bridge, and tighten the jaws securely Propeller Shaft Bearing behind the bearing. Housing Seals and Bearings Rear Seal Removal Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.
Page 353 GEARCASE COUNTER ROTATION Bearing Installation Rear Seal Installation Oil, then install new bearings in bearing housing. Install new seals back to back in bearing housing using Seal Installer. Apply Gasket Sealing Com- Place the lettered end of the bearing case on the pound to metal casings of the seals before install- bearing installer, then press the bearing into the ing.
Page 354: Propeller Shaft Bearing Housing And Gear Installation
GEARCASE COUNTER ROTATION Housing must be completely seated to install Propeller Shaft Bearing retainer tabs. Housing and Gear Installation Oil and install thrust bearing and thrust washer on the hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.
Page 355 GEARCASE COUNTER ROTATION Install wedge, screw, and washer. Apply Ultra Lock to threads and torque screw 15 to 20 in. lbs. (1.7 to 2.3 N·m). DSM02291 DSC02361 Re-torque two retainer screws to 18 to 20 ft. lbs. (24 to 27 N·m). Confirm that torque on the wedge screw is 15 to 20 in.
Page 356: Notes
GEARCASE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 357 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............356 SYSTEM DESCRIPTION .
Page 358: Service Chart
TRIM AND TILT SERVICE CHART SERVICE CHART 20” 115 HP M ODELS INGLE ISTON YSTEM 30-50 In. lbs. (4-6 N·m) 45-55 In. lbs. (5.1-6.2 N·m) 45-55 In. lbs. (5.1-6.2 N·m) Triple-Guard Grease 005002 Biodegradable TNT Fluid...
Page 359 TRIM AND TILT SERVICE CHART 25” M ODELS HREE ISTON YSTEM 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 84-108 In. lbs. 58-87 Ft. lbs. (9.5-12 N·m) (79-118 N·m) 60-84 In. lbs. 60-70 Ft. lbs. (6.8-9.5 N·m) (81-95 N·m) DO NOT OVER TIGHTEN 58-87 Ft.
Page 360: System Description
TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket And Tilt Support The power trim/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in the tilted position. This bracket The system consists of: protects the hydraulic system from damage.
Page 361: Modes Of Operation (Three Piston System)
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) MODES OF OPERATION (Three Piston System) The three piston trim/tilt hydraulic assembly achieves trim and tilt movement through the fol- lowing modes of operation. Trim-OUT / Tilt-UP Mode When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.
Page 362: Tilt-Down / Trim-In Mode
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, the trim/tilt motor rotates counterclockwise (as viewed from pump end) and turns the pump gears. Fluid pressure passes through the DOWN shuttle valve to the UP shuttle valve, which mechani- cally opens the UP check valve.
Page 363: Impact Relief
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is com- pressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact.
Page 364: Shallow Water Drive Tilt Relief
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.
Page 365: Manual Release - Up
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve. Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring.
Page 366: Manual Release - Down
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylin- ders (in the trim range), and past the manual release valve.
Page 367: Routine Inspections
TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS General Check for external signs of fluid leakage. Correct causes as necessary. Check the battery and make sure it is in good operating condition. Reservoir Fluid Check reservoir fluid level every three years or every 300 operating hours.
Page 368: Troubleshooting
TRIM AND TILT TROUBLESHOOTING If the outboard does not tilt as high as it should, TROUBLESHOOTING and the tilt motor TURNS OFF at maximum tilt (does not sound like it is stalled at the maximum FasTrak - Three Piston System tilt position), adjust the tilt limit switch higher and If the power trim/tilt system has malfunctioned and retest.
Page 369 TRIM AND TILT TROUBLESHOOTING The “B” adapter, P/N 336659, checks operation STEP 3 • of the DOWN circuit. Go to TILT/TRIM RELAY TEST on p. 151 to determine if problem is power supply. STEP 4 Remove trim motor and check condition of drive coupling.
Page 370 TRIM AND TILT TROUBLESHOOTING bypass the reservoir cap. These steps will relieve Remember that all rods must be completely the pressure in the unit. extended to check fluid level. 41739 41757 1. Manual release valve 2. Reservoir cap Starting with the tilt cylinder fully retracted, run the Remove the manual release valve retaining ring unit UP.
Page 371: Single Piston System
TRIM AND TILT TROUBLESHOOTING Remove the manual release valve. Install pres- Single Piston System sure gauge and adapter “B” to check problems in Use the following guidelines to check a single pis- the DOWN circuit. Cycle the unit down and up ton trim/tilt unit that is not working correctly.
Page 372: Electrical Circuit Tests
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Connect a 0 to 100 A DC ammeter in series ELECTRICAL CIRCUIT between the battery side of the starter solenoid TESTS and the red lead to the trim/tilt relay module. Relay Testing When the trim-UP button is pressed, the UP relay is energized and connects the blue trim motor wire to the battery positive (+) terminal.
