Page 1 † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. † ThreeBond is a registered trademark of ThreeBond International, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: ® Evinrude SystemCheck™...
Page 2: Table Of Contents
Service Manual Contents 1 Reference Information ......3 2 Routine Service ....... . 15 3 Engine Cover and Frame Service .
Page 3: Table Of Contents
Reference Information Reference Information Table of Contents Safety Notice ..............4 Abbreviations Used In This Manual .
Page 4: Safety Notice
Safety Notice Before working on any part of the outboard, read the SAFETY section at the end of this manual. This publication is written for qualified, factory- DO NOT perform any work until you have read trained technicians who are already familiar with and understood these instructions completely.
Page 5 DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propel- ler can continue to turn even after the engine is off.
Page 6: Abbreviations Used In This Manual
Reference Information Abbreviations Used In This Manual Abbreviations Used In This Manual Units of Measurement Dynamic Power Steering Amperes Electronic Throttle Body amp-hr Ampere hour Electronic Throttle Controller fl. oz. fluid ounce Exhaust Gas Temperature ft. lbs. foot pounds Engine Management Module horsepower Environmental Protection Agency inch...
Page 7: 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 any time, without notice, in specifications and Size In. Lbs. Ft. Lbs. N·m models and also to discontinue models. The right No.
Page 8: Emission-Related Installation Instructions
Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation- ship.
Page 9: Epa Emission Regulations
Reference Information Emission-Related Installation Instructions The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifica- tions. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.
Page 10: Model Designation
(A through Z). * An “A” prefix in the model number of an Evinrude E-TEC G2 indicates a Counter-Rotation model with Dynamic Power Steering (DPS). Model and serial numbers are located on the swivel bracket and on the powerhead.
Page 11: Models Covered
Reference Information Models Covered Models Covered This service manual covers information on the following Evinrude E-TEC G2, 210 cubic inch (3.4 L), 74° V6, models, starting with serial numbers: AB models, s/n 5410201 AF models, s/n 5421512 AG and newer models, s/n 5437485...
Page 12: Service Specifications
Reference Information Service Specifications Service Specifications 250 H.O. Engine 5400-6000 5400-6000 5400-6000 5400-6000 5400-6000 Full Throttle Operating Range 200 HP 225 HP 250 HP 250 HP 300 HP Power (147.1 kw) (165.5 kw) (183.9 kw) (183.9 kw) (220.6 kw) @ 5500 RPM @ 5500 RPM @ 5500 RPM @ 5750 RPM...
Page 13 Reference Information Service Specifications 250 H.O. Fuel / Oil System Fuel/Oil Ratio Controlled Starting Enrichment Controlled Preferred Fuel Regular unleaded gasoline Use unleaded regular gasoline. The use of unleaded gasoline containing alcohol above the percentage specified by government regulations is not recommended. Do Acceptable Fuel NOT use Fuel labeled "E85."...
Page 14 Reference Information Service Specifications 250 H.O. Ignition System Type Inductive Discharge Firing Order 1-2-3-4-5-6 Ignition Features Controlled RPM Limit (in gear) 6250 RPM Crankshaft Position Sensor Air Gap Fixed † Spark Plug Champion Q C 8 W E P I @ 0.028 ± 0.003 in. (0.71 mm) Gearcase Gear Ratio “SLX”...
Page 15 Routine Service Routine Service Table of Contents Inspection and Maintenance Schedule ..........16 Maintenance .
Page 16: Inspection And Maintenance Schedule
(3) Annually in salt water applications Engine Care Products The engine care products listed in the table below are referenced in this service manual, and are recom- mended for use with Evinrude E-TEC G2 outboards. HPF Pro Gearcase Lubricant Hydraulic Fluid, P/N 770891.
Page 17: Maintenance
Routine Service Maintenance Maintenance Check battery connections frequently. Periodically remove battery to clean and service connections. • Batteries Confirm that battery meets the minimum engine requirements. WARNING • Connections must be clean and tight. • Observe all wiring connections prior to disas- Battery electrolyte is acidic—handle with sembly.
Page 18: Oetiker Clamp Servicing
Routine Service Maintenance Oetiker Clamp Servicing Clamp Installation A constant stress should be applied to close the WARNING ear clamps. This method ensures a positive stress on the hose and does not result in excessive com- DO NOT re-use Oetiker clamps. Fuel leakage pression or expansion of the band material.
Page 19: Cooling System
Routine Service Maintenance • Cooling System Close clamp ear fully with Oetiker pincers (pli- ers). Check the condition of cooling system compo- nents regularly: • water intake screens • water pump • all internal water passages • thermostats • all external water hoses and fittings •...
Page 20: Propeller Shaft
Routine Service Maintenance Flushing — Outboard Running Propeller Shaft WARNING Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize To prevent injury from contact with rotating potential gearcase damage. propeller, remove the propeller before flush- ing.
Page 21 Routine Service Maintenance • Remove the low water intake screens. Then Lubricant level should be between the marks as shown. remove the lubricant drain/fill plug. Drain the lubri- cant from the gearcase into a suitable container. 1.5 in. (38 mm) Lubricant Level 009141 1.
Page 22: Spark Plugs
Routine Service Maintenance IMPORTANT: Spark Plugs The recommended gear lubricant is formulated for marine applications. Do not use Spark plugs should be removed and examined automotive gear lubricants, engine oils, or any oth- periodically. Replace worn, fouled or damaged er oil or grease. spark plugs.
Page 23: Fuel And Oil Systems
Routine Service Maintenance Installation Fuel and Oil Systems The cylinder heads of Evinrude E-TEC G2 models WARNING are manufactured with indexed spark plug threads. Q C 8 W E P I s p a r k p l u g s do NOT Failure to check for fuel leakage could allow a require indexing of the spark plug.
Page 24: Exhaust Pressure Fitting
Routine Service Maintenance Operation Test A serviceable oil filter is located in the oil supply line between the on-engine oil tank and rear oil Use the Evinrude Diagnostics software Monitor pump. screen to confirm: • barometric pressure reading; and • changes in exhaust pressure reading.
Page 25: Anti-Corrosion Protection
Routine Service Maintenance Cleaning WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa). Cleaning with Engine Tuner maintenance product can dissolve carbon build-up. Spray Engine Tuner through the fitting and allow it to soak for four to six hours.
Page 26: Storage
Internal Engine Treatment Remove the propeller, attach garden hose to flushing port and turn on water. Evinrude E-TEC G2 models are designed to be self-winterizing using one of the following meth- ods: Throttle Control Method 1. Winterization start button 009243 1.
Page 27 Routine Service Maintenance ICON Touch 7.0 CTS 356596-36 I-Command 3.5 inch Digital Gauge 008191 1. Menu/Settings 1. Menu button 2. Winterize Tab After the outboard shuts itself off, turn key switch OFF, then detach garden hose. IMPORTANT: When finished, leave the outboard in vertical position long enough to completely drain the powerhead.
Page 28: Pre-Season Service
Routine Service Lifting The Outboard Pre-Season Service Lifting The Outboard WARNING WARNING Failure to check for fuel leakage could allow a To avoid personal injury, make sure the lifting leak to go undetected, resulting in fire or capacity of the hoist is at least twice the explosion.
Page 29: Plug Installation
Routine Service Lifting The Outboard complete engine. The off-set lifting eye is used to Fasten appropriate chain hook to the centerline remove and install the powerhead. lifting eye of the tool. Lifting Fixture, P/N 357667 357667 1. Centerline lifting eye 009100 1.
Page 30: Rigging Information
Rigging related information in this section sup- ports re-installation after completing service pro- cedures. Use the current Evinrude E-TEC G2 Installation and Predelivery Guide for complete installation details if installing a new engine package. Rigging Center Evinrude E-TEC 74°...
Page 31 Routine Service Rigging Information Remove four screws from the cable entry cover. To remove the rigging hose retainer: Remove the rigging center covers. Turn the retainer 90° as shown. Pull to remove from the cable entryway. To remove the cap: Twist the cap one-quarter turn, then release the tabs from the inside of the cable entryway.
Page 32 Routine Service Rigging Information Rigging Center Hose and Cable Lengths Component inches 1. Starboard Steering Hose 10.5 2. Port Steering Hose 3. Battery Cables 21.5 4. NMEA 2000 Network 13.25 5. Control Network 6. Flush Hose 7. Remote Oil Tank Connector 8.
Page 33 Routine Service Rigging Information Hydraulic Steering Hoses Hydraulic Hose Connections Connect the PORT hydraulic hose from the helm WARNING to the PORT hydraulic steering fitting on the stern bracket. Tighten the nut by hand until fittings are Incorrect connection of hydraulic hoses will seated.
Page 34 Routine Service Rigging Information Connections To assemble the connectors: • Use the tabs to carefully align buss cable con- Also see Rigging Center Connections on the nectors. • Look at the tabs to ensure connector alignment next page. prior to making the connection. Do not rotate 1.
Page 35 Routine Service Rigging Information Rigging Center Connections Rigging Center 009118 1. Flexible Conduit 2. Starboard Steering Hose 3. Port Steering Hose 4. Positive (+)Battery Stud 5. Negative (–) Battery Stud 6. NMEA 2000 Network Cable 7. Remote Control Network Cable 8.
Page 36 Routine Service Rigging Information Water Pressure Connection Install the rigging hose to the entry port of the rig- ging center. Install the cover into place below the To send water pressure data to the EMM, along cable entryway. with an NMEA 2000 display, install 50 psi Water Pressure Transducer Kit, P/N 5008640.
