BRP EVINRUDE E-TEC 200 Service Manual
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BRP EVINRUDE E-TEC 200 Service Manual

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Summary of Contents for BRP EVINRUDE E-TEC 200

  • Page 3 † Permatex is a registered trademark of Permatex. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: Twist Grip™ ®...

  • Page 4: Table Of Contents

    ERVICE ANUAL ONTENTS SECTION ........PAGE 1 REFERENCE INFORMATION .

  • Page 5: Table Of Contents

    REFERENCE INFORMATION REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE ..............4 ABBREVIATIONS USED IN THIS MANUAL .

  • Page 6: Safety Notice

    SAFETY NOTICE Before working on any part of the outboard, read the SAFETY section at the end of this manual. This pu blication is written fo r qualified, facto ry- DO NOT perform any work unt il yo u have read trained technicia ns who ar e alrea dy familiar with and understood these instructions completely.
  • Page 7 DANGER Contact with a rot ating prope ller is likely to result in seriou s injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyon e near a pro peller, even when the engine is off. Blade s can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 8: Abbreviations Used In This Manual

    REFERENCE INFORMATION 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.

  • Page 9: Emission-Related Installation Instructions

    REFERENCE INFORMATION EMISSION-RELATED INSTALLATION INSTRUCTIONS EMISSION-RELATED Owner’s Responsibility The owner/operator is required to have outboa rd INSTALLATION maintenance performed to maintain emission lev- INSTRUCTIONS els within prescribed certification standards. The owner/operator is not to, and should not allow Failing to follow these instructio ns when anyone to, modify the outboard in any manner installing a certified engine in a vessel violates...

  • Page 10: Model Designation

    REFERENCE INFORMATION 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 or SUFFIX Z = 30” XX-long E 200 DP X IN MODEL YR: DESIGN FEATURES: PREFIX:...

  • Page 11: Models Covered In This Manual

    REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 200.1 cubic inch (3.3 L) and 210 cubic inch (3.4 L), 90° V Evinrude E-TEC models. M ode l D is pla c e m e nt Ge a rc a s e H e ight C olor...

  • Page 12: Service Specifications

    REFERENCE INFORMATION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS Full Throttle 4500–5800 RPM Operating Range 200 HP 225 HP 250 HP (183.9 kw) Power (147.1 kw) (165.5 kw) @ 5150 RPM @ 5150 RPM @ 5150 RPM Idle RPM in Gear 500 ± 50 Standard Rotation Models: P/N 436080 or P/N 396277 Test Propeller Counter Rotation Models: P/N 436081 or P/N 398674...
  • Page 13 REFERENCE INFORMATION SERVICE SPECIFICATIONS 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.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv- Alternator ery and Installation Guide for multiple battery applications.
  • Page 14 REFERENCE INFORMATION SERVICE SPECIFICATIONS 250 H Full Throttle 4500–6000 RPM 5000–6000 RPM Operating Range 250 HP 300 HP Power (183.9 kw) (220.6 kw) @ 5250 RPM @ 5500 RPM Idle RPM in Gear 500 ± 50 Standard Rotation Models: P/N 436080 or P/N 396277 Test Propeller Counter Rotation Models: P/N 436081 or P/N 398674 20 in.
  • Page 15 REFERENCE INFORMATION SERVICE SPECIFICATIONS 250 H 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.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv- Alternator ery and Installation Guide for multiple battery applications.

  • Page 16: Standard Torque Specifications

    REFERENCE INFORMATION STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE PRODUCT REFERENCE SPECIFICATIONS AND ILLUSTRATIONS BRP US Inc. reserves the right to make changes at a ny time, wit hout no tice, in specificatio ns a nd Size In. Lbs. Ft. Lbs. N·m models and a lso to discon tinue models.
  • Page 17 .ROUTINE SERVICE ROUTINE SERVICE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 16 LIFTING THE OUTBOARD .

  • Page 18: Inspection And Maintenance Schedule

    .ROUTINE SERVICE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides guidelines for inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre- quent inspections and maintenance.

  • Page 19: Lifting The Outboard

    .ROUTINE SERVICE LIFTING THE OUTBOARD LIFTING THE OUTBOARD RIGGING OUTBOARD CONNECTIONS IMPORTANT: For complete outboard riggin g WARNING and remote control installation information, refer to To avoid personal injury, make sure the lift- the Predelivery and In stallation Guide included ing cap acity of the hoist is at least twice with the service manual set.
  • Page 20 .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable, Hose, and Wire Routing Cable Retainer Clip Installation When installing retainer clips on control arm lin k- CAUTION age pins, clips should be locked and must not be bent or deformed. To prevent accidental starting while servic- ing, disconnect the battery c ables at the For proper installation, review the following steps: battery.
  • Page 21 .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Refer to the following diagram to ensure pro per same path to the starboard side of the powerhead. positioning of rigging components in grommet. Secure all cables with clamps. 003974 000095 1. Fuel supply hose 2.
  • Page 22 .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Shift Cable Installation and Adjustment Throttle Cable Installation and Adjustment Place t he s hift ca ble on t he sh ift l ever p in and With remote control lever in NEUTRAL, pull firmly install the washer and retainer clip.

  • Page 23: Battery Cable Connections

    .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS SystemCheck Harness Install trunnion cover and screw. Tighten screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). Connections Remove harness connector cover. 005039 1. Trunnion cover and screw, throttle cable 003972 Battery Cable Connections Install battery cables on starter solenoid and main...

  • Page 24: I-Command Network Connections

    .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Connect outboard main wire harness to boat wire If using a mechanical control system, con nect the harness. Secure connectors in bra cket. Refer to I-Command En gine Interface Cable to the EMM the diagram inside of the electrical cover. CANbus connector.

  • Page 25: Icon Network Connections

    .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS IMPORTANT: For an I-Command oil level display, an accessory Do not force conn ectors or lock- CANbus oil level sende r must be inst alled in the ing rings. Prop erly aligne d conne ctors a ssemble oil t ank.

  • Page 26: Water Pressure Gauge

    .ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS current, resulti ng in erratic operation of the To send wat er pre ssure da ta to the EMM, alo ng remote control system. with an I-Command d isplay, in stall a water pres- sure transducer kit. For more informati on, refer to t he ICON Remote Control System Installation Guide.

  • Page 27: Battery And Battery Connections

    .ROUTINE SERVICE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY Install a st arwasher on the threaded battery post. Stack cables from the outboard, then cables from CONNECTIONS accessories. Finish this connection with a hex nut. WARNING Keep the b attery co nnections clea n, tight, and insu lated to preve nt thei r shorting or arcing and causing an explosion.

  • Page 28: Oetiker Clamp Servicing

    .ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide co rrosion resistance, mini- mize the potential for ab rasion of rigg ing compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the p roper sealing of h ose connec- tions.
  • Page 29 .ROUTINE SERVICE OETIKER CLAMP SERVICING Clamp Installation Clamp Removal A const ant st ress sho uld be ap plied 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 30: Adjustments

    .ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS Place the outboard in normal operating position. Rotate the LOWER adjustment tab UP to reduce Tilt Limit Switch Adjustment the maximum tilt. Rot ate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side , safety re lated p arts could be damage d in...

  • Page 31: Trim Sending Unit Adjustment

    .ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment Observe the trim gau ge. If the n eedle does not show cen ter position, tilt the outboard up an d 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 32: Trim Tab Adjustment

    .ROUTINE SERVICE ADJUSTMENTS Trim Tab Adjustment Tighten the trim tab screw as follows: • 115 – 200 HP: 35 to 40 ft. lbs. (47 to 54 N·m). WARNING Improper trim tab a djustment c an 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.

  • Page 33: Dual-Outboard Alignment

    .ROUTINE SERVICE ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various bo at/motor comb inations respond differ- Dual outboards must b e connected with a tie bar ently to dua l-outboard a lignments. Each app lica- and adjuste d to a lign the o utboards for correct tion must be thoroughly tested until the idea l water flow to the gearcases and propellers.

  • Page 34: Operational Checks

    .ROUTINE SERVICE OPERATIONAL CHECKS OPERATIONAL CHECKS Fuel System Perform running checks of t he fuel system by fo l- lowing these steps: DANGER • Squeeze fuel primer bulb until hard or activa te DO NOT run the engine indoors or withou t electric primer.

  • Page 35: Cooling System

    .ROUTINE SERVICE COOLING SYSTEM COOLING SYSTEM Tachometer Pulse Setting Confirm accuracy of tachometer reading. Check the con dition of cooling system compo- • Adjust dial on back of t achometer to required nents regularly: setting (the outboard should not be running). •...

  • Page 36: Engine Flushing

    .ROUTINE SERVICE COOLING SYSTEM Engine Flushing Thread garden hose into flushing port. Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in cool- ing system passages. The outb oard can b e flu shed on th e trailer o r at dockside;...

  • Page 37: Running The Outboard Using A Hose And Flushing Adapter

    .ROUTINE SERVICE COOLING SYSTEM Running the Outboard Using a Temporarily cover the s mall hole s NOTICE Hose and Flushing Adapter on the front of M2-Type gearcases with water- proof tape to make sure enough water trave ls to the po werhead. Water can drain from aux il- WARNING iary inlets, resulting in engine overheat.

  • Page 38: Lubrication

    .ROUTINE SERVICE LUBRICATION LUBRICATION Swivel Bracket and Trailering Bracket Steering System Lubricate the swivel bracket wit h Triple-Guard grease. WARNING Apply grease until the grease begins to flo w from Failure to regrease as recom mended the upper or lower swivel bracket areas. could result in steering system corrosion.

  • Page 39: Propeller Shaft

    .ROUTINE SERVICE LUBRICATION Gearcase Lubricant • Inner casings of both the thro ttle and shift cables. Draining WARNING Gearcase lubricant may be under pressure and/or hot. If plug is remove d from a recently operated outboa rd, take precau- tions to avoid injury. IMPORTANT: Always check the fill le vel of the gearcase lub ricant at the u...
  • Page 40 .ROUTINE SERVICE LUBRICATION Inspection Remove the lubricant level plug and th e lubricant drain/fill plug. Inspect th e lu bricant a nd th e magnet s on the plugs for metal chips. The presence of metal fuzz Use Gearcase Filler, P/N 501882, to slowly fill the can ind icate normal wear of the ge ars, be arings, gearcase with HPF PRO lu bricant thro ugh th e or shafts wit hin t he gea rcase.

  • Page 41: Trim And Tilt

    .ROUTINE SERVICE LUBRICATION Trim and Tilt CAUTION Correct flui d level must be maint ained to ensure operation of the impact protection built into the unit. Check reservo ir fluid level every th ree yea rs or every 300 operating hours. •...

  • Page 42: Spark Plugs

    .ROUTINE SERVICE SPARK PLUGS SPARK PLUGS Apply Triple-Guard grease to th e ga sket surface of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m). Spark plu gs shou ld be removed and exa mined periodically.

  • Page 43: Fuel And Oil Systems

    .ROUTINE SERVICE FUEL AND OIL SYSTEMS FUEL AND OIL SYSTEMS Air Silencer The air silencer on Evinrude outboards maximizes Routine replacement of fi lters reduces the possi- air flow while minimizing noise. bility of f oreign mate rial restricting the incoming fuel or oil supplies.

  • Page 44: Exhaust Pressure Fitting

    .ROUTINE SERVICE EXHAUST PRESSURE FITTING EXHAUST PRESSURE With key ON, outb oard NOT running, the exhaust pressure sensor reading should be close to zero. FITTING With the outboard running, make sure the exhaust pressure reading chang es wit h thrott le settin g. The exh aust pressure fitting is t hreaded into the This reading will vary, based on actu al outboa rd adapter housing...

  • Page 45: Anti-Corrosion Protection

    .ROUTINE SERVICE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fre sh or salt wa ter. 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 46: Storage

    .ROUTINE SERVICE STORAGE STORAGE Software Control Method Winterization can also be run using Evinrude Diagnostics so ftware. With the outb oard ru nning, IMPORTANT: DO NOT start outboard without a start the process at the Settings/Adjustments water supply to the outbo ard’s cooling system. screen and follow the instructions.
  • Page 47 .ROUTINE SERVICE STORAGE Additional Recommendations Digital Gauge Method The ICON Pro 5 inch and I-Command 3.5 inch • Top off oil reservoir. digital gauges provide a winterize feature for 2008 • inspect the fuel filter. If there is debris in the fuel and newer V4 and V6 models.