Page 373: Trim And Tilt Motor No Load Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Test results include three basic possibilities: Monitor motor RPM and current draw. A. Low current draw – Check for: Valves leaking • Relief valve springs weak • Pump damaged • O-rings leaking • Check valves fouled or damaged •...
Page 374: Trim Gauge Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim Gauge Test Trim Sender Test To avoid immediate meter dam- STEP 1 IMPORTANT: age, never apply a multimeter to an electrical cir- Turn key switch ON. Using a voltmeter, check for cuit where voltage is present. voltage between the trim gauge “I”...
Page 375: Removal And Installation
TRIM AND TILT REMOVAL AND INSTALLATION Separate the trim/tilt unit wires in the braided tube REMOVAL AND to permit removal through the hole in the stern INSTALLATION bracket. Removal Remove port lower engine cover and disconnect the trim/tilt connectors. Refer to Powerhead REMOVAL on p.
Page 376 TRIM AND TILT REMOVAL AND INSTALLATION Remove the external snap rings from the upper Use a punch to remove the lower pin and remove pin. the trim/tilt unit from the stern brackets. 25064 25076 Use a punch to remove the upper pin. Installation Place trim/tilt unit into position.
Page 377 TRIM AND TILT REMOVAL AND INSTALLATION Install external snap rings onto upper pin with Release the tilt support and lower the outboard. sharp edge facing out. Torque the manual release valve to 45 to 55 in. lbs. (5.1 to 6.2 N·m). 25064 27381 Place trim/tilt wires in braided tube and install...
Page 378: Servicing - Three Piston System
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Screw the manual release valve in. Remove the SERVICING – THREE retaining ring using retaining ring pliers. Remove PISTON SYSTEM the manual release valve. Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down momentarily and loosen the reservoir cap one full turn.
Page 379 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the three Pozidriv screws securing the Remove the four screws securing motor to pump reservoir to cylinder body. Remove reservoir. manifold assembly. 41753 41760 Remove the reservoir O-ring from the cylinder Remove the wire shield from the pump manifold.
Page 380: Tilt Piston Removal
TRIM AND TILT SERVICING – THREE PISTON SYSTEM solvent and inspect it for tears, clogging, or other Remove the manifold. Remove five O-rings from damage. cylinder body. Check machined surfaces for nicks and scratches. 41763 1. Coupler 2. Filter screen 41799 Remove the three Allen head screws securing the Tilt Piston Removal...
Page 381: Tilt Piston Identification
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Slowly pull the piston out with a rag wrapped Remove the washer. Slide the tilt piston off the around the rod and the top of the cylinder. Drain rod. Be careful not to lose the springs, plungers, the remaining fluid from the cylinder.
Page 382: Tilt Piston Assembly
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Three of the four springs are one length, and the Use a screwdriver to carefully pry the scraper out fourth spring is shorter. On assembly, the shorter of the end cap. Discard the scraper. Remove and spring can be positioned in any hole in the piston.
Page 383 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Use a wire brush to clean all thread-locking mate- Clean any thread-locking material from the rial from the threads on the tilt rod. threads on the inside of the nut. Spray threads of with Locquic Primer and let dry.
Page 384: Trim Rod Removal
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Drain the remaining fluid from the cylinders. Trim Rod Removal Inspect both bores of the trim cylinders for exces- Unscrew trim cylinder end caps using Trim Cylin- sive scoring. If one or both trim bores are scored der End Cap Remover/Installer, P/N 436710, or or damaged, the hydraulic assembly must be Universal Spanner Wrench, P/N 912084, and a...
Page 385: Trim Rod Assembly
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the rod from the vise. Use a small screw- Lubricate and install a new O-ring and two new driver to carefully pry the scraper out of the end back-up rings on the trim rod piston. Place one cap.
Page 386: Manifold And Reservoir Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM removed later for the Pressure Leakdown Test Manifold and Reservoir on p. 367. Installation Lubricate five new manifold body O-rings. Place them in the cylinder body. 41851 Install the reservoir filter screen in the cylinder body.
Page 387: Trim Rod Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Attach the reservoir to the cylinder body with three Spanner Wrench, P/N 912084. Torque caps to 60 Pozidriv screws. Torque the screws to 35 to 52 in. to 70 ft. lbs. (81 to 95 N·m). lbs.
Page 388: Motor Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM P/N 912084. Torque cap to 58 to 87 ft. lbs. (79 to Install the filter screen. 118 N·m). 41856 1. Filter screen 41870 Lubricate and place a new O-ring on the motor. Make sure the cable is on the transom side of the Motor Installation unit;...