Page 37 Routine Service Rigging Information Make sure the crimp of each Oetiker clamp is Install cover on cable entryway with four screws. positioned forward and cannot cut into or chafe Make sure cables are not pinched between cable any other cable or hose. entryway cover and housing.
Page 38: Before Start-Up
Routine Service Before Start-Up Before Start-Up Trim and Tilt Fluid Gearcase Lubricant CAUTION With outboard vertical, check the gearcase lubri- Correct fluid level must be maintained to cant level: ensure operation of the impact protection • Inspect the lubricant level in the lubricant reser- built into the unit.
Page 39: Operational Checks
Routine Service Operational Checks Operational Checks Remote Control Operation Make sure that control can be easily moved into DANGER all gear and throttle settings. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes Emergency Stop / Key Switch to accumulate in confined areas.
Page 40: Propellers
Routine Service Propellers SystemCheck — The SystemCheck monitor self- Break-In tests by sounding a half-second beep. System- Evinrude E-TEC outboards require no break in. Check gauges self-test by turning the indicator When the outboard is delivered, refer the cus- lights on simultaneously, then off in sequence. tomer to the Oiling System information in the Operator’s Guide.
Page 41 • Occasionally, one propeller will not cover a wide IMPORTANT: Evinrude E-TEC G2 outboards range of boat applications — water skiing to REQUIRE Propeller Hub Kit, P/N 767683, and Nut high speed performance boating. In such cases, &...
Page 42: Adjustments
Routine Service Adjustments Adjustments Install the anode and screw on the propeller shaft. Tighten the screw to 177 to 204 in. lbs. (20 to 23 N·m). An in the water test is required to make sure the outboard(s) and boat are rigged correctly, propel- ler selection is correct, and that all accessories function properly.
Page 43: Fuel System Vacuum
Trim & Tilt position or modifying the boat if the possibility for interference and damage exists. The trim and tilt functions of Evinrude E-TEC G2 outboards are controlled by the engine EMM. Manual Method IMPORTANT:...
Page 44: Trim Gauge Calibration
6.1 or higher to limit maximum tilt-up. 1. Calibrate Trim Sender 009237 i-Trim Evinrude E-TEC G2 outboards are equipped with 1. Set Tilt Limit 009143 i-Trim, an automatic trim-assist feature. By default, this feature is disabled from the factory.
Page 45: Dynamic Power Steering (Dps)
Refer to DPS System Calibration on p. 309. 1. DPS Assist 009237 Multiple Outboard Alignment Most Evinrude E-TEC G2 models are equipped with Dynamic Power Steering (DPS). DPS offers NOTICE three power steering assist levels. Multiple outboard installations using AFA and...
Page 46 Routine Service Adjustments Incorrect outboard alignment could cause one or combination of performance, steering, and cooling more of the following: is found. • Propeller ventilation A common practice is to set-up the outboards par- • Reduction of top speed allel, or with a small amount of “toe-out,” and •...
Page 47: Submerged Engines
Routine Service Submerged Engines Submerged Engines Prime oil system and fuel system. Refer to Fuel System Priming on p. 160 and Oil Supply Prim- ing on p. 196. Make sure all oil injection hoses are Once an outboard has been submerged it must be clean and filled with oil.
Page 48: Filling And Bleeding The Hydraulic Steering System
Routine Service Filling and Bleeding the Hydraulic Steering System Filling and Bleeding the Hydraulic Steering System Hydraulic Steering Fluid 4. Turn the steering wheel clockwise until engine is turned fully to STARBOARD and resistance WARNING is felt. Be sure to maintain fluid level at the helm/reservoir.
Page 49 Routine Service Filling and Bleeding the Hydraulic Steering System 6. Install the Steering Lock Tool, P/N 357717, to – Be sure to maintain fluid level at the hold engine in full PORT turn. helm/reservoir. Steering Lock Tool, P/N 357717 357717 1.
Page 50: Single Station / Multiple Engine Installations
Routine Service Filling and Bleeding the Hydraulic Steering System 12.Install the steering lock tool, P/N 357717, to Single Station / Multiple Engine hold engine in full STARBOARD turn. Installations Filling and bleeding multiple engine installations is similar to single engine installations. Follow the instructions starting on page 48 in this order: •...
Page 51 Routine Service Filling and Bleeding the Hydraulic Steering System Power Purge Method 4. Turn the steering wheel counter–clockwise until engine is turned fully to PORT and resis- A Teleflex Power Purge system can be used to tance is felt. bleed the steering system. Make sure the purging unit has the correct hydraulic fluid.
Page 52: Steering System Checks
Routine Service Filling and Bleeding the Hydraulic Steering System 8. Turn the steering wheel clockwise until engine 14.Install the fill cap on the helm, tighten securely. is turned fully to STARBOARD and resistance 15.Perform Steering System Checks. is felt. Steering System Checks 1.
Page 53 Routine Service Filling and Bleeding the Hydraulic Steering System • Measure and record the distance between the mark and the reference point. Mechanical Free Play Measurement 009427 1. Mark 2. Reference point object 3. Push against gearcase 4. Measurement • Use two fingers to push the gearcase to star- board.
Page 54: Oetiker Clamp Chart
Routine Service Filling and Bleeding the Hydraulic Steering System...
Page 55 Engine Cover and Frame Service Engine Cover and Frame Service Table of Contents Service Charts ..............56 Top Cover and Center Frame .
Page 56: Service Charts
Engine Cover and Frame Service Service Charts Service Charts Top Cover and Center Frame 88 to 106 In. lbs. (10 to 12 N·m) 62 to 79 In. lbs. 15 to 22 In. lbs. (7 to 9 N·m) (2 to 3 N·m) 18 to 30 In.
Page 57: Rear Cover, Starboard Cover And Starboard Frame
Engine Cover and Frame Service Service Charts Rear Cover, Starboard Cover and Starboard Frame 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In.
Page 58: Port Cover And Frame, Front Cover And Frame
Engine Cover and Frame Service Service Charts Port Cover and Frame, Front Cover and Frame 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In. lbs. (2 to 3 N·m) 18 to 30 In.
Page 59: Rigging Center
Engine Cover and Frame Service Service Charts Rigging Center 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 18 to 30 In. lbs. (2 to 3 N·m) 009315...
Page 60: Cover Removal
Engine Cover and Frame Service Cover Removal Cover Removal Lift up on rear latch to release Remove one screw at the top of the rear cover. Unscrew and remove the retainer. 1. Rear Latch 5008559_04 Remove the top cover. 1. Screw 5008559_06 2.
Page 61 Engine Cover and Frame Service Cover Removal Loosen the port and starboard side cover screws Remove the four front cover screws. one-quarter turn. Screws (enlarged to show detail) 5009420_03-10 Remove the front cover. Port Side Shown 5008559_08 (screws enlarged to show detail) Remove the side covers.
Page 62: Cover Installation
Engine Cover and Frame Service Cover Installation Cover Installation Install the port and starboard covers. Install the front cover. Install the upper screws first. Tighten the screws 18 to 30 in. lbs. (2 to 3 N·m). 5009420_03-10 Apply Silicone Spray, P/N 775630, onto a shop towel and liberally apply to the port and starboard 5009420_03-09 rubber seals.
Page 63 Engine Cover and Frame Service Cover Installation Install the rear cover. Install the top cover. 5008559_07 5008559_05 Install one screw at the top of the rear cover. Push down on the rear of the top cover to secure Tighten the screw 18 to 30 in. lbs. (2 to 3 N·m). the latch.
Page 64: Frame Removal
Engine Cover and Frame Service Frame Removal Frame Removal Starboard, Port, and Front Frame Disconnect the trim and tilt switch connector. Remove the two Deutsch connectors from their Removal protective caps. Use a #2 Posi-drive screwdriver to remove two self-tapping screws which retain the gearcase oil reservoir.
Page 65 Engine Cover and Frame Service Frame Removal Remove the four starboard exhaust housing cover Remove the six port frame screws. screws. 5008559_19 Remove the port frame and port exhaust housing cover. 5008559_17 Remove the starboard exhaust housing cover. 5008559_20 5008559_18...
Page 66 Engine Cover and Frame Service Frame Removal Remove the four port exhaust housing cover Remove the six front cover screws. screws. 5008559_23 5008559_21 Move the front cover away from the powerhead, Remove the port exhaust housing cover. Remove the rigging grommets from the front cover.
Page 67: Center Frame Removal
Engine Cover and Frame Service Frame Removal Center Frame Removal Remove the throttle body and upper oil fill tube clamps. Use a #2 Posi-drive screwdriver and remove the three center frame screws. 1. Throttle body camp 009173 2. Oil fill tube clamp 5008559_25 Remove the oil fill cap.
Page 68 Engine Cover and Frame Service Frame Removal Disconnect the starboard side electrical connectors and hoses: 1. Ignition coil connectors (3X) 009174 2. Vapor separator and fuel pump assembly connector (remove clip from fuel rail) 3. Positive battery cable 4. Vapor separator cooling hose 5.
Page 69 Engine Cover and Frame Service Frame Removal Disconnect the port side electrical connectors and hoses. 1. Starter ground cable 009175 2. Stator connector 3. Throttle body connector (remove throttle body assembly to access) 4. EMM cooling hose 5. Fuse box (remove from bracket - remove connector from back of box) 6.
Page 70 Engine Cover and Frame Service Frame Removal Disconnect the rear electrical connectors. 1. Cylinder oil pump connector 009176 2. Water valve connector 3. Crankshaft position sensor connector 4. Knock sensor connector (starboard)
Page 71: Frame Installation
Engine Cover and Frame Service Frame Installation Frame Installation Push the air duct inward to remove it from the center frame. Center Frame Installation Locate the center frame on the powerhead mounts. Align the air duct extension opening with the cen- ter frame opening.