  • Page 48: Pre-Season Service

    .ROUTINE SERVICE PRE-SEASON SERVICE PRE-SEASON SERVICE SUBMERGED ENGINES If the ou tboard was re moved fro m th e boat for Once a n outbo ard has been submerged in fresh storage, make sure it is rein stalled with facto ry or salt water , it must be serviced with in three (3) specified hardware.
  • Page 49 .ROUTINE SERVICE SUBMERGED ENGINES Engine Dropped Overboard Prime oil system and fue l system. Refer to FUEL SYSTEM PRIMING on p. 138 and OIL SUPPLY (Running) PRIMING on p. 170. Make sure all oil injection Follow the same procedures as Engine Dropped hoses are clean and filled with oil.
  • Page 50 .ROUTINE SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 51 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 50 .

  • Page 52: Upper Cover Service

    ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Upper Cover Cap Replacement Place new upper cap into position. Latch Hook Installation Place hook into position on bracket. 006815 Tighten self-tapping screws to a torque of 24 to 36 006962 in.

  • Page 53: Lower Cover Service

    ENGINE COVER SERVICE LOWER COVER SERVICE LOWER COVER SERVICE Lower Cover Installation Install t he lo wer engine covers and tighten all Lower Cover Removal screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m). Remove lower engine cover screws. 004122 1.

  • Page 54: Latch Handle Installation

    ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006827 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to sc rew threa ds.
  • Page 55 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............54 EMM INPUTS AND OUTPUTS DIAGRAM .

  • Page 56: Description

    ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION DESCRIPTION • Stator to EMM connections; one 6-pin AMP and J2 connector. The Engine Manage ment Mo dule (EMM) is a water-cooled e ngine controller . It contro ls many outboard systems in cluding alternato r ou tput for the 12 V and 55 V circuit s.

  • Page 57: Emm Inputs And Outputs Diagram

    ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS J1-A J1-B OUTPUTS x 100 3550 M EN U 008365 1. Engine Management Module (EMM) 10. Oil Pressure Sensor (component of 18) 19. Rear Oil Injector and Manifold 2.

  • Page 58: Internal Sensors

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS INTERNAL SENSORS If sensor reads less than -67°F (-55°C) or greater than 31 1°F (155°C) a senso r circu it fault is detected and the EMM: Sensor inp uts and inte rnal EMM contro llers are used to control outboard operation.

  • Page 59: Circuit Sensor

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS 5 V Circuit Sensor Exhaust Pressure Sensor Monitors the EMM’s 5 V sensor circuit. The exhaust pressure se nsor mon itors exhaust pressure during all running conditions to compen- If sensor voltage is less than 4.75 volts, the EMM: sate for engine loads.

  • Page 60: External Sensors

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS If cylinder he ad temperature exceeds 194°F (90°C) above 2000 RPM for 3 seconds, the EMM: Sensor inp uts and inte rnal EMM contro llers are Activates S.A.F.E. used to control outboard operation. Use Evinrude Diagnostics software to troubleshoot the sensors.

  • Page 61: Oil Pressure Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Oil Pressure Sensor Throttle Position Sensor The oil pressure sensor monitors oil pressure in The throttle position sensor receives a voltage sig- the oil distribution manifold. nal from the EMM. As the th rottle lever is rotated, the EMM receives a return voltage signal through If the senso r d oes not de tect pressure f or 1 50 a second wire.

  • Page 62: Crankshaft Position Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Crankshaft Position Sensor Neutral/Shift Interrupt Switch Ribs spaced on the flywheel mark crankshaft posi- A swit ch mounted on the po werhead signa ls t he tion. As the ribs p ass th e magnetic field of the EMM when the sh ift linkage is moved from FOR- CPS, an AC volt age signal is gene rated.

  • Page 63: Internal Emm Functions

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM RPM Limiter This featu re of EMM pr ogramming prevents FUNCTIONS engine d amage due to excessive RPM. At 625 0 RPM, fuel and ignition to the cylinders is shut off. Start Assist Circuit (SAC) Normal ope ration resumes when engin e RPM When the ignition key is ON, the EMM Start Assist...

  • Page 64: Engine Monitor System

    ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITOR SYSTEM ENGINE MONITOR The EMM activates the warning horn and gau ge displays as follows: SYSTEM • LOW OIL means that oil in the tank is at reserve level (about 1/4 full). All re mote controlled outboards, 40 HP a nd •...

  • Page 65: Warning System

    ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING SHUTDOWN MODE SYSTEM Outboard “sh utdown” will occur if specific fault s are detected by the EMM. The S.A.F.E. (Speed Adjusting Failsafe Electron- Conditions that initiate shutdown ics) warn ing system alert s t he oper ator and pro- tects a gainst engine d amage fro m t he fo llowing Code 29 Excessive EMM temperature abnormal conditions:...

  • Page 66: Diagnostic Software Functions

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS DIAGNOSTIC Static Information Refers to information viewed when the outboard is SOFTWARE FUNCTIONS NOT runn ing. This include s manu facturing in for- mation. The EMM saves valuable info rmation abou t the outboard and its running history.

  • Page 67: Dynamic Information

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Information Active Faults Dynamic information is viewed while th e outboard An active fault is a se rvice code th at cu rrently is running. Change s in dat a, such as voltages or exists.

  • Page 68: Dynamic Tests

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Tests Ignition Test Use the d iagnostics software to test each ignition Dynamic test s are pe rformed with the outboa rd circuit. Refer to Static Ignition Test on p. 82. running. Fuel Test Use the diagnostics software to t est each fu el injector circuit.

  • Page 69: Oil Control Settings

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Oil Control Settings Powerhead Break-In Use the diagnostic software to initiate break-in oil- Set Oil Type ing. Brea k-in is a predetermined oiling program The TC-W3 oil type setting is the standard setting that runs fo r two hours of outb oard op eration, for all outboards.

  • Page 70: Ignition Timing

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Timing TPS Calibration Use the Ignition Timing screen to check a nd TPS Calibration synchronizes throttle plate ope n- adjust EMM timing. EMM timing must be synchro- ing with throttle position sensor voltage. nized to crankshaft position.

  • Page 71: Reports

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Reports Software Replacement Engine rep orts provide service records and can Engine Manag ement Sof tware is loaded into th e be used to document the running history of an out- EMM at the factory. Periodically, a new program board.

  • Page 72: Emm Transfer

    ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING EMM Transfer EMM Transfer is used to save engine history data IMPORTANT: when the EMM must be replaced. If a n ew EMM i s b eing installed, refer to EMM Transfer on p. 70. Select EMM Data Transfer from the Utilities menu.
  • Page 73 ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING Installation Align slots in starboard side of EMM case with iso- lator mounts o n cylinder block. Slide EMM into position. 1. EMM mounting slots 006968 2. Isolator mounts Install two EMM retaining screws. Tighten screws 12 to 16 in.
  • Page 74 ENGINE MANAGEMENT MODULE (EMM) NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 75 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............74 .

  • Page 76: Diagnostic Procedures

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Diagnostic Software Inspections Before running the out board, use Evinrude Diag- PROCEDURES nostics so ftware to review historical informatio n saved in the EMM. Visual Inspections Check the Active Faults and Occurred Faults Inspect wiring and electric al connectio ns. Disas- screens for current se rvice codes.

  • Page 77: Operational Inspections

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES • The Engine Identity Report provide s a sn ap-shot Check th e Engine Temperature Profile for evi- of current engine and sensor conditions. From the dence of cold running or overheating. Identity screen, press the Print button. Next, press Printer to print, or PDF File to save the report.

  • Page 78: Troubleshooting

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Troubleshooting • Use the diagnostics software Dynamic Tests to isolate a faulty cylinder. See DYNAMIC TESTS Outboard will not crank, st arter d oes not on p. 77. operate: • Use an inductive timing light to check ig nition •...

  • Page 79: Dynamic Tests

    SYSTEM ANALYSIS DYNAMIC TESTS DYNAMIC TESTS Fuel Control Adjustment Use this test is to help identify a cylinder that may Cylinder Drop Tests be too rich or too lean. This feature should not be used by itself to identify a faulty injector. Use the Evinrude Diagnostics sof tware Dynamic Tests to moment arily disable one cylinder while Evinrude Diagnostics software a llows temporary...

  • Page 80: Emm Led Indicators

    SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS LED 2 – CRANK POSITION OKAY – inpu t from CPS, EMM powered ON. For NO LIGHT, check for: The EMM LED ind icators provide a quick refer- • ence to the st atus of several outb oard systems. Code 16 –...

  • Page 81: Running

    SYSTEM ANALYSIS EMM LED INDICATORS Running • Code 7 – PORT Knock sensor circuit fault • Code 8 – STBD Knock sensor circuit fault When the outbo ard is runn ing, all of the LEDs • Code 12 – TPS circuit fault should be off.

  • Page 82: Ignition Output Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS IGNITION OUTPUT Crankshaft Position Sensor • Provides EMM with input. TESTS • Outboard cranking speed exceeds 75 RPM and a steady CPS signal is generated. DANGER Alternator Output/System Voltage • System voltage from EMM (white/red) provides The electrica l syste m present s a serious 55 VDC to the oil injection pump, the fuel injec- shock hazard.

  • Page 83: Crankshaft Position Sensor (Cps) Test

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Crankshaft Position Sensor (CPS) System Voltage Test Test The ig nition system is po wered by the 55 V sys- tem. When the CPS is working properly , EMM LED 2 turns on while the outboard is being started. Use the Evinrude Diagnostics so ftware Monitor screen to check system voltage.

  • Page 84: Static Ignition Test

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Static Ignition Test IMPORTANT: You may n eed to remove shield- ing from wire if pickup does not read signal. Perform the static ignition test using Evinrude Diagnostics software and an inductive timing light. IMPORTANT: DO NOT use a spark checker tool.

  • Page 85: Running Ignition Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Running Ignition Tests Results: Steady voltage and strobe, engine misfires: Use Evinrude Diagnostics software to monitor • Inspect or replace spark plugs system voltage (55 V). • Refer to FUEL DELIVERY TESTS on p. 85. •...

  • Page 86: Ignition Control Circuit Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector and test t he continuity of each ignition control cir- Use a digital multimeter to test the following: cuit (orange). Check resistance bet ween J1-B •...

  • Page 87: Fuel Delivery Tests

    SYSTEM ANALYSIS FUEL DELIVERY TESTS FUEL DELIVERY TESTS If the pump does not run: • The EMM controls power to the fuel pump (pur- ple/black wire). Check voltage at p in 1 of fue l WARNING pump connector. Voltage should be 12 V when KEY is first ON, when fuel pump test activated, Protect ag ainst hazardous fue l spray.

  • Page 88: Running Fuel System Tests

    SYSTEM ANALYSIS FUEL DELIVERY TESTS Results: Results: No injectors actuate: No light activation on any injector wires (outboa rd • cranks and starter turns flywheel): Use the Monitor screen of the diagnostics soft- • ware t o make su re volt age is present on the Check stator input to EMM, CPS operation, and system voltage circuit.
  • Page 89 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............88 IGNITION SYSTEM CIRCUIT DIAGRAM .

  • Page 90: Service Chart

    ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 50-70 In. lbs. (5.6-8 N·m) 30-42 In. lbs. 30-42 In. lbs. (3-5 N·m) (3-5 N·m) 30-42 In. lbs. (3.5-4.7 N·m) 30-42 In. lbs. 140-160 Ft. lbs. (3.5-4.7 N·m) (190-217 N·m) 15-30 Ft.
  • Page 91 ELECTRICAL AND IGNITION SERVICE CHART 60-84 in. lbs (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 168-192 in. lbs (19-21.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 00803 Liquid Neoprene...

  • Page 92: Ignition System Circuit Diagram

    ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM CIRCUIT DIAGRAM FUSE 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Fuse Crankshaft position sensor Main harness ground Stator Capacitor +12 V from battery...

  • Page 93: Electrical Harness Connections

    ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electric al connectio ns. Disas- semble a nd clean all corrode d co nnections. Replace damaged wiring, con nectors, o r termi- nals. Repair any shorted electrical circuit s. Refer to wirin g diagrams and refere nce ch arts for spe- cific wiring details.
  • Page 94 ELECTRICAL AND IGNITION ELECTRICAL HARNESS 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 vacant Injector, cylinder 3 Purple Isolated B+ Red/Black Rear oil injector control (ground) Blue/Red Battery ground...

  • Page 95: Ground Circuits

    ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS Additional Ground Tests Check connections and continuity at the followin g All groun d circuit s are essential to reliable out- locations: board performance. Make sure all ground connec- • Trim and Tilt module ground at main ground ter- tions are clean and tight.

  • Page 96: Sensor Tests

    ELECTRICAL AND IGNITION SENSOR TESTS SENSOR TESTS (1.85 mm). Th e accep table clearance is 0 .036 to 0.110 in. (1 to 2.8 mm). All senso r circu its a re de pendent o n wiring a nd connections, EMM supplied current (5 V), and sensor resist ance.