Page 389 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Fill the reservoir to the bottom of the fill hole with Check the tilt rod bushings. Replace them if they Power Trim/Tilt & Steering Fluid. Install and are worn excessively. tighten the reservoir cap. Turn the manual release valve in until it seats.
Page 390: Servicing-Single Piston System
TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Slowly remove the manual release valve. There SERVICING–SINGLE may be pressure behind the valve—wear safety PISTON SYSTEM glasses. Disassembly Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from con- taminating internal parts.
Page 391: Assembly
TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Remove drive coupler from either the motor or the Position the motor on the manifold and install four pump assembly. new screws and lock washers. Tighten the screws 35 to 50 in. lbs. (4 to 6 N·m). 004281 004282 Assembly...
Page 392: Adjustments
TRIM AND TILT ADJUSTMENTS Fill the oil reservoir up to the fill plug with ADJUSTMENTS Biodegradable Fluid. Evinrude/Johnson Install and tighten the fill plug. Do not torque the Refer to Trim Sending Unit Adjustment on plug at this time. p. 76. Refer to Tilt Limit Switch Adjustment on p.
Page 393 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
Page 394 S–2...
Page 395: Marine Products And The Safety Of People Who Use Them
SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.
Page 396: Outboard Shift Systems And Safety
SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...
Page 397: Outboard Speed Control System And Safety
SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...
Page 398: Outboard Steering Control System And Safety
SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: Must not come apart; • Must not jam; and •...
Page 399 SAFETY How can loss of steering control be minimized? Use a steering system recommended by the outboard manufacturer which meets • Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions • When Follow warnings marked “ ” closely. •...
Page 400: Outboard Fuel, Electrical System, And Safety
SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? Fuel leakage must be eliminated.
Page 401 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads •...
Page 402 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard Check for leaks GASOLINE under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.
Page 403: Outboard Mounting System And Safety
SAFETY Outboard Mounting System and Safety The mounting system includes: outboard parts • bolts, nuts, and washers • boat’s transom • What is most important? Outboard must stay in position on boat’s transom. • What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
Page 404 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.
Page 405: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety
SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? Shock absorption system must always be ready to absorb • some blows to the lower parts of the outboard. Outboard must not trim in too far suddenly. •...
Page 406: Outboard Emergency Stop System And Safety
SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled •...
Page 407 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.
Page 408: Summing Up
SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...
Page 409: Marine Products And The Safety Of People Who Fix Them
SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: Rigging boats •...
Page 410 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
Page 411 SAFETY Running outboard too fast (Overspeeding) “Too fast” means running faster than outboard normally runs on boat. • Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
Page 412 SAFETY Running outboards: Propellers 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.
Page 413: Handling Lead/Acid Batteries
SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.
Page 414: Gasoline - Handle With Care
SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...
Page 415: Hazardous Products
SAFETY Hazardous Products Know how items in the shop can hurt people... READ “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an • emergency arise “How to dispose of can” •...
Page 416: Safety Awareness Test
SAFETY Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations...
Page 417: Index
INDEX INDEX Batteries n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Battery Charge Isolator 38 Abbreviations 12 Battery Switches 37...
Page 418 INDEX Cooling System Diagnostic Software Components 230 Break-In Programming 67, 72, 109 Cylinder Block Venting 231 CANbus Activation 64 Engine Temperature Check 228 Communication with Outboard 105 Flushing 82 Crankshaft Position Sensor 100, 130 Hose Routing and Water Flow 226, 227 Cylinder Drop Test 120 Operating Temperatures 72 Description 105, 117...
Page 419 INDEX Electrical Connectors 168 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n AMP Connectors 169 Flushing, Cooling System 82 Deutsch Connectors 168...