Page 72 Engine Cover and Frame Service Frame Installation Install the oil fill hose to the center frame. Assemble all starboard side electrical connectors • and hoses. Refer to the Powerhead section for Secure with one 51.5 mm Oetiker clamp if oil fill starboard side reference views.
Page 73: Front, Port, And Starboard Frame Installation
Engine Cover and Frame Service Frame Installation Use a #2 Posi-drive screwdriver and install the Front, Port, and Starboard Frame center frame screws. Installation IMPORTANT: Turn self-tapping screws counter Place the frame on the front of the powerhead. clockwise to start the threads and clockwise to insert the rigging grommets in to the frame.
Page 74 Engine Cover and Frame Service Frame Installation Assemble the port exhaust housing cover. Install the port frame and lower port exhaust hous- ing cover to the outboard. Seat the frame into the groove of the exhaust grommet. 5008559_22 5008559_20 Tighten the four screws to a torque of 18 to 30 in. Tighten the six port frame screws to a torque of 18 lbs.
Page 75 Engine Cover and Frame Service Frame Installation Assemble the starboard lower exhaust cover to Connect the tilt and trim connector. Assemble the the Starboard frame. Tighten the four screws to a two Deutsch connectors to the bosses on inside of torque of 18 to 30 in.
Page 76 Engine Cover and Frame Service Frame Installation tighten. Failure to follow this procedure can dam- age the threads of the gearcase oil reservoir. Tighten the screws securely. 5008559_12A...
Page 77 Engine and Control Systems Engine and Control Systems Table of Contents Engine Management Module (EMM) ..........78 EMM Inputs and Outputs Diagram .
Page 78: Engine Management Module (Emm)
Engine and Control Systems Engine Management Module (EMM) Engine Management Make sure EMM connections are clean and tight. • Engine wire harness to EMM connectors; J1-A, Module (EMM) J1-B, J2, J3, J4. • Stator to EMM connections; one 6-pin AMP and The Engine Management Module (EMM) is a J2 connector.
Page 79: Emm Inputs And Outputs Diagram
Engine and Control Systems EMM Inputs and Outputs Diagram EMM Inputs and Outputs Diagram 009289...
Page 80: Engine Control Systems
Engine and Control Systems Engine Control Systems Engine Control Systems 55 V Circuit Sensor Monitors the EMM’s 55 V alternator circuit. Sensor inputs and internal EMM controllers are If system voltage exceeds 57 volts, the EMM: used to control the outboard’s engine operation. Activates S.A.F.E.
Page 81: Exhaust Pressure Sensor
Engine and Control Systems Engine Control Systems If the BP sensor reads less than 70 KPa, the If the AT sensor temperature value is below EMM: –22° F (–30° C), the EMM: Stores fault code 45 Stores fault code 48 Engine Monitor: TEMP display ON If the BP sensor reads greater than 105 KPa, the EMM:...
Page 82: Low Oil Level Switch
Engine and Control Systems Engine Control Systems If the cylinder head temperature exceeds 212° F After LOW OIL is displayed, the EMM counts oil (100° C) below 3500 RPM, the EMM: pump pulse cycles again. When it reaches 20,000 pulses, the EMM: Activates S.A.F.E.
Page 83: Crankshaft Position Sensor
Engine and Control Systems Engine Control Systems Crankshaft Position Sensor Internal EMM Functions Ribs spaced on the flywheel mark crankshaft posi- ROM Verification tion. As the ribs pass the magnetic field of the CPS, an AC voltage signal is generated. The The EMM performs a self-test of programming EMM uses this signal to identify crankshaft posi- every time it is turned ON.
Page 84: Rpm Limiter
Engine and Control Systems Throttle, Shift and Steering Control Systems RPM Limiter Throttle, Shift and Steer- This feature of EMM programming prevents ing Control Systems engine damage due to excessive RPM. At 6250 RPM, fuel and ignition to the cylinders is Shift and throttle information is transmitted and shut off.
Page 85 Engine and Control Systems Throttle, Shift and Steering Control Systems The EMM monitors the TPS connections and volt- If signal from TPS A and TPS B are lost, the ages on the remote control network. EMM: Activates S.A.F.E. If communication from co-processor to processor Stores fault code 175 is lost for more than 250 milliseconds, the EMM: Engine Monitor: CHECK ENGINE display ON...
Page 86: Electronic Shift Controller
Engine and Control Systems Throttle, Shift and Steering Control Systems The EMM monitors how much effort is required to If the SPS voltage is greater than 4.75 V, the move the throttle plate. When the 20ms duty cycle EMM: sum is greater than 5500, the throttle plate Activates S.A.F.E.
Page 87 Engine and Control Systems Throttle, Shift and Steering Control Systems The EMM monitors shift calibration. If the FOR- WARD or REVERSE calibration exceeds the lim- its saved in the EMM, the EMM: Activates SHUTDOWN Stores fault code 199 Engine Monitor: CHECK ENGINE display ON The EMM monitors the ESC driver current.
Page 88: Engine Monitor System
For information about the Evinrude E-TEC welcome screen, followed by boat mounted Information Display System options, the tachometer display. refer to the current Evinrude E-TEC G2 Installa- tion and Predelivery Guide. Note: The warning horn does NOT sound in an I-Command installation.
Page 89: Warning System
Engine and Control Systems Warning System Warning System Activation When one of these conditions occurs, the EMM S.A.F.E. interrupts fuel injector and ignition operation, reducing engine speed to 1200 RPM. The warning The S.A.F.E. (Speed Adjusting Failsafe Electron- horn sounds and an Engine Monitor message dis- ics) warning system alerts the operator and pro- plays.
Page 90: Diagnostic Software Functions
Communication Shutdown related to code 29 and 31: • Engine will NOT restart until the EMM and/or Evinrude E-TEC G2 models communicate diag- engine temperature to return to normal. nostic information over the NMEA 2000 network. • Correct the cooling problem.
Page 91 Engine and Control Systems Diagnostic Software Functions Identification Faults and Fault Codes The Identification screen displays the engine An abnormal condition that occurs is known as a model and serial numbers as well as other manu- fault. There are three types of faults: facturing information.
Page 92 Engine and Control Systems Diagnostic Software Functions Occurred Faults that runs for two hours of outboard operation, above 2000 RPM. The Occurred Faults screen displays the code number, the number of times the event occurred, and operating hours of first and last occurrences. Settings Screen 009243 1.
Page 93 Engine and Control Systems Diagnostic Software Functions Tests Dynamic Tests Dynamic tests are performed with the outboard The Tests screen displays both static and dynamic running. tests. The appropriate buttons are active depend- ing on whether the outboard is running or not run- ning.
Page 94 Engine and Control Systems Diagnostic Software Functions Fuel Injector Servicing History and Reports All E-TEC fuel injectors use software program- Engine history and reports provide service records ming to compensate for variations in fuel flow. and can be used to document the running history Each injector and its location on the outboard is of an outboard.
Page 95 Engine and Control Systems Diagnostic Software Functions Software Various management software is loaded into the EMM at the factory. Periodically, a new program may be available to enhance the operation of an outboard. Select from: • Update EMM to update engine management software •...
Page 96: Emm Servicing
Engine and Control Systems EMM Servicing EMM Servicing IMPORTANT: If a new EMM is being installed, refer to Software on p. 95. Removal Removal and installation of the EMM requires removal of the engine covers and frames. • See Engine Cover and Frame Service on p. 55. After covers and frames are removed from the engine continue with the procedure on the next page.
Page 97 Engine and Control Systems EMM Servicing Remove EMM mounting screws (2X). Rotate EMM away from frame as shown. These two screws do not require removal. Disconnect J1-A, J1-B, J2, J3 and J4 connectors from EMM.
Page 98 Engine and Control Systems EMM Servicing Remove EMM from frame. Installation Align slots in bottom side of EMM case with isolator mounts on the frame. Slide EMM into position. Install J1-A, J1-B, and J2, J3, and J4 connectors.
Page 99 Engine and Control Systems EMM Servicing Install two EMM retaining screws. Tighten screws 12 to 16 in. lbs. (1.5 to 2 N·m). Install exhaust pressure hose and water cooling hoses. Secure each hose with one 15.7 mm Oetiker clamp, P/N 346786. After the EMM is installed onto the center frame, install of the frames and engine covers.
Page 100 Engine and Control Systems Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 101 System Analysis System Analysis Table of Contents Diagnostic Procedures ............102 Visual Inspections .
Page 102: Diagnostic Procedures
System Analysis Diagnostic Procedures Diagnostic Procedures The Active Faults screen displays fault codes that currently exist. An active fault becomes an occurred fault only if the outboard is running. Visual Inspections Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals.
Page 103: Operational Inspections
System Analysis Diagnostic Procedures • • Check the RPM Profile for long periods of low Press Open Exports Folder to view saved speed operation or periods of over-revving rpm. reports. • Press Show Selected Report to view a report selected from the Engine History Records List. RPM Profile 009290 •...
Page 104: Troubleshooting
System Analysis Diagnostic Procedures Data Logging Outboard runs, low on power, misfires: • Use the Evinrude Diagnostics software Monitor Run the outboard in the water at all speeds. Be screen to check system (55 V) and TPS volt- sure to run at any report problem engine speeds ages.