  • Page 97: Engine Temperature Sensor Test

    ELECTRICAL AND IGNITION SENSOR TESTS Air Temperature Sensor (AT) Test Connect red meter lea d to terminal “A” and black meter lead to terminal “C.” Rotate the sensor lever Remove the electrical connector from the air tem- through it s range of trave l. Resistance reading perature sensor.

  • Page 98: Stator Tests

    ELECTRICAL AND IGNITION STATOR TESTS STATOR TESTS To che ck for a g rounded winding, conne ct on e meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The st ator consists of 3 windings (6 poles each) read no contin uity.

  • Page 99: Charging System Tests

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS 12 V Charging Circuit To test the operation of the regulator in the EMM, you must be able to run the outboard continuously at approximately 5000 RPM, such as in a test tank or on a marine dynamometer.

  • Page 100: Auxiliary Battery Charge Wire

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Auxiliary Battery Charge Wire With outboard running at 1000 RPM, voltage must read higher than with key OFF and increase The auxiliary battery charge feature requires aux- steadily t o appr oximately 1 4.5 V as the outboard iliary battery charg e kit, P/N 500625 3 (or equiva- RPM increases.

  • Page 101: Electric Start Circuit

    ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 004112 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.
  • Page 102 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The st arter must engag e and tu rn the flywhee l. • Red/purple wire provides 12 V to key switch ter- The outboard must crank a minimum of 100 RPM minal “B”.

  • Page 103: Electric Start Tests

    ELECTRICAL AND IGNITION ELECTRIC START TESTS ELECTRIC START TESTS Key Switch, START Position Key switch START: Starter Solenoid Test • Switches 12 V to terminal “S” of key switch and to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- •...
  • Page 104 ELECTRICAL AND IGNITION ELECTRIC START TESTS Starter Voltage Drop Test • Observe voltage reading. STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to To prevent accidental starting of outboard, starter motor terminal. disconnect cranksha ft posi tion sen sor •...

  • Page 105: Remote Control Switch Tests

    ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or con tinuity light to test SWITCH TESTS continuity of th e circu it while p ositioning th e remote control in NEUTRAL, FOR WARD, an d Key Switch Test REVERSE.
  • Page 106 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Switch Test Emergency Stop Switch Test Use an ohmmeter or a continuity light to test neu- This switc h can be part of the ke y switc h or tral start switch operation. installed as a separate swit ch.

  • Page 107: Tilt/Trim Relay Test

    ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST Test Procedure Make sure re d and b lack wires are conne cted to The tilt and trim (TNT) modu le con tains the cir- 12 V battery power supply. cuitry and relays required for power trim and tilt operation.

  • Page 108: Systemcheck Circuit Tests

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS SystemCheck CIRCUIT instrument harne ss terminal 1 (purple wire) and terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the opera tor durin g a “NO OIL,” “W ATER TEMP” or “HOT ,” “CHECK ENGINE,” or “LOW OIL”...
  • Page 109 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS WATER TEMP/ HOT Circuit Test the two connectors, r eplace SystemCheck gauge. The tan wire of engine harness and the MWS har- ness receives a signal f rom the EMM. The EMM receives information from the temperature sensor on the cylinder head.

  • Page 110: Tachometer Circuit Tests

    ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT LOW OIL Circuit Test Turn the key switch ON. Using a jumper wire, con- TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean en gine ground. The LOW Check voltage at the battery.

  • Page 111: Flywheel And Stator Servicing

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING FLYWHEEL AND ST ATOR Apply Moly Lube grease to th e thre ads of th e puller pressing screw, P/N 307637, and the center SERVICING hole of the crankshaft. Place the puller on flywheel with body flat side up. IMPORTANT: Weak flywheel mag nets can...

  • Page 112: Flywheel Installation

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Flywheel Installation IMPORTANT: DO NOT over apply Nut Lock on flywheel t aper. This pr events Nut Lock from CAUTION migrating into upper seal of crankshaft. To avoi d injury , keep han ds and finge rs Align the flywheel keyway and install the flywheel.

  • Page 113: Ignition Coil Servicing

    ELECTRICAL AND IGNITION IGNITION COIL SERVICING IGNITION COIL Remove four screws and bracket. SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil. Disconnect ignition coil electrical connector. Remove two ignition coil retaining screws. Do not lose the rub ber washers between coil a nd bracket.

  • Page 114: Timing Adjustments

    ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TIMING ADJUSTMENTS Rotate flywheel counterclockwise until the num- ber 1 piston con tacts the tool. Keep pressure on Timing Pointer the flywh eel t o position the piston firmly ag ainst the tool. Mark the flywheel directly across from the pointer.

  • Page 115: Timing Verification

    ELECTRICAL AND IGNITION TIMING ADJUSTMENTS location to align with the cast-in TDC boss on the Check ignit ion timing a fter any of t he followin g flywheel. Tighten retaining screw. procedures: • Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement •...
  • Page 116 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Use Ball Socket Remover, P/N 342226, to remove While holdin g the throt tle plates closed, advance throttle link from actuator arm. the throttle linka ge un til it stop s. Th e “Me asured TPS Calibration”...

  • Page 117: Electric Starter Servicing

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Remove t he screws, lock washers, and p inion housing. SERVICING Starter Removal IMPORTANT: Do not clean the st arter drive while the st arter motor and drive are in stalled on the powerhe ad.
  • Page 118 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Hit the socket with a ma llet to lower th e sp acer Remove pin ion and plastic weathe r cover from and expose the retaining ring under the spacer. pinion shaft. 30368 Remove the driven gear and thrust washer. 30371 30367 30360...
  • Page 119 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the two thru-bolts. Mark the end ca p ori- Note the alignment marks by the positive terminal entation, and remove the cap. stud. Hold the armature in place, and slide frame away from the gear housing. 30365 Gently tap the starter frame with a rubber mallet to loosen it.

  • Page 120: Starter Cleaning And Inspection

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Starter Cleaning and Inspection matter which could con tribute to fa ilure of win d- ings. Inspect the brushes fo r wear an d dama ge. Replace brushes if dama ged or worn. Replace weak brush springs.

  • Page 121: Starter Assembly

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Starter Assembly Align the st arter frame and make sure th e lon g alignment mark matches the mark next to the pos- IMPORTANT: itive terminal stud on the gear housing. If removed, apply Locquic Primer and Screw Lock to the brush card screws be fore Push the arma ture down firmly and slide installing.
  • Page 122 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 coa t the drive gear with Triple-Guard grease, and install it on the armature shaf t.

  • Page 123: Starter Installation

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Lightly coat the pinion s haft splines (helix) with Install the bracket . Apply Nut Lock to th e th ru- Starter Bendix Lube. Lower th e pinion into place bolts. Install the nuts and tighten to a torque of 50 without disp lacing the driven gear or thrust to 65 in.

  • Page 124: Connector Servicing

    ELECTRICAL AND IGNITION CONNECTOR SERVICING CONNECTOR Release terminal latch and gently pull on wire. SERVICING DEUTSCH Connectors IMPORTANT: Grease is reco Electrical mended. Incorrect grease applica tion can cause electrical or warning system problems. 423293 1. Terminal latch (receptacle) To disconnect th e connector, press the latch and 2.
  • Page 125 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors IMPORTANT: Always use the appropriate meter test probe s and ada pters 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 126 ELECTRICAL AND IGNITION CONNECTOR SERVICING UPER OWER IMER ERIES The J1-A and J1-B conn ectors of the EMM are The J2 con nector of the EMM is a AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOT H latches and pull con nector from Use a screw driver to open latch.
  • Page 127 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back sid e of the terminal engages a terminal with se al in to conn ector housing until shoulder in the connector housing to hold the ter- seated.
  • Page 128 ELECTRICAL AND IGNITION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 129 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............128 FUEL SYSTEM HOSE ROUTING .

  • Page 130: Service Chart

    FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 30-42 In. lbs. (3.5-4.7 N·m) 60-84 In. lbs. (7-9.5 N·m) 100-110 In. lbs. (11-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) (Lower screw only) Hand tighten to seal contact then 1/2 - 1 turn 60-84 In.
  • Page 131 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Important: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 60-84 in. lbs. (7-9.5 N·m) Start at center and use a spiral torque pattern 60-80 in. lbs. (7-9.5 N·m) 30-42 in.
  • Page 132 FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Tighten 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 133: Fuel System Hose Routing

    FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Return 3.3 L Models 003985 Fuel Supply Fuel Return 3.4 L Models 006977 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 134: Fuel System Circuit Diagram

    FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM J1-A J1-B 007109 Injectors Capacitor High pressure fuel pump Grounds (neg) Fuel filter/water separator 55 V circuit (white/red) Fuel Injector grounds...

  • Page 135: Fuel System Requirements

    FUEL SYSTEM FUEL SYSTEM REQUIREMENTS FUEL SYSTEM Portable Fuel Tanks REQUIREMENTS WARNING If engine is equi pped with a quick -discon- Regulations and Guidelines nect fuel hose, you MUST disc onnect the Vessel man ufacturer, and /or inst aller of an EP A fuel hose from the engine and the fuel tank certified outboard, must meet minimum specifica- to prevent fuel leaks:...

  • Page 136: Fuel Requirements

    FUEL SYSTEM FUEL SYSTEM REQUIREMENTS Fuel Requirements When using alcoho l-extended fue ls, be aware of the following: • The b oat’s fuel system may h ave different WARNING requirements regarding the use of alcohol fuels. Gasoline is e xtremely flammable and Refer to the boat’s owner guide.

  • Page 137: Components

    FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The fuel syste m includes the following compo- high-pressure components of the fuel system from nents: contaminants. Refer to INSPECTION AND MAIN- • Fuel Lift Pump TENANCE SCHED ULE on p.

  • Page 138: Fuel Circulation Pump

    FUEL SYSTEM COMPONENTS Fuel Reservoir to flow t o the int ake manifold through the ve nt hose. The vapor separator accumulates fuel in an inter- nal fuel reservoir and supplies fuel to the electric As the vapor pressu re in the va por sep arator circulation p ump.

  • Page 139: Fuel Manifolds

    FUEL SYSTEM COMPONENTS Fuel Manifolds The EMM is programmed to compensate for vari- ations in fuel flow. Each injector and its location on The fuel supply and return manif olds route fu el the outb oard is identified b y t he EMM. DO NOT through the high pressure side of the fuel system.

  • Page 140: Fuel System Priming

    FUEL SYSTEM FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System Vent Line Clamp WARNING Federal Reg ulations require that a ll o utboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the foll owing procedure in a well venti- vent line clamp inst alled.

  • Page 141: Fuel System Tests

    FUEL SYSTEM FUEL SYSTEM TESTS FUEL SYSTEM TESTS Shut OFF outbo ard. Mo nitor pr essure gaug e. Pressure should not drop below 15 psi (103 kPa). WARNING IMPORTANT: If outb oard does not run, prime fuel system and crank outboard; check circulation Use cau tion whe n working on any pres- pump operation;...

  • Page 142: Pressure Regulator Test

    FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Sep arator Service on p. 146 to This te st re quires Inj ector T est Fi tting ki t, remove vapor separator. P/N 5005844. Make su re filter is no t clogg ed.

  • Page 143: Fuel Injector Resistance Test

    FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Resistance Test Circulation Pump Resistance Test Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter with app ropriate adapter coil resistance.

  • Page 144: Lift Pump Vacuum Test

    FUEL SYSTEM FUEL SYSTEM TESTS Results: START outboard and run at FULL THROT TLE for at least two minutes. Monitor clear vinyl ho se for Normal pressure the presence of air . Air bubbles ind icate a faulty • Perform the Lift Pump Vacuum Test on p. 142. hose, connection, o r f uel tank p ick-up.

  • Page 145: Anti-Siphon Valve Test

    FUEL SYSTEM FUEL COMPONENT SERVICING FUEL COMPONENT Anti-Siphon Valve Test Remove anti-sip hon valve from fuel t ank. Inst all SERVICING adapter fittings and a 36 in. (91.4 cm) len gth of clear hose to the inlet side (tank end) of valve. WARNING Gasoline is ex tremely fl ammable and...

  • Page 146: Fuel Filter Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Filter Service Wrap a shop towel complete ly a round the pre s- sure te st valve while connecting f itting from Fu el Removal Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly. Disconnect the battery cables at the battery.

  • Page 147: Fuel Lift Pump Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Installation Place fu el pu mp bracket, with rubb er isola tor The fuel lif t pump is servicea ble as a co mplete mounts, in front of the throttle body. assembly.

  • Page 148: Vapor Separator Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Vapor Separator Service Fuel Manifold Service Removal Removal Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Relieve fuel system pressure. Refer to Relieving Relieve fuel system pressu re. Refer to Relieving Fuel System Pressure on p.