Page 420 INDEX Trim Gauge Test 372 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Gearcase Lubrication Assembly 334...
Page 421 INDEX Oiling System Predelivery Checks 70 Components 201 Pre-Season Service 92 Engine Lubricant 66 Pressure Relief Valve, Cooling System 233 New Engine Set-Up 43, 66 Priming Oil Distribution Hose Replacement 222 Fuel System 66 Oil Filters 88 Oiling System 108, 215 Oil Injector Electrical Circuits 204 Propeller Oil Pressure Sensor 99...
Page 422 INDEX Spark Plugs n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Indexing 160 S.A.F.E.
Page 423 INDEX Tilt Support 358 SYSTEMCHECK CANbus Gauges 112 Tilt Tube CHECK ENGINE Warning Signal 97, 100, Installation 286 Lubrication 84 Dash Connections 138 Removal 285 Description 112 Timing Pointer Adjustment 157 Gauges 35, 112 Timing Verification 109, 159 LOW OIL Warning Signal 221 Tools NO OIL Warning Signal 99, 202, 205 Alignment Pin Kit, P/N 5007167 263...
Page 424 INDEX Gearcase Alignment Kit, P/N 5007231 310 Terminal Release Tool, P/N 351413 170 Hydraulic Cylinder Rod Holder, Test Propeller 18 P/N 983213 382, 383 Thermal Joint Compound, P/N 322170 229 Injector Test Fitting Kit, P/N 5005844 184 Tilt Cylinder End Cap Remover/Installer, Large Puller Jaws, P/N 432129 246, 326, P/N 326485 378, 385 347, 350...
Page 425: Trouble Check Chart
INDEX Reservoir Fluid 365 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Tilt Piston Identification 379 Upper Mount Troubleshooting 366, 370...
Page 427 TROUBLE CHECK CHART OUTBOARD WILL NOT START TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Battery switch not ON Check battery switch operation Discharged battery Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit.
Page 428 TROUBLE CHECK CHART OUTBOARD WILL NOT START OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Check wiring and emergency stop switch. Check Stop circuit grounded the safety lanyard is installed and stop circuit is not grounded. No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return Water in fuel manifold.
Page 429 TROUBLE CHECK CHART OUTBOARD HARD TO START OUTBOARD HARD TO START OBSERVATION POSSIBLE CAUSE PROCEDURE Weak battery Check battery, recharge or replace Clean and tighten connections, check voltage Battery cables and connections drop on high amperage circuit Starter or bendix/drive gears Check starter, inspect bendix/drive gears Check water separator/fuel filter, sample fuel from Water in fuel system...
Page 430 TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OBSERVATION POSSIBLE CAUSE PROCEDURE Check key switch and ground to key switch, refer Key switch or wire harness to SYSTEM ANALYSIS on p. 113 and ground ELECTRICAL AND IGNITION on p. 135 Outboard starts and Check EMM LED indicators.
Page 431 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM service codes and check System- SystemCheck light Outboard is in S.A.F.E. Check warning Refer to specifications, check recommended WOT Incorrect propeller RPM;...
Page 432 TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSERVATION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F.E. Access EMM fault codes Incorrect, fouled, or worn spark Replace spark plugs plugs Check water separator/fuel filter, sample fuel from Water in fuel system fuel return manifold test port Contaminated or poor fuel...
Page 433 MWS Instrument Wiring Harness DRC6165R...
Page 434 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
Page 436 CANbus Keyswitch/TNT Wiring Harness A. Trim down B. Trim up C. Trim sender 47 ohm 1/4 watt resistor 5. Battery + (12V) 1. Stop circuit 2. Start solenoid 3. Ground (B-) 6. Choke 4. Switched B+ (12V) Switched B+ (12V) 10 Amp Fused B+ (12V) Ground (B-)
Page 437 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH WATER PRES. FUEL VOLTMETER TRIM/TILT FUEL TANK SENDER WARNING HORN TO OUTBOARD DRC6278R...
Page 438 Evinrude E-TEC EMM LED Diagnostic Indicators Charging/55V Circuit Injection/Ignition/Fuel Sensors/5V Analog Circuits No Oil/Overheat ON: LED’s illuminate to indicate circuit function Start assist circuit (SAC), V-EMM models only Sensor circuits – TPS, CPS and 5V circuits FLASHING LED – Use Diagnostic Software and see Service Code Chart.
Page 439 J1-B 1. Oil Injector 2. Electric Starter J1-A 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12.
Page 440 J1-B 1. Oil Injector 2. Electric Starter J1-A 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12.
Page 441 EVINRUDE EMM SERVICE CODE CHART SYSTEM CHECK TIME TO EMM CIRCUIT/SENSOR EMM LED ACTIVATION SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION WARNING LIGHT ACTIVATE ACTIVATION Throttle Position Sensor TPS Voltage > 0.65 with key ON. Becomes stored fault when outboard starts. (TPS) out of idle range When both hard and stored faults present, check for improperly adjusted throttle cable.
Page 442 SYSTEM CHECK TIME TO EMM CIRCUIT/SENSOR EMM LED ACTIVATION SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION WARNING LIGHT ACTIVATE ACTIVATION 51 Fuel injector circuit #1 OPEN INJECTOR/IGNITION FAULT (LED 2) 8 seconds 52 Fuel injector circuit #2 OPEN INJECTOR/IGNITION FAULT (LED 2) 8 seconds 53 Fuel injector circuit #3 OPEN INJECTOR/IGNITION FAULT (LED 2)