Page 105: Static Tests
System Analysis Static Tests Static Tests Results: No spark on one or more cylinders: Ignition System Static Test • Inspect or replace spark plugs • Refer to Ignition Circuit Tests on p. 123 Perform the static ignition test using Evinrude •...
Page 106: Oil System Static Tests
System Analysis Static Tests Fuel Injector Static Test Oil System Static Tests Use the Evinrude Diagnostics software Fuel Injec- Crankcase Oil Pump Static Test tor Static Test to activate each fuel injector. Listen for an audible click from each injector when it is IMPORTANT: Static tests operate the oil pumps actuated.
Page 107: Cylinder Drop Tests
System Analysis Static Tests Cylinder Oil Pump Static Test Dynamic Power Steering (DPS) The EMM controls the pump by providing ground Use the Power Steering screen of Evinrude Diag- through pin 10 (blue/orange wire) of the J3 con- nostics software to observe DPS system reactions nector and pin B (blue/orange wire) of the oil while turning the steering wheel.
Page 108: 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 software Dynamic Tests to momentarily disable one cylinder while Evinrude Diagnostics software allows temporary...
Page 109 Electrical and Ignition Electrical and Ignition Table of Contents Service Charts ............. . . 110 Electrical Harness Connections .
Page 110: Service Charts
Electrical and Ignition Service Charts Service Charts Modules and Sensors 12 to 18 in. lbs. 84 to 106 in. lbs. 12 to 18 in. lbs. (2 to 3 N·m) (10 to 12 N·m) (2 to 3 N·m) 18 to 30 in. lbs. (2 to 3 N·m) 18 to 30 in.
Page 111 Electrical and Ignition Service Charts Electrical and Ignition 140 to 160 Ft. lbs. (190 to 217 N·m) 15 to 17 Ft. lbs. (20 to 23 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 24 to 36 In. lbs. (3 to 4 N·m) 84 to 106 In.
Page 112: Electrical Harness Connections
Electrical and Ignition Electrical Harness Connections Electrical Harness Con- EMM J1-A Connector nections Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
Page 113 Electrical and Ignition Electrical Harness Connections EMM J1-B Connector EMM J2 Connector 004046 001876 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 3 Purple Injector, cylinder 5 Green Fused B+ (12V) Red/Purple Isolated B+ Red/Black Trim UP signal to trim relay Blue/White Battery ground Black...
Page 114 Electrical and Ignition Electrical Harness Connections EMM J3 Connector EMM J4 Connector 3011784 3011161 Description of Circuit Wire Color Description of Circuit Wire Color CAN low (NMEA 2000) Dark Blue empty CAN high (NMEA 2000) White empty CAN low (remote control network) Dark Blue empty CAN high (remote control network)
Page 115: Ground Circuits
Electrical and Ignition Ground Circuits Ground Circuits Fuses All ground circuits are essential to reliable out- The engine harness circuits are protected by auto- board performance. Make sure all ground connec- motive style minifuses and relays. tions are clean and tight. Refer to wiring diagrams A fuse panel is located on the port side of the for specific wiring details.
Page 116: Sensor And Circuit Tests
Electrical and Ignition Sensor and Circuit Tests Sensor and Circuit Tests Air Temperature Sensor Circuit Test NOTICE Remove the electrical connector from the air tem- Use appropriate test leads or adapters such perature sensor. as Test Probe Kit, P/N 342677, when perform- Use a digital multimeter with appropriate test ing electrical tests.
Page 117: Crankshaft Position Sensor (Cps) Operation Test
Electrical and Ignition Sensor and Circuit Tests Crankshaft Position Sensor (CPS) CPS Circuit Test Operation Test Remove the electrical connector from the CPS. Use the Evinrude Diagnostics software CPS Sync Use a digital multimeter with appropriate test and engine RPM displays to confirm a valid CPS probe leads to measure sensor circuit resistance.
Page 118: Engine Temperature Sensor Test
Electrical and Ignition Sensor and Circuit Tests Engine Temperature Sensor Test Exhaust Temperature Sensor (EGT) Test Remove the electrical connector from the engine temperature sensor. Remove the electrical connector from the air tem- perature sensor. Use a digital multimeter with appropriate test probe leads to measure sensor resistance.
Page 119: Knock Sensor Test
Electrical and Ignition Sensor and Circuit Tests Isolate the faulty component. Check wiring and connections. Repair or replace faulty wiring. Knock Sensor Test There are no tests for the knock sensor. If Evin- rude Diagnostics reports Fault Code 7 or 8, replace with a new sensor.
Page 120: Ignition System
Electrical and Ignition Ignition System Ignition System Crankshaft Position Sensor • Provides EMM with input. • Outboard cranking speed exceeds 75 RPM and DANGER a steady CPS signal is generated. The electrical system presents a serious shock hazard. Allow outboard to sit for two Alternator Output/System Voltage minutes after running before handling capaci- •...
Page 121: Ignition System Circuit Diagram
Electrical and Ignition Ignition System Ignition System Circuit Diagram 1. Ignition Coils 2. EMM 3. 55V Circuit 4. Capacitor 5. Grounds (Negative) 6. Crankshaft Position Sensor 7. Stator 8. Remote Control Private Network (Stop Circuit) 9. Main Harness Grounds 009330...
Page 122: Wiring Inspection
Electrical and Ignition Ignition System Wiring Inspection Use the Evinrude Diagnostics software Monitor screen to check system voltage. Visually inspect all wiring, connections, and grounds. Use a digital ohmmeter to test resistance on all ground circuits and connections. Ohmmeter read- ings should be approximately 0.0 Ω.
Page 123: Ignition Coil Tests
Electrical and Ignition Ignition System revolution. The strobe of the timing light should be • The secondary spark plug lead provides conti- the same for each cylinder. nuity. If all of the above tests are good, and a cylinder does not have spark, replace the ignition coil with a known good coil.
Page 124 Electrical and Ignition Ignition System Connect the negative meter lead to the red/white the negative meter lead to engine ground. Turn wire of a known good circuit such as a fuel injec- the key switch to the ON position. tor. Ignition 55V Circuit Resistance Wire Result...
Page 125: Stator Tests
Electrical and Ignition Stator Tests Stator Tests Use an appropriate adapter to connect the meter leads to the following pins of the stator connector: NOTICE Stator Winding Resistance Wire Result Use appropriate test leads or adapters such 0.512 ± 0.020 Ω as Test Probe Kit, P/N 342677, when perform- YELLOW ing electrical tests.
Page 126 Electrical and Ignition Charging System Tests • Charging System Tests 62 VAC at 300 RPM The charging system provides 12 VDC for battery charging. Alternator total output, or GROSS out- put is: • 10 A at 500 RPM • 50 A from 2000 RPM to WOT. Charging system available output to the battery, or NET output is shown in the following graph: 1.
Page 127: Charging System Tests
Electrical and Ignition Charging System Tests Connect an inductive amp meter to the positive tery down at a rate equivalent to the stator’s full (B+) battery cable at the battery. output. • The ammeter should indicate nearly full output, approximately 40 A (or 20 A if the auxiliary bat- tery charge is installed).
Page 128 Electrical and Ignition Charging System Tests 55 V Alternator Circuit Check battery ground cable for continuity. With the key switch ON, check battery voltage at battery (12 V). Then, use Electrical Test Probe Kit, P/N 342677, and a digital multimeter set to read 55 VDC to check voltage on white/red wires at an ignition coil or fuel injector electrical connector.
Page 129: Electric Start Circuit
Electrical and Ignition Electric Start Circuit Electric Start Circuit Start Circuit Diagram 1. Negative Battery Cable 2. Main Harness Grounds 3. Positive Battery Cable 4. Red Wire: 12 Volts to EMM & Fuse Panel 5. Red/Purple Wire: Fused B+ 6. Fuse (Starter Solenoid) 7.
Page 130: Start Circuit Operation
Solenoid activation through the start switch, and • Provides 12 V from the HELM fuse (terminal EMM. 2B) to the remote control. Refer to the Evinrude E-TEC G2 Installation and Black wire: Predelivery Guide for battery, terminal, and cable • Provides HELM ground.
Page 131: Electric Starter Tests
Electrical and Ignition Electric Starter Tests Electric Starter Tests • Less than recorded battery voltage: Check posi- tive and negative cable connections at the starter, center frame and at the battery. WARNING Connect the positive meter lead to the start (S) To prevent accidental starting of outboard, terminal on the starter.
Page 132: Tilt/Trim Relay Test
Electrical and Ignition Tilt/Trim Relay Test STEP 3: Connect positive (+) lead to starter sole- Tilt/Trim Relay Test noid terminal. Connect negative (–) lead to oppo- site starter solenoid terminal. The tilt and trim (TNT) module contains the cir- • Activate the starter motor and record the volt- cuitry and relays required for power trim and tilt age reading.
Page 133: Flywheel And Stator Servicing
Electrical and Ignition Flywheel and Stator Servicing Flywheel and Stator Ser- Test Procedure vicing Make sure red and black wires are connected to 12 V battery power supply. NOTICE Set voltmeter to 12 VDC scale. Connect test leads to terminals “A” and “B” of TNT motor connector. Perform the timing verification procedure after flywheel replacement.
Page 134 Electrical and Ignition Flywheel and Stator Servicing Use Flywheel Socket, P/N 357715, to remove fly- attach the flywheel puller to the flywheel with three wheel nut. Discard the flywheel nut. puller screws. 1. Flywheel Socket, P/N 357717 009334 Flywheel Puller, P/N 357714 009335 1.