  • Page 149: Fuel Injector Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injector Service Installation Check condition of sealing O-rings on fuel man i- Mark fuel injectors to show cylinder locations. fold fittings. Lubricate O-rings wit h outboard lubri- cant a nd inse rt fue l manif old fittings into in jector. Fuel inje ctors m ust be inst alled in NOTICE Both fittings must be fully se ated into the injector...
  • Page 150 FUEL SYSTEM FUEL COMPONENT SERVICING Remove injector screws. tor filter. Install new crush ring and O-rings. Lubri- cate O-rings with STP † Oil Treatment. 008195 1. Injector screws 002196 1. Adaptor Remove fuel injector and insulator. Crush Ring Replacement Injector crush rin gs must be NOTICE replaced if i njector is installed in a different...
  • Page 151 FUEL SYSTEM FUEL COMPONENT SERVICING Installation Use the drop down menu to navigate to the saved coefficient file location. All injectors must be installed in the NOTICE The co efficient file name must match t he seria l correct cylinde r by serial number. Improper number of the injector.
  • Page 152 FUEL SYSTEM FUEL COMPONENT SERVICING Install Injector Tighten screws in st ages, st arting with the lower screw. The followin g it ems and their mating su rfaces • First torque is 5 ft. lbs. (7 N·m) must be cleaned before reassembly: •...

  • Page 153: Intake Manifold Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Intake Manifold Service Disassembly All reed plat e assembly and reed valve assem- Removal blies must be cleaned before reassembly . DO Disconnect vapor sep arator vent hose, thrott le NOT use strong carb uretor cleaner or the hot position sensor connector, and throttle link arm.
  • Page 154 FUEL SYSTEM FUEL COMPONENT SERVICING Installation Inspect the int ake manifold . All gasket su rfaces must be cleaned, smooth, and free of nicks. Use a Install ga sket on reed plate assembly . DO NOT machinist’s st raight-edge an d a feeler gaug e to use sealer on the gasket.
  • Page 155 FUEL SYSTEM FUEL COMPONENT SERVICING Connect throttle linkage a nd throttle position sen- Position clamps as shown. sor connector. IMPORTANT: DO NOT lu bricate TPS to thrott le shaft surface. 004248 1. Throttle linkage 2. TPS electrical connector 3. Vapor separator vent hose 006990 1.
  • Page 156 FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 157 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............156 OILING SYSTEM CIRCUIT DIAGRAM .

  • Page 158: Service Chart

    OILING SYSTEM SERVICE CHART SERVICE CHART Engine Oil Programming Labels NOTICE NOTICE XD 100 XD 30 This outboard has This outboard has been programmed been programmed for use of for use of Evinrude®/Johnson® Evinrude®/Johnson® XD25™, XD30™, XD100™ oil. XD 50 XD50™...

  • Page 159: Oiling System Circuit Diagram

    OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM 1 2 3 4 5 1 2 3 4 5 J1-A J1-B 008364 Crankcase Oil Injection Pump Oil Pressure Sensor Signal (TAN/WHITE) Cylinder Oil Injection Pump Rear Oil Injector control (BLUE/RED) Rear Oil Injector +12 V (RED/YELLOW) 55 V Circuit (WHITE/RED) Low Oil Switch (TAN/BLACK)

  • Page 160: Oil Supply Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 200 – 250 HP (3.3 L) M ODELS Rear oil manifold delivers oil to cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4. Cylinder 1 5. Cylinder 3 6. Cylinder 5 Oil tank assembly Oil pick-up Oil supply hose...
  • Page 161 OILING SYSTEM OIL SUPPLY DIAGRAMS Port View Starboard View 008208...
  • Page 162 OILING SYSTEM OIL SUPPLY DIAGRAMS 250 – 300 HP (3.4 L) M ODELS Rear oil pump delivers oil to cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4. Cylinder 1 5. Cylinder 3 6. Cylinder 5 Oil tank assembly Oil pick-up Oil supply hose In-line oil filters...
  • Page 163 OILING SYSTEM OIL SUPPLY DIAGRAMS Port View Starboard View 008432...

  • Page 164: Oil Recirculation Diagrams

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS Complete View 008205 Top View 008206 1. Recirculation fitting...
  • Page 165 OILING SYSTEM OIL RECIRCULATION DIAGRAMS Port View Starboard View 008207...

  • Page 166: Oil System Requirements

    OILING SYSTEM OIL SYSTEM REQUIREMENTS OIL SYSTEM COMPONENTS REQUIREMENTS The oiling system consists of the following compo- nents: Recommended Lubricants • Oil tank • Oil injection pump and manifold assembly Evinrude/Johnson XD100, XD50, or XD30 out- • Oil pressure sensor board oils are recommende d for use in Evinrude •...

  • Page 167: Oil Injection Pump

    OILING SYSTEM COMPONENTS Oil Injection Pump Oil Pressure Sensor The oil injection pump is an electric (55 V) actua- The oil pressure sensor react s to chang es in oil tor st yle pump. It d raws oil from the oil tank manifold pressure.

  • Page 168: Rear Oil Manifold (3.3 L Models)

    OILING SYSTEM COMPONENTS Rear Oil Manifold (3.3 L models) Electrical Circuit (12 V) The rear oil manifold receives oil from the primary The rear oil pu mp is powered by the 12 V electri- manifold and distributes it to the cylinder sleeves. cal circuit.

  • Page 169: Cylinder And Crankcase

    OILING SYSTEM COMPONENTS Cylinder and Crankcase Oil Recirculation System The p rimary oil distributio n manifold provides External hoses and fittings, inte rnal cylin- crankcase lub rication th rough o il d istribution der/crankcase passages, and intake manifold pas- hoses an d p ressed-in fitting s at t he front of the sages are used to recirculate any accumulation of crankcase, port side.

  • Page 170: Oil Control Settings

    OILING SYSTEM OIL CONTROL SETTINGS OIL CONTROL SETTINGS Check valves pre ssed into the cra nkcase b elow #4 and #6 ree d valve assemblies connect to Oil Injection Rate hoses which route to a fitting at the top of the block, above #2 cylinder.

  • Page 171: Break-In Oiling

    OILING SYSTEM OIL CONTROL SETTINGS Install decals in a hig hly visible locatio n, such as Running a n Evinrude E-TEC out- NOTICE one of the following: board on other grades of oil while s et to the • Dashboard/deck of boat, next to key switch XD100 oil ratio will res ult in increased engine •...

  • Page 172: Oil Supply Priming

    OILING SYSTEM OIL SUPPLY PRIMING OIL SUPPLY PRIMING 250 – 300 HP (3.4 L) M ODELS Start the outboard. Use the oil priming functions in the sof tware to m ake sure t he sy stem is com - WARNING pletely primed.
  • Page 173 OILING SYSTEM OIL SUPPLY PRIMING • Observe oil flo w through all oil distribution hoses. The pump assembly cannot prime itself until it has been filled with oil. Air must be purged during the priming procedure. 008391 1. Cylinder oil pump 008392 1.
  • Page 174 OILING SYSTEM OIL SUPPLY PRIMING Make sure that oil flows through the rear oil distri- 200 – 250 HP (3.3 L) M ODELS bution manifold to the cylinder block fittings. Start the outboard. Use th e oil priming function in the sof tware to mak e sure the s ystem i s co m- pletely primed.

  • Page 175: Oiling System Tests

    OILING SYSTEM OILING SYSTEM TESTS OILING SYSTEM TESTS Oil Injection Pump Voltage Tests Use a digital multimeter calibrated to a scale that IMPORTANT: Always perform visual inspections reads 55 V (DC) to mea sure voltage between the to identify oiling system le aks. Ma ke sure t he oil oil pump electrical connector and engine ground.

  • Page 176: Oil Injection Pump Circuit Resistance Test

    OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Circuit Use the Oil Injector te st o f Evinrude Diagnostic software Static Test screen to activate the oil Resistance Test pump. IMPORTANT: The complete oil injection pump electrical circu it includes EMM alternator outp ut, the engine wire harness, the injection pump wind- ing and connectors, and the oil injector control cir- cuit of the EMM.

  • Page 177: Cylinder Oil Pump Voltage Tests

    OILING SYSTEM OILING SYSTEM TESTS Cylinder Oil Pump Voltage Tests Use the Cylinder Oiler Test fu nction of Evinrude Diagnostic software Static Test screen to activa te The EMM controls the pu mp by providing grou nd the cylinder oil pump. through pin 4 (blue/red wire) of the J1-A connector and pin A (blue/red wire) of the oil pump connec- tor.

  • Page 178: Cylinder Oil Pump Resistance Test

    OILING SYSTEM OILING SYSTEM TESTS Cylinder Oil Pump Resistance Oil Supply Vacuum Test Test WARNING Disconnect the battery cables at the battery. Wear safety glasse s to avoid personal Disconnect th e e lectrical connector f rom the oil injury, and set compressed air pressure to injection pump.

  • Page 179: Oil Injection Pump Function Test

    OILING SYSTEM OILING SYSTEM TESTS Static Test on the hose for at least five min utes. Re pair or replace any le aking components. Reinstall the oil Use the Evinrude Diagnostics software oil injector hose. test to activate inje ctor. Confirm t hat a small amount of oil is discharged while injection pump is Check height of pickup assembly.

  • Page 180: Oil Component Servicing

    OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Once h ose is re moved from the manifold, make sure hose support is in the end of the hose. SERVICING WARNING To preve nt acci dental s tarting while s er- vicing, discon nect the battery cable s at the battery.

  • Page 181: Oil Injection Pump

    OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Route oil d istribution h oses f rom the oil distrib u- Removal tion manifold to the crankcase oil delivery fittings Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP- PLY DIAGRAMS on p.

  • Page 182: Rear Oil Pump

    OILING SYSTEM OIL COMPONENT SERVICING Rear Oil Pump Install oil pump o n bracket with clamp and retain- ing screw. Tighten to a torque of 24 to 36 in. lbs. (3 Removal to 4 N·m). Disconnect the battery cables at the battery. Remove engine cover.
  • Page 183 OILING SYSTEM OIL COMPONENT SERVICING Remove two screws to remove oil pump assembly Connect oil hoses to cylinder sleeve oil fittings on from mounting bracket. the crankcase and fasten with tie straps. 008476 008456 1. Screws 1. Cylinder sleeve oil fittings – port Installation Clean threa ds o f screws an d apply Nut Lock to threads.
  • Page 184 OILING SYSTEM OIL COMPONENT SERVICING Make sure oiling system is primed. Check oil flow through o il d istribution ho ses. Check oil syste m operation and rou ting o f oil h oses. Refer to OIL SUPPLY PRIMING on p. 170. Run the outboard and check for leaks.
  • Page 185 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAM 3.3 L ........184 HOSE ROUTING AND WATER FLOW DIAGRAM 3.4 L .

  • Page 186: Hose Routing And Water Flow Diagram 3.3 L

    COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAM 3.3 L HOSE ROUTING AND WATER FLOW DIAGRAM 3.3 L PORT REAR Water intake screens Water pump Water tube Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) Water supply, EMM to vapor separator Vapor separator water outlet to adapter Port thermostat tower to blow-off valve...

  • Page 187: Hose Routing And Water Flow Diagram 3.4 L

    COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAM 3.4 L HOSE ROUTING AND WATER FLOW DIAGRAM 3.4 L PORT REAR Water intake screens Water pump Water tube Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) Water supply, EMM to vapor separator Vapor separator water outlet to adapter Port thermostat tower to blow-off valve...

  • Page 188: Components

    COOLING SYSTEM COMPONENTS COMPONENTS Water Supply Tube The wa ter pump outlet co nnects with the wa ter Water Pump and Intakes supply tube located in th e outboard’s midsection. Grommets seal the water tube to the water pump External water int akes mo unted in t he ge arcase housing and the inner exhaust housing.

  • Page 189: Pressure Relief Valve

    COOLING SYSTEM COMPONENTS Pressure Relief Valve Thermostats A pressu re relief valve is used to control water Thermostats control water flow and operating tem- flow and operating temperature at higher speeds perature at lower speeds (below 1200 RPM). (above approximately 1200 RPM) . Th e p ressure Overheating: A restricted or faulty thermostat typ- relief valve op ens as wate r pressure incre ases.

  • Page 190: Operation

    COOLING SYSTEM OPERATION OPERATION At low speed , th e pressure valve is against t he seat and the thermostats are closed. Warm water from the cylinder block gr adually migra tes to t he All models use a two-stage cooling system thermostat pocket at the to p of each cylind er design.

  • Page 191: Emm And Vapor Separator Cooling

    COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE adapter. The water reduces inner exhaust temper- atures and cools the propeller hub. CHECK IMPORTANT: The e ngine te mperatures liste d below are based o n an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and place outboard in a test tank or in the water.