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BRP Evinrude E-Tec Series Service Manual

Safety Information

Service Specifications and Special Tools 1

Installation and Predelivery

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil Priming

Before Start-Up

Running Checks

Propellers

Final Adjustments

Maintenance

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Lubrication

Fuel and Oil Systems

Battery and Battery Connections

Spark Plugs

Exhaust Pressure Fitting

Storage

Pre-Season Service

Submerged Engines

Notes

Maintenance Notes Notes

Description

Sensors and Functions

Emm Inputs and Outputs Diagram

Shutdown Mode

Warning System

Emm Diagnostics

Systemcheck Engine Monitor

System Analysis

Electrical Connections

Ground Circuits

Fuse

Emm Diagnostics

Diagnostic Procedures

Specialized Test Procedures

Start Circuit

Ignition and Electrical Circuits

Ignition Output

Fuel Delivery

Fuel Injector Operation

Exhaust Valve

Electrical and Ignition

Table of Contents

Service Chart

Components

Fuel System Hose Routing

Direct Injection Electrical Circuits

Fuel Component Tests

Fuel Component Servicing

Intake Manifold

Oiling System

Service Chart

Components

Priming

Oiling Rates

Oiling System Tests

Oil Component Servicing

Quick Links

Chapters

Troubleshooting

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Summary of Contents for BRP Evinrude E-Tec Series