Page 135: Ignition Coil Servicing
Electrical and Ignition Ignition Coil Servicing Ignition Coil Servicing Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry. Ignition Coil Removal Remove spark plug lead from the spark plug. Disconnect ignition coil electrical connector. Remove the screw and washer retaining the igni- tion coil bracket.
Page 136: Timing Adjustments
Electrical and Ignition Timing Adjustments Timing Adjustments Use Flywheel Nut Socket, P/N 357715, to rotate the flywheel clockwise past the 28° ATDC mark on the flywheel. NOTICE Make sure the timing pointer is set and the outboard reaches operating temperature BEFORE making any timing adjustments.
Page 137 Electrical and Ignition Timing Adjustments 2. Record the degrees ATDC on the flywheel 6. With the piston against the tool, adjust the directly across from the pointer. pointer to read the result from Step 5. 7. – Rotate the flywheel counterclockwise until the piston contacts the tool.
Page 138: Timing Verification
Electrical and Ignition Electric Starter Servicing Timing Verification Electric Starter Servicing Use Evinrude Diagnostics software to synchronize Starter Removal the mechanical timing of the outboard with the IMPORTANT: Do not clean the starter drive electronic timing of the EMM. while the starter motor and drive are installed on Start the outboard.
Page 139: Connector Servicing
Electrical and Ignition Connector Servicing Connector Servicing Starter Installation Install the ground cable to the starter housing. DEUTSCH Connectors Tighten the screw to a torque of 60 to 84 in. lbs. IMPORTANT: Dielectric Grease, P/N 503243 is (7 to 10 N·m). recommended.
Page 140 Electrical and Ignition Connector Servicing Release terminal latch and gently pull on wire. wire securely. Do not solder. Crimp insulation in 14/16-gauge notch of crimping pliers. 1. Terminal latch (receptacle) 423293 2. Terminal latch (plug) 1. End of wire strands DRC6205 2.
Page 141 Electrical and Ignition Connector Servicing use Primary Lock Tool, P/N 777077, to release Align locking device with connector housing and locking tab of connector housing. Release locking terminals. Secondary Lock Installer, tab and pull on wire to remove from connector P/N 777079, to seat device in connector.
Page 142 Electrical and Ignition Connector Servicing Terminal Removal Connect Open lock mechanism and remove terminal from Push connector until seated in plug. Close latch connector housing. completely. 1. Latch 002453 1. J2 connector 002120 2. Lock mechanism 2. Latch (closed) Terminal Installation Terminal Removal Push terminal through seal until it is seated in con- Use Terminal Release Tool, P/N 351413, to...
Page 143 Electrical and Ignition Connector Servicing Terminal Installation ing the tab and then pushing the terminal and wire through connector housing. Align terminal with connector housing and push terminal with seal into connector housing until Insert a thin tool into the connector above the ter- seated.
Page 144 Electrical and Ignition Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 145 Fuel System Fuel System Table of Contents Service Charts ............. . . 146 Reed Plate Assembly and Throttle Body .
Page 146: Service Charts
Fuel System Service Charts Service Charts Reed Plate Assembly and Throttle Body 84 to 106 In. lbs. (10 to 12 N·m) 35 to 60 In. lbs. (4 to 6 N·m) Start at center and use a spiral torque pattern 84 to 106 In. lbs. (10 to 12 N·m) 35 to 60 In.
Page 147: Fuel Pump And Vapor Separator, Fuel Filter And Fuel Rails Aba & Afa Models
Fuel System Service Charts Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails ABA & AFA Models 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) Hand tighten until seal contacts filter housing.
Page 148: Fuel Pump And Vapor Separator, Fuel Filter And Fuel Rails Aga & Newer Models
Fuel System Service Charts Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails AGA & Newer Models Late Models Early Models 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In.
Page 149: Fuel Injectors
Fuel System Service Charts Fuel Injectors Tighten in 3 stages 84 to 106 In. lbs. (10 to 12 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 120 In. lbs. (14 N·m) 24 to 26 Ft. lbs. (33 to 35 N·m) A, X Triple-Guard Grease Outboard Engine Lubricant...
Page 150: Fuel System Flow Diagram (Ab, Af Models)
Fuel System Fuel System Flow Diagram (AB, AF Models) Fuel System Flow Diagram (AB, AF Models) Fuel Supply Fuel Return Fuel Vapor 009278 Fuel supply from boat fuel system Fuel injector(s) Inline fuel filter (250 micron) Fuel return rail (red connector) Fuel pump/vapor separator assembly Fuel return filter Internal passage...
Page 151: Fuel System Flow Diagram (Ag & Newer)
Fuel System Fuel System Flow Diagram (AG & Newer) Fuel System Flow Diagram (AG & Newer) Fuel Supply Fuel Return Fuel Vapor Crankcase Pulse 009585 Fuel supply from boat fuel system Electric fuel circulation pump Inline fuel filter (250 micron) Fuel supply rail (green connector) Fuel lift pump (crankcase pulse) Fuel injector(s)
Page 152: Fuel System Circuit Diagram
Fuel System Fuel System Circuit Diagram Fuel System Circuit Diagram Injectors 55 V circuit (white/red) Capacitor Grounds (neg) Fuel Injector grounds Fuel pump/vapor separator Fuel level float Electric fuel lift pump High pressure fuel pump Fuel filter/water separator Fuel vapor vent solenoid 009279...
Page 153: Fuel System Requirements
Fuel System Fuel System Requirements Fuel System Requirements Regulations and Guidelines Fuel Flow Requirements Vessel manufacturer, and/or installer of an EPA 200 – 300 HP certified outboard, must meet minimum specifica- Fuel tank pickup 3/8 in. (9.5 mm) tions for boat fuel systems established by: tube;...
Page 154: Fuel Requirements
Fuel System Fuel System Requirements Fuel Requirements alcohol in gasoline exceeds the current govern- ment regulation limits. WARNING Use in North America Gasoline is extremely flammable and highly NOTICE explosive under certain conditions. Improper handling of fuel could result in property dam- Do NOT use fuel from fuel pumps labeled age, serious injury or death.
Page 155: Components
Fuel System Components Components The fuel system includes the following compo- • Electric fuel circulation pump nents: • composite turbine impeller pump • • Mechanical Fuel Lift Pump runs 100% duty cycle (AGA & newer models only) • Filter (fuel return rail fitting) •...
Page 156 Fuel System Components System Priming on p. 160). The fuel pump runs separator self-drains when the outboard is stored continuously during engine operation. vertically. 1. Fuel lift pump 009185 1. Fuel reservoir 009185 2. Cooling passage The EMM monitors the fuel pump electrical circuit. Pressure Regulators •...
Page 157 Fuel System Components sure regulator. The pressure regulator maintains Fuel Vapor Venting approximately 24 to 34 psi (165 to 234 kPa) of fuel The fuel vapor vent solenoid regulates fuel level in pressure to the fuel injectors in the high pressure the reservoir.
Page 158: Fuel Filters
Fuel System Components Fuel Level Fuel Filters The fuel level in the reservoir is regulated by the Fuel filters protect the fuel lift pump, vapor separa- fuel vapor vent solenoid. tor and the high-pressure components of the fuel system from contaminants. A 250 micron inline filter and a 10 micron water separating fuel filter are installed.
Page 159: Fuel Injectors
Fuel System Components The fuel return rails can be identified by the red grammed for this injector’s unique fuel flow locking device on each connector fitting. characteristics. NOTICE Fuel injectors MUST NOT be moved from one cylinder to another. EMM programming is associated with the cylinder location of each injector.
Page 160: Fuel System Priming
NOT be installed on Evinrude E-TEC WARNING G2 models. Protect against hazardous fuel spray. Before Evinrude E-TEC G2 models are equipped with an starting any fuel system service, carefully electric fuel lift pump. The electric fuel lift pump relieve fuel system pressure.
Page 161 Fuel System Fuel System Tests Make sure the pickup is attached to only one wire. Mechanical Fuel Pump Pressure Test Flashes on the timing light indicate current in the Remove the Oetiker clamp at the vapor separator circuit is being switched by the EMM. The inlet.
Page 162 Fuel System Fuel System Tests • Prime the fuel system and check for leaks. START Check fuel flow through fuel lift pump. Use fuel primer bulb to force fuel through pump. the outboard and run at idle speed. Hold the fuel pressure gauge level with the fuel inlet fitting and No pressure monitor the gauge for pressure reading.
Page 163 Fuel System Fuel System Tests Non-Running Outboard Temporarily install a vacuum gauge, T-fitting, and 8 in. (20.3 cm) of clear vinyl hose between the fuel If the outboard does not run, turn the key switch to supply hose and fuel lift pump (inlet). Secure con- the ON position to prime the fuel system.
Page 164: Fuel System Electrical Tests
Fuel System Fuel System Tests Anti-Siphon Valve Test Fuel System Electrical Tests Remove anti-siphon valve from fuel tank. Install NOTICE adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve. Use appropriate test leads or adapters such as Test Probe Kit, P/N 342677, when perform- ing electrical tests.
Page 165 Fuel System Fuel System Tests Vapor Vent Solenoid Circuit Test Electric Fuel Lift Pump Resistance Test Remove the electrical connector from the vapor Disconnect the battery cables at the battery. vent solenoid. Remove the electrical connector from the fuel pump and vapor separator assembly. Use the diode test function of a digital multimeter with appropriate test probe leads to check the sig- Use a digital multimeter with appropriate test...
Page 166 Fuel System Fuel System Tests Use a digital multimeter to measure the resistance Connect the negative meter lead to the wire listed of the fuel pump and vapor separator assembly in the table, connect the positive meter lead to electrical connector and engine ground. engine ground.