  • Page 192: Software Method

    COOLING SYSTEM ENGINE TEMPERATURE CHECK Software Method Typical pyrometer readings at IDLE speed should be 143°F ± 15°F (62°C ± 8°C) Use Evinrude Diagnostics sof tware to read te m- perature displays. IMPORTANT: If you get low or inaccurate read- ings with a digital pyrometer, coat the probe loca- tion with Thermal Joint Compound, P/N 322170.
  • Page 193 COOLING SYSTEM ENGINE TEMPERATURE CHECK If IDLE temperature is too low, pinch off the water Start the outboard and check IDLE operating tem- outlet hoses from p ressure relief valve to cylin der perature using Evinrude Diagnostics software pro- heads. gram.

  • Page 194: Temperature Sender Servicing

    COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 007209 004338 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.

  • Page 195: Pressure Relief Valve Servicing

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Inspection Inspect all parts for cracks, heat damage, or signs VALVE SERVICING of corrosion. Rep lace d amaged p arts. Clea n debris from housing and parts. The pressure relief valve assembly should be ser- viced at the same time as the thermostats.
  • Page 196 COOLING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 197 EVINRUDE ICON REMOTE CONTROL SYSTEM EVINRUDE ICON REMOTE CONTROL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............196 COMPONENTS .

  • Page 198: Service Chart

    EVINRUDE ICON REMOTE CONTROL SYSTEM SERVICE CHART SERVICE CHART 60 to 84 in. lbs. (7 to 9.5 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 18 to 20 ft. lbs. (24.5 to 27 N·m) ESM to EMM connector ESM to engine harness key switch connector ESM to trim/tilt...

  • Page 199: Components

    EVINRUDE ICON REMOTE CONTROL SYSTEM COMPONENTS COMPONENTS Shift Actuator The shift actuator converts electronic signals from The ICON rem ote c ontrol sy stem consis ts of the the ESM into the mechanical motion required to following components: shift the outboard into and out of gear. •...

  • Page 200: Throttle Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM COMPONENTS Throttle Actuator If the throttle cann ot move toward op en positio n, the FOR WARD or REVERSE indicator LED The throttle actu ator c onverts electronic signals flashes (dep ending on gear p osition whe n fault from the ESM into the mechanical motion required occurred).

  • Page 201: Icon Component Servicing

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING ICON COMPONENT Installation Install grommets on ESM. Apply soapy water to SERVICING grommets and push assembly on to studs. WARNING To preve nt accid ental s tarting while s er- vicing, discon nect the battery cable s at the battery.
  • Page 202 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Continue harness routing und er pressure relief Make sure the oil recirculation hose NOTICE valve hoses to EMM connector. Clip conne ctor to is not pinched during assembly. fuel rail. Make sure harness is not strained and does not rub against EMM mounting boss.
  • Page 203 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Secure sh ift actua tor harne ss wit h tie st rap, Install cop per crush washer over ESM positive P/N 317893. ring termina l. T hen, install star washer , battery cable, and nut.

  • Page 204: Shift Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Shift Actuator Route all ESM harnesses as shown and secure to shift actuator with tie straps, P/N 907833. Removal Disconnect the battery cables at the battery. Remove electrical bracket cover. Observe and note all wire routings before disas- sembling.
  • Page 205 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Installation Remove the shift actuator connector from the clip on the mounting plate. Disconnect the shift actua- Remove old adhesive from clamp retaining screw tor harness. and shift actuator retaining screws. Apply Nut Lock to the threads of the screws. Install shift actuator o n mounting plate with thre e long screws an d one short screw.

  • Page 206: Throttle Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Throttle Actuator Connect the shif t actuator harne ss. Attach to clip on mounting plate. Removal Disconnect the battery cables at the battery. Remove the flywheel cover. Remove the electrical bracket cover. Observe and note all wire routings before disas- sembling.
  • Page 207 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Installation Remove the clamp retaining screw. Remove old adhesive from clamp retaining screw and shift actuator retaining screws. Apply Nut Lock on the threads of the screws. Install thro ttle actuator on mounting plat e with three long screws and one short screw .
  • Page 208 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Secure ESM to throt tle actu ator harness with tie Route the thrott le actua tor harness behin d and strap, P/N 320107. over the oil recirculation hose as shown. Connect the throttle actu ator harness. Att ach to clip on Route ESM to shift actuator harness behind throt- mounting plate.

  • Page 209: Icon System Settings

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS ICON SYSTEM SETTINGS Calibrate Actuator Stroke Set Engine Identity (Instance) CAUTION In a multi-engine application, the transom position After inst allation, dealer MUST us of the outboard must be identified on the network. Evinrude Diagnostics software, version 5.1 or higher, to calibrate the actuators for cor- Engine identity is se t by a n Engin e Ident ity Plug...
  • Page 210 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS • linkage. Evinrude Diagnostics report s when the Select FOR WARD under Shift Position on t he process is complete. ICON screen. The actu ator arm will move for- ward. • Use the Nudge butt ons to move the actuator arm forward or backward until the shif t link aligns with the actuator arm and shift lever pins.
  • Page 211 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS • After forward and reverse strokes have been cali- With the shift link disconnected, rotate the pro- brated, the ESM calculates neutral position. peller and manually shif t the outbo ard into reverse gear with the shift lever.

  • Page 212: Icon Remote Control System Troubleshooting Chart

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULTS ICON System Faults The ICON System exhibits two types of faults: Recoverable and Non-recoverable. ICON System faults are visually indicated by the remote control, the swit ch panels, the gat eway, and the 6-po rt hub LED’s. ICON System faults are also displayed on the Faults page of Evinrude Diagnostics and on the NMEA 2000 gauges.
  • Page 213 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULTS Non-recoverable Faults When a non-recoverable fault occurs, the ICON System: • Flashes all gear position LED’s of the affected engine five times per second • Sends a fault message to the outboard EMM, which in turn se nds a “Check Engin e” message to the NMEA 2000 gauges •...

  • Page 214: Icon Remote Control System Fault Messages

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULT CODE CHART ICON System Fault Code Chart Use this chart and Evinrude Diagnostics software to identify ICON Remote Control System fault codes. Use the ICON System Troubleshooting Flowcharts to resolve a problem on an ICON Syste m. Refer to the Evinrude ICON System Troubleshooting Guide.
  • Page 215 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULT CODE CHART Possible Causes and Fault Code Description LED Indicators Flowchart Reference Trim and tilt switch panel harness is damaged or not connected to the remote control. Trim Switch Module Com- Trim and tilt switch panel harness munication Fault is damaged or not connected to the switch panel.
  • Page 216 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULT CODE CHART Possible Causes and Fault Code Description LED Indicators Flowchart Reference Throttle link arm from ICON add- Throttle Actuator Motion on kit is not assembled to the out- Fault board. FORWARD or REVERSE LED The ESM tries to move the Throttle linkage components are flashes (depending on gear...
  • Page 217 POWERHEAD TABLE OF CONTENTS POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............216 COMPRESSION TESTING .

  • Page 218: Service Chart

    POWERHEAD SERVICE CHART SERVICE CHART Triple-Guard Grease 60-84 In. lbs. Gasket Sealing Compound (7-9.5 N·m) Moly Lube Red Ultra Lock 60-84 In. lbs. (7-9.5 N·m) Blue Nut Lock Outboard Engine Lubricant 30-42 In. lbs. Thermal Grease (3.5-5 N·m) Pipe Thread Sealing Compound 120-144 In.
  • Page 219 POWERHEAD SERVICE CHART 96-120 In. lbs. (11-13.5 N·m) 60-65 Ft. lbs. (81-88 N·m) 96-120 In. lbs. (11-13.5 N·m) 96-120 In. lbs. ( 1 1-13.5 N·m ) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Extreme Pressure Grease 004108...

  • Page 220: Compression Testing

    POWERHEAD TAPER PIN TOOL TAPER PIN TOOL Scale: FULL SIZE – Hole for Storage COMPRESSION TESTING Start and run outboard until it achieves o perating If engine sh ows a variation greater than 15 psi temperature, then shut OFF. (100 kPa) between cylinders, check for: •...

  • Page 221: Powerhead Removal

    POWERHEAD POWERHEAD REMOVAL POWERHEAD REMOVAL Remove water hoses and exhaust back pressure hose from adapter. WARNING Protect ag ainst hazardous fue l spray. Before st arting any fuel syst em service, carefully relieve fuel system pressu re. Refer to Relie ving Fue l System Press ure on p.
  • Page 222 POWERHEAD POWERHEAD REMOVAL Remove trim/tilt harness from clamp. Fasten appropriate chain hook to eye of tool a nd support weight of powerhead with hoist. 005041 1. Trim harness 2. Clamp 48758 Remove pin and wa sher from shif t rod lever to Remove all powerhead retaining screws and nuts.

  • Page 223: Powerhead Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Throttle Linkage Removal Remove throttle cam and throttle lever. DISASSEMBLY Systems Removal To simplify reasse mbly and wiring inst allation, lay out the various screws and clamp s in the order of their proper location. Remove the electric starter.

  • Page 224: Crankcase Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY Crankcase Disassembly Remove the upper crankcase head screws. Use the TAPER PIN TOOL, or equivalent, to push the crankcase taper pins toward th e front side of the engine. IMPORTANT: Do not use a t apered punch or any oth er tool that could jam in or da mage the taper bore when removing the pin.

  • Page 225: Cylinder Head Removal

    POWERHEAD POWERHEAD DISASSEMBLY Connecting Rods and Pistons Separate crankcase and cylinder block. It may be necessary to tap on cranksha ft with a rawhide or Use a permanent marker to identify each connect- rubber mallet to loosen. ing rod cap, connecting rod, and piston by cylinder number.

  • Page 226: Crankshaft Removal

    POWERHEAD POWERHEAD DISASSEMBLY Use one hand to su pport the piston , and remove Remove wrist pin retaining rings. Discard retaining the rod cap screws with your other hand. Remove rings. each piston and rod assembly. 000689 Use W rist Pin Pressing Tool, P/N 396747, to 49432 remove wrist pin.
  • Page 227 POWERHEAD POWERHEAD DISASSEMBLY Use a punch to remove the upper crankshaft seal. Remove the O-ring from cr ankshaft sleeve an d Remove and discard two crankcase head O-rings. inspect it. Repla ce the O-ring if it is not in goo d condition.
  • Page 228 POWERHEAD POWERHEAD DISASSEMBLY IMPORTANT: Remove center ma in be arings an d sp lit sleeves If the lower main bearing is for inspection. DO NOT mix parts. Note location of removed fro m the cranksha ft, it must be dis- bearings for reassembly.

  • Page 229: Cylinder Block Cleaning

    POWERHEAD CYLINDER BLOCK CLEANING CYLINDER BLOCK Use Gel Seal and Gasket Remover to remove all traces of ga skets, adhesives, and Gel-Seal II™ CLEANING sealant from the cylinder block and crankcase. WARNING IMPORTANT: Before inspecting or assembling To avoid personal injury, wear eye protec- powerhead, all internal components must be com- tion an d rub ber gloves when usin g Gel pletely clean and free of contaminants.

  • Page 230: Powerhead Inspection

    POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diame ter of ea ch crankpin and main INSPECTION bearing journal. The lower main be aring journal would only be measu red if the bearing was For d imensions, refer t o SERVICE SP ECIFICA- removed for another reason.

  • Page 231: Cylinder Bore

    POWERHEAD POWERHEAD INSPECTION Cylinder Bore Pistons Visually inspect pisto ns for signs o f abn ormal Use a Cylinder Bore Gauge to inspect each cylin- wear, scuffing, cracks, or burning. der bore for an out-of-round, oversize, or t apered condition. Be sure the gauge is perfectly square in Piston Rings the bore when measuring.

  • Page 232: Bearings

    POWERHEAD POWERHEAD ASSEMBLY POWERHEAD Bearings Inspect center main bearing and split sleeve s for ASSEMBLY excess wear, nicks, or scratches. Replace if ne c- essary. IMPORTANT: Proceed slowly. Make no forced assemblies u nless a pressing operation is called for. All internal comp onents must be perfectly clean and lightly coated with outboard lubricant.
  • Page 233 POWERHEAD POWERHEAD ASSEMBLY new sleeve o nto the crankshaft u ntil the inst aller Use retaining ring pliers to install bearing retaining contacts the lower main bearing. ring with sharp edge facing away from bearing. 30061 Lubricate a new driveshaft O-ring and lightly lubri- 30074 cate crankshaf t splines with Moly Lube.
  • Page 234 POWERHEAD POWERHEAD ASSEMBLY Lightly coat the outside edge of a new crankshaft Install new seals on th e fo ur be aring ret ainer seal with Gasket Sealing Compound. Use Se al screws. Appl y Nut Lock t o th e threads o f t he Installation T ool, P/N 3254 53, to install seal in screws and tighten to a torque of 96 to 120 in.