Page 167 Fuel System Fuel System Tests Isolate the faulty component. Check wiring and Fuel Injector Circuit Test connections. Repair or replace faulty wiring. Remove the electrical connector from the fuel injector. Use a digital multimeter with appropriate test probe leads to measure the resistance of the fuel Use the diode test function of a digital multimeter level switch ground circuit.
Page 168: Fuel Component Servicing
Fuel System Fuel Component Servicing Fuel Component Servicing Use the Tests screen of Evinrude Diagnostic soft- WARNING ware v 6.1 or higher. Select the Vapor Separator Gasoline is extremely flammable and highly button to activate the fuel vapor vent solenoid. explosive under certain conditions.
Page 169: Mechanical Fuel Lift Pump Service
Fuel System Fuel Component Servicing Water Separating Fuel Filter Inline Fuel Filter IMPORTANT: Replace the water separating fuel Removal filter when replacing a vapor separator. Removal Install hose pinching pliers on the short hose between the fuel filter bracket to the vapor separa- tor assembly.
Page 170: Vapor Separator Service
Fuel System Fuel Component Servicing Disconnect the fuel lift pump pulse hoses at the Removal crankcase fittings. WARNING When servicing the fuel system, always shift the outboard to NEUTRAL position, turn the key switch OFF and remove the key, so the outboard cannot be started accidentally.
Page 171 Fuel System Fuel Component Servicing • separator. A full assembly can hold over 32 oz. upper & lower water cooling hoses. • (1 L) of fuel. vapor separator vent outlet hose. • fuel inlet hose from the boat fuel supply hose. •...
Page 172: Fuel Rail Service
Fuel System Fuel Component Servicing • Install the following hoses with new Oetiker fuel inlet hose at the rigging center clamps: • inlet hose from inline fuel filter • outlet hose from fuel lift pump • inlet hose from water separating fuel filter 1.
Page 173 Fuel System Fuel Component Servicing device and push to unlock the quick connector fit- Use a #2 Posi-drive screwdriver to remove the tings. three screws retaining the center frame to the frame mounts. Remove the center frame. Refer to Engine Cover and Frame Service on p.
Page 174: Fuel Injector Service
Fuel System Fuel Component Servicing Installation tighten. Failure to follow this procedure can dam- age the threads of the center frame mounts. WARNING Next, install the front frame. After servicing the fuel system check for leaks. Failure to check for fuel leakage could Connect the battery cables at the battery.
Page 175 Fuel System Fuel Component Servicing nozzle port in cylinder head to prevent contamina- 3. TOP injector: remove the lower screw com- pletely, then loosen the upper screw several tion of combustion chamber. turns (do NOT remove upper screw). Removal 4. Remove the upper screw from the TOP injec- tor.
Page 176 Fuel System Fuel Component Servicing To separate the injectors: Align the angled edges of both sides of the tool • base with the edge of the fuel injector housing as Carefully pull each injector to separate it from the fuel tubes. shown.
Page 177 Fuel System Fuel Component Servicing Turn the puller nut until the fuel injector is Installation of a replacement injector requires that removed from the fuel injector housing. coefficient data for the new injector is uploaded to the EMM. Coefficient data can be downloaded from the Evinrude dealer website.
Page 178 Fuel System Fuel Component Servicing Select the Open button. • Install new o-rings on the fuel fitting, each fuel tube and the plug fitting. • Apply 2-stroke outboard oil to the o-rings. • Install the fuel fitting in the top injector. •...
Page 179 Fuel System Fuel Component Servicing grease. Install washers (one per screw) on injec- • Final torque is 24 to 26 ft. lbs. (33 to 35 N·m). tor retaining screws. Tighten Screws in Stages 009214 002316 Install fuel rails. Refer to Fuel Rail Service on Install screws and washers through mounting p.
Page 180: Throttle Valve Service
Fuel System Fuel Component Servicing Throttle Valve Service Install the front frame. Then install the port and starboard frames. Removal Install the engine front, top cover and rear covers. Disconnect the battery cables at the battery. Install the port and starboard side panels. Refer to Engine Cover and Frame Service on p.
Page 181 Fuel System Fuel Component Servicing Remove the: Remove the tie straps and oil recirculation hoses • from the reed plate assembly. center frame spacers and mounts from the ple- num. • Oetiker clamp from the vapor solenoid vent hose, then remove the vent hose from the ple- num.
Page 182 Fuel System Fuel Component Servicing Remove the reed valve retainer screws and Assembly remove the assembly. Remove old adhesive from reed valve retaining screws. Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate and install screws.
Page 183 Install the rigging housing with four retaining screws. Install the port and starboard frames. Connect all cables and hoses at the engine. Refer to the Evinrude E-TEC G2 Installation and Pre- delivery Guide. Install the engine front, top cover and rear covers. 1. 18 retaining screws 009190 Install the port and starboard side panels.
Page 184 Fuel System Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 185 Oiling System Oiling System Table of Contents Service Charts ............. . . 186 Oil Tank Assembly .
Page 186: Service Charts
Oiling System Service Charts Service Charts Oil Tank Assembly 15 to 22 In. lbs. (2 to 3 N·m) 15 to 22 In. lbs. (2 to 3 N·m) 60 to 84 In. lbs. (7 to 9 N·m) 15 to 17 Ft. lbs. (20 to 23 N·m) 6 to 8 Ft.
Page 187: Cylinder Oil Pump Assembly
Oiling System Service Charts Cylinder Oil Pump Assembly 35 to 60 In. lbs. (4 to 6 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 009250...
Page 188: Oiling System Circuit Diagram
Oiling System Oiling System Circuit Diagram Oiling System Circuit Diagram 009247 Stator Cylinder Oil Pump Cylinder Oil Pump control (BLUE/ORANGE) Capacitor LOW Oil Switch 55 V Circuit (WHITE/RED) LOW OIL Signal (TAN/WHITE) Grounds, NEG (BLACK) Oil Level Sender Crankcase Oil Pump Oil Level Signal (PINK) Crankcase Oil Pump control (BLUE) Remote Oil Pump Electrical Connector...
Page 189: Oil Recirculation Diagram
Oiling System Oil Recirculation Diagram Oil Recirculation Diagram Complete View 009248 Oil inlet fitting upper main bearing Check valve out (reed plate #2 cylinder) Check valve out (reed plate #4 cylinder) Oil inlet fitting to lower main bearing Oil outlet fitting from lower main bearing Check valve out (reed plate #6 cylinder) to lower main bearing Check valve from area in inside plenum to lower main bearing Check valve out (reed plate #5 cylinder) to lower main bearing...
Page 190: Oil Supply Diagrams
Oiling System Oil Supply Diagrams Oil Supply Diagrams 200, 225, 250 HP, 250 H.O., 300 HP Models - Starboard Oil fill cap Remote oil fill hose Oil tank vent hose Oil tank assembly Crankcase oil pump LOW Oil switch Oil level sender Crankcase oil distribution hoses Crankcase oil fittings Oil hose assembly...
Page 191: 200, 225, 250 Hp, 250 H.o., 300 Hp Models - Rear
Oiling System Oil Supply Diagrams 200, 225, 250 HP, 250 H.O., 300 HP Models - Rear Oil tank assembly Oil hose assembly (to cylinder oil pump) Oil filter Cylinder oil pump Cylinder oil distribution hoses Cylinder oil fittings 009252...
Page 192: Oil Requirements
Oil Tank Assembly Evinrude XD100, or XD50 outboard oils are rec- ommended for use in Evinrude E-TEC G2 out- The oil tank is located on the starboard side of the boards. If these oils are not available, use a TC- engine and the oil level must be monitored.
Page 193: Crankcase Oil Pump
Oiling System Components Crankcase Oil Pump oil tank through a hose and filter assembly and supplies pressurized oil to the oil manifold. The crankcase oil pump is an electric actuator style pump. The EMM supplies 55 V and controls activation of the pump. The pump draws oil from the oil tank and supplies pressurized oil to the oil manifold.
Page 194: Low Oil Switch
Oiling System Components LOW OIL Switch Cylinder and Crankcase An oil level switch in the oil tank assembly moni- The crankcase oil manifold provides crankcase tors the oil level in the oil tank. lubrication through oil distribution hoses and pressed-in fittings at the front of the crankcase, starboard side.
Page 195: Oil Recirculation System
Oiling System Break-In Oiling Break-In Oiling Oil Recirculation System External hoses fittings, internal cylin- NOTICE der/crankcase passages, and intake manifold pas- The operator must monitor the oil tank level sages are used to recirculate any accumulation of to confirm oil consumption. This may require oil from various locations in the powerhead.
Page 196: Oil Supply Priming
The following procedures require running tests that are per- formed with the outboard’s motor cover removed. The oil system of Evinrude E-TEC G2 outboards is primed at the factory. Priming the oiling system is only required if: •...
Page 197 Oiling System Oil Supply Priming 5. Inspect for air bubbles in the crankcase oil dis- 7. Inspect for air bubbles in the cylinder oil distri- tribution hoses. bution hoses. – If air bubbles ARE present, proceed to – If air bubbles ARE present, proceed to step 6.
Page 198: Oiling System Tests
Oiling System Oiling System Tests Oiling System Tests IMPORTANT: Always perform visual inspections Use an appropriate test probe lead to connect to identify oiling system leaks. Make sure the oil positive meter lead to pin B (blue wire) of oil pump tank is filled and oil supply is not contaminated.