  • Page 235: Pistons And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Lightly coat two new O-rings with Gasket Sealing Apply outboard lubricant to the wrist pin bearings. Compound, and install on upper cra nkcase head. Install the bearings in the wrist pin bore. Keep sealer away from oil passage. Oil the wrist pin bore and wrist pin.

  • Page 236: Cylinder Head Installation

    POWERHEAD POWERHEAD ASSEMBLY in each wrist pin hole. Gap of retaining ring faces Before continuing, mak e sure that NOTICE away from notch in piston. all Gel-Seal II has been removed from the cyl- inder blo ck and crank case ma ting flange s. If traces of ha rdened Gel-Seal II are l eft, ma in bearings could be misaligned.

  • Page 237: Crankshaft And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Install cylinder he ad wit h the thermostat toward Gently lower crankshaft into place. • the top. Apply Triple-Guard grease to threads and Turn all crankcase seal ring gaps to face up. install the cylinder head screws. DO NOT use any •...
  • Page 238 POWERHEAD POWERHEAD ASSEMBLY Lubricate rod cap screw threads and under screw Install Rod Cap Alignme nt Fixture, P/N 39674 9, before tighten ing rod cap screws. Align the flat head matin g su rface with a light coat of Triple- Guard gre ase.
  • Page 239 POWERHEAD POWERHEAD ASSEMBLY Apply a light coat of outboard lubricant to the cor- Loosen both rod cap screws one-quarter turn. ners of the con necting rod and rod cap. Place Use Torquing Socket, P/N 346187, to tighten rod frame on connecting rod using the followin g pro- cap screws in three stages: cedure: •...

  • Page 240: Crankcase Assembly

    POWERHEAD POWERHEAD ASSEMBLY Crankcase Assembly IMPORTANT: The use of Locquic Primer is NOT recommended. If primer is used, crankcase Thoroughly clean an d deg rease the mating halves must be assemble d an d tig htened within flanges of the crankcase and cylinder block with a ten minutes after the Gel-Seal II has been applied.

  • Page 241: Shift Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Shift Linkage Installation Apply Permatex No. 2 to crankcase flange screws where thre aded hole is op en t o crankcase .Install Install Neut ral/Shift In terrupt switch. Apply screws and tighten to a torque of 84 to 108 in. lbs. Lock to screw threads and tighten to a torque of 7 (9.5 to 12 N·m).

  • Page 242: Throttle Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Throttle Linkage Installation Final Powerhead Assembly Apply Nut Lock to threads of throttle lever screw. Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 151. Insert spring into cavity of throttle lever. Install oil recirculatin g hoses and che ck valves.

  • Page 243: Powerhead Installation

    POWERHEAD POWERHEAD INSTALLATION POWERHEAD Apply Gasket Sealing Compound to the threads of all powerhead screws. INSTALLATION Loosely install all fasteners before tightening. Apply Permatex No. 2 to both sides of a new base Tighten the 3/8 in. diameter powerhead screws to gasket around the exhaust port only.
  • Page 244 POWERHEAD POWERHEAD INSTALLATION Install wa ter hoses and exha ust back pressure hose. 004252 1. Rear powerhead nut Place the shift rod in the shift rod lever. Install the retaining pin an d washer. Tighten pin to a torque Port side 008443 of 60 to 84 in.

  • Page 245: Pre-Service Adjustments

    POWERHEAD POWERHEAD INSTALLATION Pre-Service Adjustments After installing a new or reb uilt NOTICE powerhead, perform the follo wing procedures before returning outboard to service: • Adjust timing pointer. • Index all spark plugs. Refer Spark Plu g Indexing on p. 40. •...

  • Page 246: Powerhead Views

    POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings – 3.3 L models 007153...

  • Page 247: Starboard Hose Routings - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.3 L models 007154...

  • Page 248: Port Hose Routings - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Port Hose Routings – 3.4 L models 008503...

  • Page 249: Starboard Hose Routings - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.4 L models 008502...

  • Page 250: Port - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Port – 3.3 L models 008448...

  • Page 251: Starboard - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Starboard – 3.3 L models 008449...

  • Page 252: Port - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Port – 3.4 L models 008441...

  • Page 253: Starboard - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Starboard – 3.4 L models 008442...

  • Page 254: Front - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Front – 3.3 L models 008450...

  • Page 255: Front - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Front – 3.4 L models 008439...

  • Page 256: Rear - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Rear – 3.3 L models 007142...

  • Page 257: Rear - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Rear – 3.4 L models 008440...

  • Page 258: Top

    POWERHEAD POWERHEAD VIEWS 008438...

  • Page 259: Starboard - Icon Models

    POWERHEAD POWERHEAD VIEWS Starboard – ICON models 008504...
  • Page 260 POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 261 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............260 STERN BRACKET .

  • Page 262: Service Chart

    MIDSECTION SERVICE CHART SERVICE CHART Stern Bracket 40-50 In. lbs. (4.5-5.5 N·m) 64-72 Ft. lbs. (87-98 N·m) 8-12 In. lbs. 10-16 In. lbs. (0.9-1.4 N·m) (1.1-1.8 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.5 N·m) 28-30 Ft.

  • Page 263: Exhaust Housing - 3.3 L Models

    MIDSECTION SERVICE CHART Exhaust Housing – 3.3 L models 22-24 Ft. lbs. (30-33 N·m) See Assembly Instructions 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (14-16 N·m) 144-168 In. lbs. 60-84 In. lbs. (16-19 N·m) (7-9.5 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In.

  • Page 264: Exhaust Housing - 3.4 L Models

    MIDSECTION SERVICE CHART Exhaust Housing – 3.4 L models 22-24 Ft. lbs. (30-33 N·m) 144-168 In. lbs. (16.5-19 N·m) 144-168 In. lbs. (16.5-19 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In. lbs. (7-9.5 N·m) 40-42 Ft. lbs. 144-168 In. lbs. (54-57 N·m) (16.5-19 N·m) 60-84 In.

  • Page 265: Muffler

    MIDSECTION SERVICE CHART Muffler 007117...

  • Page 266: Tilt Tube

    MIDSECTION TILT TUBE TILT TUBE Remove the nut from the starboard side. 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. Pull the locking tabs on the tilt limit cam loose from 30747 the collar.

  • Page 267: 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 threa d are WARNING engaged. Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.

  • Page 268: Exhaust Housing Service

    MIDSECTION EXHAUST HOUSING SERVICE EXHAUST HOUSING Remove the exhaust housing. SERVICE Exhaust Housing Removal Before removing the exhaust housing: • Remove th e gearcase . Re fer to Ge arcase GEARCASE RE MOVAL AND INSTALLATION on p. 289. • Remove the p owerhead. Refer to POWER- HEAD REMOVAL on p.

  • Page 269: Exhaust Housing Installation

    MIDSECTION EXHAUST HOUSING SERVICE Exhaust Housing Installation If re moved, coat the lower mount s with soap y water and press into the exhaust housing with the Bring the exhaust housing into position with th e “OUTSIDE” mark facing outward. stern bracket.

  • Page 270: Exhaust Housing Disassembly - 3.3 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Exhaust Housing Disassembly – Attach the ground lead and lockwasher to the star- board side of the steering arm. 3.3 L models Remove two f ront adapter to o uter exhaust hous- ing screws. Remo ve thre e nut s at rear of adapter.

  • Page 271: Exhaust Housing Disassembly - 3.4 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Exhaust Housing Disassembly – Mark the water tube for correct reassembly loca- tion. Remove six inner exhaust ho using screws. 3.4 L models Remove the inner exhaust housing. Remove two fr ont adapter to o uter exhaust hous- ing screws.

  • Page 272: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING SERVICE Cleaning and Inspection Loosen and remove the upper mount plate screws and remove the mount plate. WARNING Wear safety glasse s to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). Clean all parts with parts cleaning solvent and dry with comp ressed air .

  • Page 273: Exhaust Housing Assembly - 3.3 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Inspect the wa ter tube fo r obstructions or kinks, Coat the outside diameter o f a n ew water tub e which may restrict water flow. grommet with Adhesive 847. Install grommet in the inner exhaust housing. Install the water tube. Exhaust Housing Assembly –...
  • Page 274 MIDSECTION EXHAUST HOUSING SERVICE Install a new inne r exha ust ho using sea l. Apply Lubricate the upp er mou nt with so apy water a nd Adhesive 847 to the seal groove. push into place in the adapter housing. The mount radius must face af t with the “T OP”...

  • Page 275: Exhaust Housing Assembly - 3.4 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Tighten th e small a dapter to exha ust ho using Install gro mmet and wate r tube in the inn er screws and nuts to a torque of 60 to 84 in. lbs. (7 exhaust housing. to 9.5 N·m).
  • Page 276 MIDSECTION EXHAUST HOUSING SERVICE Loosely inst all the small r etaining screws, n uts, Install four mount plate screws and washers a nd and washers. tighten t o a to rque o f 22 to 24 f t. lbs. (30 to 33 N·m).

  • Page 277: Stern Bracket

    MIDSECTION STERN BRACKET STERN BRACKET Remove the steering shaf t an d thru st washer . It may be necessary to t ap the ste ering shaf t out Stern Bracket Disassembly using a wood dowel and mallet. Before servicing the stern bracket: •...
  • Page 278 MIDSECTION STERN BRACKET Remove the anode. Remove the tilt limit swi tch and retainer from t he 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 279: Stern Bracket Assembly

    MIDSECTION STERN BRACKET Stern Bracket Assembly Remove th e two trim rod rollers from th e swivel bracket. IMPORTANT: Before proceeding, make sure all components ha ve be en thoro ughly cleane d. Replace any seals th at h ave been remove d. Inspect all thrust washe rs and bushin gs for evi- dence of deterioration.
  • Page 280 MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in. (25 to 27 N·m).
  • Page 281 MIDSECTION STERN BRACKET • Install the steering shaf t keepe r. App ly Locquic Coat the bushings and se al lip s with Triple- Primer and Nut Lock to the splines of the steering Guard grease. shaft and lower mount bracket. 30765 / 30764 Coat tilt t ube bu shings with Triple-Guard grease and, if removed, install them in the swivel bracket.

  • Page 282: Exhaust Relief Muffler Assembly

    MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY EXHAUST RELIEF The overboard indicato r and flush port in exhaust re lief gro mmet conne ct to the adaptor MUFFLER ASSEMBLY housing assembly with a hose. This ho se is n ot connected to the muffler assembly. The exhaust relief muffler is located at the rear of the adaptor housing and con cealed by the lower motor co vers.
  • Page 283 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............282 GEARCASE TYPES .

  • Page 284: Service Chart

    GEARCASE SERVICE CHART SERVICE CHART V6 P “L2”–T ERFORMANCE ODELS EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (3-4 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft. lbs. 26-28 Ft. lbs. (24-27 N·m) 60-84 in.
  • Page 285 GEARCASE SERVICE CHART V6 S “M2”– TANDARD OTATION TYPE EARCASE 60-84 In. lbs. (7-9.5 N·m) 24-36 In. lbs. (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft.
  • Page 286 GEARCASE SERVICE CHART V6 C “M2”–T OUNTER OTATION EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 60-84 in. lbs. 18-20 Ft.

  • Page 287: Gearcase Types

    GEARCASE GEARCASE TYPES GEARCASE TYPES Housing Outboard Model Description of Features Gear Ratio Type high speed profile, external water screens, pressed in 90°V6 20 in. “L2” 14:26 (.538) propeller bearing housing, performance gearset (V6). 90°V6 20 in. front water inlets and straight leading edge, pressed in 90°V6 25 in.

  • Page 288: Propeller Service

    GEARCASE PROPELLER SERVICE PROPELLER SERVICE Propeller Selection Inspection CAUTION Carefully examine p ropeller and o utboard f or the Selection of the wro ng propell er could following: reduce engine service l ife, affect boat pe r- • Damaged blades and sign s of pro peller cavita- formance, or cause serious damage to the tion (burned paint, etc.) powerhead.
  • Page 289 GEARCASE PROPELLER SERVICE Propeller Hardware Installation When selecting a propeller, consider the following: • Use an accurat e t achometer t o determine the engine’s full-throttle RPM. WARNING • The outboard should be trimmed for top speed. To prevent accidental starting while servic- •...

  • Page 290: Gearcase Leak Test

    GEARCASE GEARCASE LEAK TEST GEARCASE LEAK TEST If cotter pin holes in t he nut (without keeper) and shaft do not align, tighten further. Do not loosen. Drain lubricant before testing. Install keeper (if applicable). Install new cotter pin. Use Gearcase Pressure Tester, P/N 507977.

  • Page 291: Gearcase Removal And Installation

    GEARCASE GEARCASE REMOVAL AND INSTALLATION GEARCASE REMOVAL Remove the 3/8-16 x 3.5 in . scr ew and washe r, and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To preve nt accid ental s tarting while s er- vicing, twis t and remove all sp ark plug leads.
  • Page 292 GEARCASE GEARCASE REMOVAL AND INSTALLATION Gearcase Installation Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. • WARNING Water tube enters the water pump. • Lower inner exhaust housing installs correctly. During service, the outboard may drop •...
  • Page 293 GEARCASE GEARCASE REMOVAL AND INSTALLATION IMPORTANT: ft. lbs. (47 to 54 N· m). For adjustme nt, refer to New gearcase screws are treated Trim Tab Adjustment on p. 30. with a thread-locking material. Apply Triple-Guard grease to thre ads t o ensure th at the correct clamping force is ach ieved when tig htening—If a previously inst alled screw is re-used, use a wire...

  • Page 294: Water Pump Service

    GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE Assembly Apply a drop o f Adhesive 847 in the seal ring Disassembly groove at each of the four ribs. Rotate the driveshaf t coun terclockwise to unlock IMPORTANT: Do not allow any sealer to get into the impeller key .
  • Page 295 GEARCASE WATER PUMP SERVICE On outb oard models with 1/2 in. diamete r water Guard grease to the o-rings and install water tube tube, install the water tube grommet with the in exhaust housing. inside taper facing up. 007152 1. O-rings 32000 1.
  • Page 296 GEARCASE WATER PUMP SERVICE Apply a thin bea d of Adhesive 847 in the s eal Slide the water pump down the driveshaft. Alig n groove, and install the special shaped O-ring seal. impeller slot with th e impeller key . Rot ate t he driveshaft to engage the key with the impeller, and slide water pump down over key.

  • Page 297: Shift Rod Adjustment

    GEARCASE SHIFT ROD ADJUSTMENT SHIFT ROD On 25 in. and 30 in. models, place the appropriate water tube sp acer and grommet on the impeller ADJUSTMENT housing cover. Check the shift rod height from the shift rod hole to the surface of the gea rcase using Universa l Shift Rod Height Gauge, P/N 389997.

  • Page 298: Gearcase - Standard Rotation

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY GEARCASE • Hydrostatic Seal Grooves — Must be in go od GEARCASE – STANDARD ROTATION condition to help prevent propeller ventilation. DISASSEMBLY Pre-Disassembly Inspection WARNING Wear safety glass es to avoid persona l injury, and set compressed air pressure to less than 25 psi (172 kPa).

  • Page 299: Propeller Shaft Bearing Housing Removal

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the propeller shaft bearing ho using from the gearcase using: Removal • Propeller Shaf t Bearing Housing Puller Kit, P/N 354060. IMPORTANT: Identify gearcase type before dis- assembly. For counter rotation gearcases, refer to DO NOT use tools designed to push on the pro- GEARCASE DISASSEMBLY on p.

  • Page 300: Pinion Gear And Driveshaft Removal

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Pinion Gear and Driveshaft Pull propeller shaf t and bearing housing far enough to loosen t he PRESSED bear ing housing Removal from the gearcase housing. Adjust the sh ift rod to move the clutch dog as far forward as possible.
  • Page 301 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Locked Driveshaft Removal Remove t he drivesh aft from th e gearcase . The bearing housing, shims, thrust bearing, and thrust The driveshaft to pinion taper is a locking taper. If washer will come out with the driveshaft. necessary, use Driveshaft Puller, P/N 390706, and Backing Plate , P/N 325867, to break the lock.

  • Page 302: Driveshaft Service

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Driveshaft Service Install the roll pin to the specified dimension. To separate the uppe r driveshaft (if ne eded) from the lower d riveshaft, remove the roll pin. Replace the damaged component. 0.125 in. (3.2 mm) DR4610 1.

  • Page 303: Gearcase Housing Inspection

    GEARCASE – STANDARD ROTATION GEARCASE HOUSING INSPECTION GEARCASE HOUSING Remove propeller shaft assembly from gearcase. INSPECTION Thoroughly clean gearcase housing to remove all dirt and deb ris p rior to inspe ction. Inspect pinion bearing an d forward thrust surfa ce of gea rcase housing.

  • Page 304: Shifter, Bearing And Seal Servicing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING SHIFTER, BEARING AND Alignment Ga uge Puller , NOTICE P/N 354718, to install and remove press fit pro- SEAL SERVICING peller shaft bearing housing in L2 and M2 Type gearcase housings. Pinion Bearing Removal Failure to follow this procedure will result in Remove pinion bearing retaining screw.

  • Page 305: Shift Housing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Pinion Bearing Installation Position new O-ring on the pinion bearing retain- ing screw. Apply Gasket Sealing Compound to O- Assemble the following compone nts of Pinion ring. Apply Nut Lock to screw thre ads. Install the Bearing Remover and Inst aller, P/N 5005927, a s screw and tighten to a torque of 60 to 84 in.
  • Page 306 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Push the pin out of the clutch dog . Remove all shifter detent as needed to help ease re moval of parts. parts. 006888 006890 1. Pin 1. Shift lever pin 2.
  • Page 307 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Shift Housing Assembly Thoroughly grease 25 needle bearings wit h Nee- dle Bearing grease and place in the bearing case. IMPORTANT: Clean and inspect all parts before beginning assembly procedures. Replace damaged parts.
  • Page 308 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro- shift cradle. Pull shifter dete nt back up to NEU- peller shaft.

  • Page 309: Driveshaft Bearing Housing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Driveshaft Bearing Housing Do not install the O-ring in the bear- NOTICE Service ing h ousing’s b ottom groove . The bot tom groove is an oil p assage. Gearcase dama ge The driveshaft bearing is not serviceable.

  • Page 310: Propeller Shaft Bearing Housing Service

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Propeller Shaft Bearing Housing Inspect th e b earing h ousing anode. Replace anode if it is reduced to two-thirds of original size. Service Tighten screws to a torque of 108 to 13 2 in . lbs. (12 to 15 N·m).
  • Page 311 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Bearing Installation OUNTER OTATION HOUSING Bearing Installation Tool: Oil, then install new bearings in bearing housing. • P/N 432401 – front bearing Place the lettered end of the bearing case on the •...

  • Page 312: Driveshaft Shimming

    GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing. If a ne w p inion gear is needed, NOTICE replace gear set before shimming. Use Seal Installation Tool to install new seals back to back in bearing housing.
  • Page 313 GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING Select collar, P/N 341440, and th e co rrect shim Check squareness of the be aring housing mount- gauge bar: ing surface by holding the shim gauge bar against • the pinion while rot ating just th e be aring ho us- “M2”: Shim gauge bar, P/N 349957 ing.

  • Page 314: Gearcase Assembly

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY GEARCASE 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 th e shift rod cover. Install water in take screens. Tighten screws to a torque of 60 to 84 in.

  • Page 315: Pinion Gear And Driveshaft Installation

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Apply Gasket Sealing Compound to the threads of “L2” T EARCASES the shift rod cover screws. Tighten the screws to a Apply Gasket Sealing Compound to both sid es of torque of 60 to 84 in. lbs. (7 to 9.5 N·m). a new shift rod cover gasket.
  • Page 316 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Using Drivesh aft Sea l Protector , P/N 318674, Lightly coat the thre ads of a new pinion nut with slide th e driveshaf t b earing ho using o nto the outboard lubricant. Use Pinion Nut Starting Tool, driveshaft and into position in the gearcase.

  • Page 317: Propeller Shaft Bearing Housing And Gear Installation - "L2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Pad handle of holde r to prevent damage to gear- Slide the gear a ssembly on to the propeller shaf t case. until it engages the pinion gear. 006843 1. Thrust bearing and thrust washer Lightly apply Triple Guard Grease to a new be ar- 006875 ing housing O-ring.

  • Page 318: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Propeller Shaft Bearing Housing gearcase. Alig n and level gearcase assembly in fixture as shown. Secure fixture to floor press. and Gear Installation – “M2” Type IMPORTANT: The propeller shaft bearing hous- ing on the “M2” type gear cases is PRE SSED into the gearcase housing.
  • Page 319 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Place bearing housing in gearcase. gearcase. Align and level gearcase assembly in fixture as shown. Secure fixture to floor press. 006846 Align ret aining holes in bearing housing with screw holes in gearcase . Thread Alignment Pins, P/N 354140, into gearcase.

  • Page 320: Final Assembly And Adjustment

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Apply Ultra Lock to threads and inst all two retain- ing screws. Tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m). 006835 1. Retainer screws Final Assembly and Adjustment To complete gearcase assembly, refer to: •...

  • Page 321: Gearcase - Counter Rotation

    GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY GEARCASE Install the threaded adaptor from th e puller kit on GEARCASE – COUNTER ROTATION to the propeller shaft until seated. DISASSEMBLY IMPORTANT: Counter rot ation (CR) gearcase s use unique components and require different ser- vice proce dures.

  • Page 322: Pinion Gear Removal And Driveshaft Servicing

    GEARCASE – COUNTER ROTATION GEARCASE HOUSING INSPECTION Remove propeller shaft, forward gear and bearing Use an app ropriate tool to apply downward pres- housing assembly from gearcase. sure on the dete nt wh ile pulling on the pro peller shaft assembly. Remove propeller shaft assembly from the gearcase.

  • Page 323: Shifter, Bearing And Seal Servicing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING SHIFTER, BEARING AND Remove the ge ar, thrust bearing, and thrust washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. IMPORTANT: The shift housing and bearing are serviced a s an assembly .
  • Page 324 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a sho p cloth to catch ball able tool. Once the detent is past the ball, remove and sp ring. Pull the shif ter de tent straig ht ou t of the tool and position detent to engage NEUTRAL.
  • Page 325 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Install a rms of shif t lever into de tent slot s. Align Coat thrust bearing and thrust washer with Needle the pivot holes and insert the retaining pin. Push Bearing grease. Place t he bearing on the ba ck of shifter detent down.

  • Page 326: Pinion Bearing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Slide the pro peller shaft onto the shif t shaft, align the hole in the sh aft with the h ole in the clutch dog, inst all the pin and then, a new cl utch dog retaining sp ring.
  • Page 327 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Assembly Push propeller shaft out of the bearing housing. Position the forward gear bearing housing assem- bly on a flat, level surface. (Mirror or glass can b e used.) Use depth gauge to measure distance from flange of housing to flat surface as shown.
  • Page 328 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Coat bearing surfaces of propeller shaft with gear- Use Spanner Wrench, P/N 4324 00, to tighten t he case lu bricant. Slide the prop eller housing onto gear assembly t o a torque o f 10 0 f t. lbs. (1 36 the propeller shaft.

  • Page 329: Driveshaft Shimming

    GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar: • “M2”: Shim gauge bar, P/N 349957 Slide the collar o nto the driveshaft with large en d If a new pinion gear is needed, NOTICE in contact with the bearing housing.
  • Page 330 GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Check squareness of the bearing housing mount- Remove the driveshaft from the tool and add the ing surface by holding the shim gauge bar against required shims be tween the b earing housing a nd the pinion while ro tating just the b earing h ous- the thrust washer.

  • Page 331: Gearcase Assembly

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Cover Refer to Shift Rod Housi ng I nstallation on Water Intake Screens p. 312 Install water in take screens. Tighten screws to a Pinion Gear and Driveshaft torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Installation Refer to Pinion Gear and Driveshaft Installation on p.

  • Page 332: Final Assembly And Adjustment

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Align ret aining holes in bearing housing with Housing must be completely sea ted in gea rcase screw holes in gearcase . Thread Alignment Pins, to inst all ret ainer screws. Bearing housing P/N 354140, into gearcase. approximately level with gearcase.
  • Page 333 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............332 SYSTEM DESCRIPTION .

  • Page 334: Service Chart

    TRIM AND TILT SERVICE CHART SERVICE CHART 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 58-87 Ft. lbs. 84-108 In. lbs. (79-118 N·m) (9.5-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-70 Ft. lbs. (81-95 N·m) DO NOT OVER TIGHTEN 45-55 In.

  • Page 335: System Description

    TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket and Tilt Support The power tr im/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in th e tilted position . This bracket The system consists of: protects the hydraulic system from damage.

  • Page 336: Modes Of Operation

    TRIM AND TILT MODES OF OPERATION MODES OF OPERATION The trim/tilt hydraulic assembly achieves trim and tilt moveme nt through the following mod es 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 337: Tilt-Down / Trim-In Mode

    TRIM AND TILT MODES OF OPERATION Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, t he trim/tilt motor rot ates 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 mechanically opens the UP check valve.

  • Page 338: Impact Relief

    TRIM AND TILT MODES OF OPERATION Impact Relief Should the gearcase hit an underwater object and the ou tboard suddenly tilts u p, th e t ilt cylinder extends. The fluid abo ve the piston is co m- pressed, producing high pressure. This h igh pressure f luid p asses th rough the impact relie f valves in t he tilt piston, dissipating much of the energy of the impact.