Page 199 Oiling System Oiling System Tests Check the control signal while the Oil Injector test Cylinder Oil Pump is running. Set the digital multimeter to the fre- The EMM controls the pump by providing ground quency setting or the Hertz (Hz) scale. through pin 10 (blue/orange wire) of the J3 con- •...
Page 200: Oil Pump Circuit Tests
Oiling System Oiling System Tests Use the Cylinder Pump function of Evinrude Diag- • The voltage at pin A should be approximately nostic software Tests screen to activate the oil 55 V. pump. Results: • If voltage at pin A is within range, refer to Oil Pump Resistance Test on p.
Page 201: Oil Pump Resistance Test
Oiling System Oiling System Tests the negative meter lead to the red/white wire of a Oil Pump Signal Circuit (Diode Test) known good circuit such as a fuel injector. Wire Result BLUE (Crankcase Oil Pump) approximately 0.5 VDC BLUE/ORANGE (Cylinder Oil Pump) Results: ∞...
Page 202: Oil Pump Function Test
Oiling System Oiling System Tests Oil Pump Function Test Oil Fittings Flow Test Remove oil distribution hose from oil manifold. Make sure the oil fittings of the cylinder and crank- Refer to Oil Distribution Hoses on p. 204. Tem- case assembly allow fluid to move. porarily install a length of oil hose, P/N 778708.
Page 203: Oil Level Sender Resistance Test
Oiling System Oiling System Tests Connect the positive meter lead to the engine har- • A reading of zero (0) indicates an short circuit. ness connector wire listed in the table. Connect Isolate the faulty component. Check wiring and the negative meter lead to engine ground. connections.
Page 204: Oil Component Servicing
Oiling System Oil Component Servicing Oil Component Servicing After the hose is removed from the manifold, make sure hose support is in the end of the hose. WARNING To prevent accidental starting while servic- ing, disconnect the battery cables at the bat- tery.
Page 205: Oil Tank Servicing
Oiling System Oil Component Servicing Oil Tank Servicing Remove the nuts retaining the oil tank. Then remove the oil tank from its mounting studs. ENVIRONMENTAL NOTE Dispose of used oil or oil contaminated towels in an environmentally responsible manner, or according to local regulations.
Page 206: Crankcase Oil Pump
Oiling System Oil Component Servicing Crankcase Oil Pump Installation Apply a drop of outboard lubricant to a new oil ENVIRONMENTAL NOTE pump o-ring. Install o-ring on oil pump flange. Dispose of used oil or oil contaminated towels in an environmentally responsible manner, or according to local regulations.
Page 207: Cylinder Oil Pump
Oiling System Oil Component Servicing Cylinder Oil Pump Remove the oil pump assembly. IMPORTANT: The cylinder oil pump and mani- ENVIRONMENTAL NOTE fold is an assembly and cannot be serviced as in- Dispose of used oil or oil contaminated towels in dividual components.
Page 208 Oiling System Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 209 Cooling System Cooling System Table of Contents Water Flow and Hose Routing Diagrams ......... 210 Water Flow .
Page 210: Water Flow And Hose Routing Diagrams
Cooling System Water Flow and Hose Routing Diagrams Water Flow and Hose Routing Diagrams Water Flow Refer to the water flow diagram on the next page, or in the Diagrams section of this manual. Cooling water (1) flows from the gearcase water inlet screens to the water pump (2). From the water pump, cooling water flows through a water tube (3) inside the exhaust housing (4) to the exhaust adapter (5).
Page 211 Cooling System Water Flow and Hose Routing Diagrams 1 21 Incoming water (cool) Circulating water (warm) Outgoing water (warm/hot) 009737...
Page 212: Cooling Hose Routing Diagram - Port
Cooling System Water Flow and Hose Routing Diagrams Cooling Hose Routing Diagram - Port Cooling Hose Diagrams Water supply from filter to EMM, vapor separator, DPS module & exhaust cooling Water supply to EMM & vapor separator Water to exhaust cooling (Non-DPS models) Water to DPS module &...
Page 213: Cooling Hose Routing Diagram - Starboard
Cooling System Water Flow and Hose Routing Diagrams Cooling Hose Routing Diagram - Starboard Water from EMM, to vapor separator Vapor separator Water from block vents Water from EMM, vapor separator and block vents to overboard indicator Water from thermostats to exhaust adapter Water from thermostats to exhaust adapter (lower hose) Water from exhaust adapter (rear) to...
Page 214: Cooling Hose Routing Diagram - Rear
Cooling System Water Flow and Hose Routing Diagrams Cooling Hose Routing Diagram - Rear Water from thermostats to exhaust adapter Water from cylinder heads to pressure relief valve Water from exhaust adapter (rear) to exhaust housing Water from block vents Water from EMM &...
Page 215: Cooling Hose Routing Diagram - Top
Cooling System Water Flow and Hose Routing Diagrams Cooling Hose Routing Diagram - Top Water supply from filter to EMM, vapor separator and DPS module Water supply to EMM & vapor separator Water to exhaust cooling (Non-DPS models) Water to DPS module & exhaust cooling Water from EMM to vapor separator Block vent Water from EMM &...
Page 216: Components
Cooling System Components Components Water Supply Tube The water pump outlet connects with a water tube Water Pump and Intakes and hose assembly located in the outboard’s mid- section. O-rings seal the water tube to the water External water intakes mounted in the gearcase pump housing.
Page 217: Thermostats
Cooling System Operation Operation Overcooling: Debris may prevent the valve from closing completely. All models use a two-stage cooling system Plunger design. The cooling system is dependent on water pump pressure and controlled by thermostat and pressure valve operation. NOTICE Restricted or inadequate water flow through the outboard reduces cooling system perfor- mance and may lead to severe powerhead...
Page 218: Emm And Vapor Separator Cooling
Cooling System Engine Temperature Check Engine At low speed, the pressure valve is closed and the thermostats regulate water to flow to maintain a temperature of approximately 143°F (62°C). Temperature Check Water from the thermostat flows out of the cylinder heads through a hose, to the exhaust adapter, IMPORTANT: The engine temperatures listed in...
Page 219: Software Method
Cooling System Engine Temperature Check Software Method Measure temperature at the top of cylinder block, next to the thermostat housing and cylinder head. Use the Monitor screen of Evinrude Diagnostics Check temperature on both sides of powerhead. software v 6.1 or higher, to read temperature dis- plays.
Page 220 Cooling System Engine Temperature Check Start the outboard and check IDLE operating tem- Thermostats perature. Remove thermostat cover(s) and inspect thermo- stat(s). If IDLE temperature is too low, pinch off the water hose from the cylinder heads to the pressure relief valve.
Page 221: Component Servicing
Cooling System Component Servicing Component SLOWLY tighten temperature sensor to a torque of 12 to 18 in. lbs. (1.35 to 2.0 N·m). Wait 10 min- utes for trapped air to bleed from cavity. Thermal Servicing compound may seep past threads. Re tighten sensor.
Page 222: Pressure Relief Valve Servicing
Cooling System Component Servicing Assembly tighten the cover to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m). Assembly is the reverse of disassembly. Pay close attention when performing the following Pressure Relief Valve Servicing additional tasks. Install valve on powerhead.
Page 223 Evinrude ICON II Remote Control System Evinrude ICON II Remote Control System Table of Contents Components ..............224 ICON II Remote Control .
Page 224: Components
Evinrude ICON II Remote Control System Components Components The ICON II remote control system includes the following components: • • ICON II remote control(s) Up to four Evinrude E-TEC G2 74° V6 out- • boards Remote control (private) network • NMEA 2000 network START 12.5 –...
Page 225: Remote Control (Private) Network
The network may include back- bone buss cables, backbone extension cables, one or more 6-port hubs, or accessories. Refer to the Evinrude E-TEC G2 Installation and Prede- livery Guide. NMEA 2000 Network For safety, the remote control data is also shared on a NMEA 2000 network as backup.
Page 226: Throttle Valve Assembly
Evinrude ICON II Remote Control System System Settings and Diagnostics System Settings Throttle Valve Assembly The electronic throttle body assembly converts and Diagnostics electronic signals sent from the Electronic Throttle Controller (ETC) in the EMM into the mechanical motion required to move the throttle plate. Use Evinrude Diagnostic software, v 6.1 or higher to communicate with the remote control.
Page 227 Evinrude ICON II Remote Control System System Settings and Diagnostics Manual Instancing Method board #3. Connect the private network cable to outboard #4. Then press the STOP button for WARNING outboard #4. Do NOT vary from this procedure. 7. After setting the instance on the last outboard, Pressing any other button on the remote con- turn the key switch OFF.
Page 228 Evinrude ICON II Remote Control System System Settings and Diagnostics 3. Select the Identification screen and note the 6. Then select the engine’s transom position from model number and serial number of the out- the available Engine Selection list. board. Engine Option Configuration 009237 Identification Screen...
Page 229: Remote Control Configuration
Evinrude ICON II Remote Control System System Settings and Diagnostics Remote Control Configuration Remote Control Identity Select the Config button to make remote control Select the Identification button to view identifica- configurations changes or calibrate the remote tion information. control lever(s). After making setting selections, be sure to press the Save Changes button.
Page 230: Remote Control Monitor
Evinrude ICON II Remote Control System System Settings and Diagnostics Remote Control Monitor ICON II System NEUTRAL Idle Mode The following conditions will cause the ICON II Select the Monitor button to view certain power system to enter NEUTRAL idle mode: faults and remote control functions.
Page 231: Icon Ii System Fault Detection
Evinrude ICON II Remote Control System ICON II System Fault Detection ICON II System Fault Detection Type Description Response Indication A conditional fault requiring remedial action to correct that does not affect normal Response based on condition operation. Condition Code or Warning - upon resolution the system will resume full performance.