  • Page 339: Shallow Water Drive Tilt Relief

    TRIM AND TILT MODES OF OPERATION Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water d rive mode (tilted up be yond the trim range ), increase d pressure ben eath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.

  • Page 340: Manual Release - Up

    TRIM AND TILT MODES OF OPERATION Manual Release – UP The outboard can be positio ned manually by fir st opening (loosening) the manual release valve. Open the manu al relea se valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring.

  • Page 341: Manual Release - Down

    TRIM AND TILT MODES OF OPERATION Manual Release – DOWN When the manual release valve is opened and the outboard is ma nually tilted do wn or trimmed in, fluid f lows f rom th e botto m of the tilt cylinder ( in the tilt range), or from the bottom of all of the cylin- ders (in the t rim range), and p ast the manu al release valve.

  • Page 342: Routine Inspections

    TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General If the power trim/tilt system has malfunctioned and the cause h as not been d etermined, th e Symp- Check for exte rnal signs of fluid leakage. Correct toms Chart on p. 341 should help locate the causes as necessary.

  • Page 343: Symptoms Chart

    TRIM AND TILT TROUBLESHOOTING If th e outboa rd does not tilt as hig h as it should, STEP 3 and the tilt mot or TURNS OF F at maximum tilt Go to TILT/TRIM RELA Y TEST on p. 105 to (does not sound like it is st alled at the maximum determine if problem is power supply.
  • Page 344 TRIM AND TILT TROUBLESHOOTING • bypass the reservoir cap. These steps will relieve The “B” adapter, P/N 336659, checks operation the pressure in the unit. of the DOWN circuit. 41739 27340 1. Manual release valve 1. A Adapter 2. Reservoir cap 2.
  • Page 345 TRIM AND TILT TROUBLESHOOTING all rods mu st be complete ly e xtended to check Remove the manual release valve. Inst all pres- fluid level. sure gauge and a dapter “B” to check pr oblems in the DOWN circuit. Cycle the unit down and several times to p urge a ir.

  • Page 346: Electrical Circuit Tests

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS ELECTRICAL CIRCUIT Connect a 0 to 100 A DC ammete r in series between the ba ttery side of the st arter 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 347: Trim And Tilt Motor No Load Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS C. Normal current draw, slow operating The motor shaft must rotate clockwise, as viewe d speed – Check for: from the pump end, when positive (+) is applied to • the blu e le ad, a nd ne gative (– ) is connected to Manual release valve damaged green lead.

  • Page 348: Trim Gauge Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim Gauge Test Trim Sender Test IMPORTANT: STEP 1 To avoid immedia te me ter dam- age, never apply a multimeter to an electrical cir- Turn key switch ON. Using a voltmeter , check for cuit where voltage is present.

  • Page 349: Trim And Tilt Replacement

    TRIM AND TILT TRIM AND TILT REPLACEMENT TRIM AND TILT Separate the trim/tilt unit wires in the braided tube to p ermit removal t hrough the hole in t he ste rn REPLACEMENT bracket. Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector.

  • Page 350: Installation

    TRIM AND TILT TRIM AND TILT REPLACEMENT Installation Use a punch to remove the upper pin. Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. Install external snap rings on lower pin with sharp edge of ring facing out.

  • Page 351: Trim And Tilt Service

    TRIM AND TILT TRIM AND TILT SERVICE TRIM AND TILT SERVICE Place trim/tilt wire s in b raided tu be a nd install through hole in the stern bracket. Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down mom entarily and loosen the reservoir cap one full turn.
  • Page 352 TRIM AND TILT TRIM AND TILT SERVICE Screw the man ual rele ase valve in. Remo ve the Remove the three Pozidriv sc rews securing the retaining ring using re taining ring pliers. Remove reservoir to cylinder body. Remove reservoir. the manual release valve.
  • Page 353 TRIM AND TILT TRIM AND TILT SERVICE Remove the four screws securing motor to pump solvent and inspect it for tears, clogging, or other manifold assembly. damage. 41760 41763 1. Coupler 2. Filter screen Remove the wire shield from the pump manifold. Remove the three Allen head screws securing the Remove the motor an d in spect t he motor O-ring pump manifold assembly to cylinder body.

  • Page 354: Tilt Piston Removal

    TRIM AND TILT TRIM AND TILT SERVICE Remove the ma nifold. Rem ove f ive O-rings fro m Slowly pull the piston out with a rag wrapped cylinder body. Check machined surfaces for nicks around the ro d and th e top of the cylinder . Drain and scratches.

  • Page 355: Tilt Piston Identification

    TRIM AND TILT TRIM AND TILT SERVICE Remove the washer . Slide t he tilt piston of f the Two of the piston relief holes are small, the oth er rod. Be careful not to lo se the springs, plunger s, two holes are larger.

  • Page 356: Tilt Rod Assembly

    TRIM AND TILT TRIM AND TILT SERVICE Use a screwdriver t o carefully pry the scraper out Use a wire brush to clean all thread-locking mate- of the end cap. Discard the scraper. Remove and rial from the threads on the tilt rod. discard the large outer O-ring.

  • Page 357: Trim Rod Removal

    TRIM AND TILT TRIM AND TILT SERVICE Trim Rod Removal Clean any thread -locking ma terial from the threads on the inside of the nu t. Spray threads of Unscrew trim cylin der end caps using T rim Cylin- with Locquic Primer and let dry . App ly a small der End Cap Remove r/Installer, P/N 43 6710, or amount of Nut Lock to the threads.

  • Page 358: Trim Rod Assembly

    TRIM AND TILT TRIM AND TILT SERVICE Drain th e re maining fluid from th e cylinder s. Remove the rod from the vise. Use a small screw- Inspect both bores of the trim cylin ders for exces- driver to carefully pry the scraper out of t he e nd sive scoring.

  • Page 359: Manifold And Reservoir Installation

    TRIM AND TILT TRIM AND TILT SERVICE Manifold and Reservoir Lubricate a nd inst all a new O-ring and two new back-up rin gs on the trim rod piston. Place o ne Installation back-up ring on each sid e of the O-ring. Position Lubricate five new manifo ld b ody O-rings.

  • Page 360: Trim Rod Installation

    TRIM AND TILT TRIM AND TILT SERVICE removed later for the Pressure Leak down Test Attach the reservoir to the cylinder body with three on p. 341. Pozidriv screws. Tighten the screws to a torque of 35 to 52 in. lbs. (4.0 to 5.9 N·m). 41851 41866 Install the re servoir f ilter screen in the cylin der...

  • Page 361: Tilt Rod Installation

    TRIM AND TILT TRIM AND TILT SERVICE P/N 912084. Tighten caps to a torque of 60 to 70 P/N 912084. Tighten cap to a torque of 58 to 87 ft. ft. lbs. (81 to 95 N·m). lbs. (79 to 118 N·m). 41868 41870 Tilt Rod Installation...
  • Page 362 TRIM AND TILT TRIM AND TILT SERVICE Install the filter screen. Fill the reservoir to the bottom of the fill hole with Power Trim/Tilt & Steering Fluid. Inst all a nd tighten the reservoir cap. Turn the manual release valve in until it sea ts. Cycle the unit up and down several times to purge air.
  • Page 363 TRIM AND TILT TRIM AND TILT SERVICE Check the tilt ro d bushings. Replace them if the y are worn excessively. 41888 Check the bushings on the bottom of the manifold body. Replace them if they are worn excessively. 41878 Check system operation in both trim and tilt range.
  • Page 364 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 365 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 366 S–2...

  • Page 367: 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 a ll shop technicians. Always follow common shop safety practices.

  • Page 368: 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 369: 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 370: 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;...
  • Page 371 SAFETY How can loss of steering control be minimized? • Use a steer ing syst em recommende d by th e outbo ard ma nufacturer which me ets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When •...

  • Page 372: 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? •...
  • Page 373 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 Sleeves, boots, shields •...
  • Page 374 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 375: 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 376 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 377: 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. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.

  • Page 378: 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 from the emergency stop / key switch.
  • Page 379 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 380: 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 381: 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: •...
  • Page 382 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 383 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 eng ine speed below 200 0 RPM. With no load, outboard will run too fa st very easily.
  • Page 384 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is lik ely t o result in s erious in jury or de ath. Ass ure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyon e near a propeller, even when th e engine is off.

  • Page 385: 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 386: 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 387: 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” It’s all on the back of the can or bottle label.

  • Page 388: 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 t ake resp onsibility for the safe mainte nance 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, precau tions, instructions and recommendations...
  • Page 389 INDEX INDEX Procedure 67 Abbreviations 6 Accessories Cable, Hose, and Wire Routing 18 I-Command Water Pressure Transducer Capacitor Test 84 Kit, P/N 5008300 24 Connecting Rods XD100 Outboard Oil Decal, P/N 352369 Installation on Crankshaft 235, 233 Orientation 233, 236 Adapter Housing 186 Removal from Crankshaft 223 Service 266...
  • Page 390 INDEX Description 60 AMP Connectors 123 Operation Test 81 Deutsch Connectors 122 Resistance Test 94 Packard Connectors 125 Cylinder Bore Electrical Harness Honing 227 Connections 21, 22, 23 Inspection 229 Pin Locations 91 Cylinder Head Emergency Stop Switch Inspection 228, 234 Operation Check 32 Removal 223 Test 104...
  • Page 391 INDEX Fuel Filter Water Pressure Gauge 24 Installation 144 I-Command Network Removal 144 Outboard connections 22 Fuel Injectors ICON Component Servicing Crush Ring Replacement 148 Electronic Servo Module (ESM) 199 EMM Programming 68, 147, 149 Shift Actuator 202 Installation 149 Throttle Actuator 204 ICON Network Removal 147...
  • Page 392 INDEX Lower Cover Removal 180 Installation 51 Oil Tank 164 Removal 51 Oiling Rate 67, 168 Lubrication Oiling System Engine Oil 164 Components 164 Gearcase 37, 288 Electrical Circuits 157, 164 Propeller Shaft 37 New Engine Set-Up 164 Swivel Bracket 36 Oil Distribution Hose Replacement 178, 41, Throttle and Shift Linkage 36, 39 59, 162, 167, 158, 159, 161, 67...
  • Page 393 INDEX Removal 300 Assembly 305, 322 Propeller Shaft Bearing Housing Installation 312, 329 Bearing Installation 309, 308 Removal 300 Installation 315 Shift Housing, Counter Rotation Rear Seal Installation 310, 308 Disassembly 321 Propeller Shaft Bearing Housing, Counter Removal 320 Rotation Shift Interrupt Switch 60 Shift Linkage Assembly 325...
  • Page 394 INDEX Removal 276 Lubrication 36 SystemCheck Removal 264 Circuits 105, 106 Timing Adjustments Oil System Warnings 166, 21 Timing Pointer 112, 113 Tests 106, 107, 108 Tools Winterization Procedure 44 Alignment Pins, P/N 354140 317, 330 Backing Plate, P/N 325867 299, 151, 309, 69 Collar, P/N 341440 311, 327, 122, 230, 123, Tachometer Pulse Setting 33...
  • Page 395 INDEX Circuits 105 Disassembly 349 Water Intake Screens 33 Electrical Circuit Tests 105 Inspection 33, 312, 329 Inspection 340, 348 Removal 301, 320 Lubrication 39 Water Pressure Gauge 24 Manifold and Reservoir Installation 357, 338 Water Pump Pressure Leakdown Test 341 Assembly 292 Removal 347, 340 Description 186, 292...
  • Page 396 INDEX I–8...
  • Page 397 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 398 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 399 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 400 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 and ELECTRICAL AND ground IGNITION Outboard starts and Check EMM LED indicators.
  • Page 401 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 402 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 408 Evinrude E-TEC EMM LED Diagnostic Indicators V Models In-line Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS in the Service Manual. KEY ON : LED’s illuminate to indicate circuit function Start assist circuit (SAC) OK (V models only) Sensors / 5V Circuits OK FLASHING LED –...
  • Page 409 FUSE 3.3 L V6 / 200-250HP E-TEC 1 2 3 1 2 3 4 5 1 2 3 4 5 1. Oil Injector J1-A 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor J1-B 6.
  • Page 411 FUSE 3.4 L V6 / 250-300HP E-TEC 1 2 3 1 2 3 4 5 1 2 3 4 5 1. Oil Injector J1-A 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor J1-B 6.
  • Page 413 EVINRUDE 115 – 300 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied. 1-6 Excessive knock detected CHECK ENGINE Immediate...
  • Page 414 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Last digit indicates affected cylinder. 51-6 Fuel injector circuit OPEN LED 2: ON (Running) 10 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C). CHECK ENGINE TPS <...

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