Page 232 Evinrude ICON II Remote Control System Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 233 Powerhead Powerhead Table of Contents Service Charts ............. . . 234 Cylinder Head .
Page 234: Service Charts
Powerhead Service Charts Service Charts Cylinder Head 120 to 144 in. lbs. 47 to 49 ft. lbs. (14 to 15 N·m) (64 to 66 N·m) A, I, X 12 to 18 In. lbs. (1.4 to 2 N·m) 35 to 60 In. lbs. (4 to 6 N·m) 15 to 17 Ft.
Page 235: Crankshaft And Pistons
Powerhead Service Charts Crankshaft and Pistons H, X 63 to 69 Ft. lbs. (86 to 93 N·m) Gasket Sealing Compound Moly Lube Outboard Lubricant 009313 See Service Manual Procedure...
Page 236: Cylinder And Crankcase (Port, Starboard, Front)
Powerhead Service Charts Cylinder and Crankcase (Port, Starboard, Front) {1.} 11.5 to 13.5 Ft. lbs. (15.5 to 18.3 N·m) {2.} 28 to 30 Ft. lbs. (37.9 to 40.6 N·m) {3.} 41 to 43 to Ft. lbs. (55.5 to 58 N·m) 84 to 106 In.
Page 237: Cylinder And Crankcase (Bottom, Top, Rear)
Powerhead Service Charts Cylinder and Crankcase (Bottom, Top, Rear) 84 to 106 In. lbs. (10 to 12 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 15 to 17 Ft. lbs. (21 to 23 N·m) 20 to 22 Ft. lbs. (27 to 29 N·m) 35 to 60 In.
Page 238: Cylinder And Crankcase To Exhaust Adapter And Exhaust Housing
Powerhead Service Charts Cylinder and Crankcase to Exhaust Adapter and Exhaust Housing 22 to 24 ft. lbs. (30 to 32 N·m) 009272 See Service Manual Text...
Page 239: Compression Testing
Powerhead Compression Testing Compression Testing Procedure Start and run outboard until it achieves operating IMPORTANT: Before removing the powerhead temperature, then shut OFF. trim the engine to the vertical position. Disconnect crankshaft position sensor (CPS) con- nector. Remove all spark plugs. Install compression tester’s hose attachment into spark plug hole (14 mm threads).
Page 240 Powerhead Powerhead Removal Starboard Remove the following hose clamps and hoses: 6. Oil level sender (oil tank). 1. 51.5 mm clamp – Oil fill hose (upper), remove 7. Trim relay, three Amp connectors and two 2 the hose from the center (top) frame. ring terminals (1 ground on the block and 1 on the starter solenoid).
Page 241 Powerhead Powerhead Removal Port Remove the following hose clamps and hoses: Disconnect the electrical connectors from the fol- lowing: 1. 15.7 mm Tee fitting, hose from tee fitting to DPS module, remove the hose from the tee fit- 6. Exhaust temperature sensor ting.
Page 242 Powerhead Powerhead Removal Rear Remove the following hose clamps and hoses: 2. 15.7 mm Tee fitting, hose to overboard indica- tor, remove hose from tee fitting. 1. 10.5 mm Rear oil pump(s) hose(s), remove the supply hose from the oil pump. 009176...
Page 243 Powerhead Powerhead Removal Lifting the Powerhead Remove the 12 nuts and washers retaining the powerhead to the exhaust adapter and exhaust WARNING housing. To avoid personal injury, make sure the lifting On the port side, there are four nuts and washers capacity of the hoist is at least twice the on the exhaust adapter and four nuts and washers weight of the outboard.
Page 244: Powerhead Disassembly
Powerhead Powerhead Disassembly Powerhead Disas- teners or hose connections that may have been overlooked during the removal procedures. sembly Systems Removal To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the center frame, EMM and engine har- ness as an assembly.
Page 245: Crankcase Disassembly
Powerhead Powerhead Disassembly Crankcase Disassembly Carefully remove the crankcase from the cylinder block to avoid damaging the crankshaft seal rings. Remove crankcase flange screws. 009689 009668 Cylinder Head Removal Loosen in stages, and remove the main bearing screws and nuts. Loosen in stages and remove 8 cylinder head retaining nuts.
Page 246: Connecting Rods And Pistons
Powerhead Powerhead Disassembly Deck Cover Removal Use Torquing Socket, P/N 346187, to loosen in stages the rod cap retaining screws. DO NOT Remove 14 deck cover screws. remove the screws. 1. Deck cover screws 009733 000825 Remove the deck cover and gasket. Use one hand to support the piston, and remove the rod cap screws with your other hand.
Page 247: Crankshaft Removal
Powerhead Powerhead Disassembly Use an appropriate ring expander to remove all Crankshaft Removal piston rings from pistons. Discard the rings. WARNING WARNING Wear safety glasses to avoid injury. Wear safety glasses to avoid injury. Carefully lift crankshaft straight up and remove from crankcase.
Page 248 Powerhead Powerhead Disassembly Remove the lower bearing seal housing. Remove the O-ring from crankshaft sleeve and inspect it. Replace the O-ring if it is not in good condition. 1. Bearing retaining screws 009673 Remove the housing O-ring. Discard O-ring. 009674 Inspect the crankshaft sleeve and replace if nec- essary.
Page 249: Powerhead Studs
Powerhead Powerhead Disassembly Remove and inspect crankcase seal rings. Iden- If a stud remover/installer tool is not available, two tify each ring for installation in its original location. powerhead retaining nuts can be used for an alter- native method of removal. Install a powerhead retaining nut fully onto the stud.
Page 250: Cylinder Block Cleaning
Powerhead Cylinder Block Cleaning Install studs into the block to the dimensions Cylinder Block Cleaning shown: IMPORTANT: Before inspecting or assembling powerhead, all internal components must be com- pletely clean and free of contaminants. Remove any carbon accumulation from exhaust port areas.
Page 251: Powerhead Inspection
Powerhead Powerhead Inspection Powerhead Inspection Use Gel Seal and Gasket Remover to remove all traces of gaskets, adhesives, and Threebond sealant from the cylinder block and crankcase. For dimensions, refer to Service Specifications on p. 12. WARNING Before any inspection process can begin, all inter- To avoid personal injury, wear eye protection nal components must be completely clean and and rubber gloves when using Gel Seal and...
Page 252 Powerhead Powerhead Inspection Crankshaft Cylinder Bore Measure the diameter of each crankpin and main Use a Cylinder Bore Gauge to inspect each cylin- bearing journal. The lower main bearing journal der bore for an out-of-round, oversize, or tapered would only be measured if the bearing was condition.
Page 253 Powerhead Powerhead Inspection Pistons Bearings Visually inspect pistons for signs of abnormal Inspect center main bearing and split sleeves for wear, scuffing, cracks, or burning. excess wear, nicks, or scratches. Replace if nec- essary. Piston Rings For new ring sets, place each ring separately in its respective bore.
Page 254: Powerhead Assembly
Powerhead Powerhead Assembly Powerhead Assembly The sleeve must contact the flange on the bottom of the crankshaft. Use a small soft-faced mallet to gently tap the sleeve into place. IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called for.
Page 255 Powerhead Powerhead Assembly Lubricate the center main bearings and split Install a new o-ring on the lower housing. Apply a sleeves with outboard lubricant and install them in thin coat of Gasket Sealing Compound to the o- their original positions. The split sleeve ring ring.
Page 256: Pistons And Connecting Rods
Powerhead Powerhead Assembly Pistons and Connecting Rods Insert Bearing Installer, P/N 338646, into the con- necting rod. Remove the cardboard retainer as the tool is installed. NOTICE It is very important that the pistons in this engine are installed in the correct location and direction.
Page 257: Installing Pistons
Powerhead Powerhead Assembly Use Driver, P/N 396747, to install the wrist pin through the piston, pushing the bearing installer out through the piston. 1. Gap in retaining ring 009701 2. Notch in piston Installing Pistons 1. Driver, P/N 396747 009700 When all pistons and connecting rods are assem- Use Wrist Pin Cone, P/N 331913, and Driver, bled, install piston ring sets.
Page 258: Cylinder Head Installation
Powerhead Powerhead Assembly Slide piston and rod assembly into the correct cyl- Apply soapy water to water dams and insert into inder, as marked during disassembly. Guide con- block. necting rod through cylinder block to avoid scratching cylinder wall. 1. Water dams 009731 Apply a thin bead of RTV around each of the 009703...
Page 259: Deck Cover Installation
009726 Deck Cover Installation 009714 Install a new deck cover gasket, then install the IMPORTANT: Evinrude E-TEC G2 models use deck cover. Install 14 deck cover screws. Start in connecting rod bearing halves containing 9 needle...
Page 260 Powerhead Powerhead Assembly bearings each. Do NOT substitute earlier Evinrude Install rod cap screws finger tight (NO MORE than E-TEC connecting rod bearing halves which con- 6 in. lbs. (1 N·m) maximum). tain only 8 needle bearings each. 009716 1. G2 Connecting rod bearing half 009686 IMPORTANT: Be sure alignment dot on rod cap...
Page 261 Powerhead Powerhead Assembly est setting (two lines showing). Rotate adjustment • Tighten forcing screw until jaws contact con- knob 180° to lock the stop in position. necting rod. • Slide frame down until adjustment stop contacts the rod cap. The groove lines on the jaws must be centered on the rod/crankpin diameter.
Page 262: Crankcase Assembly
Powerhead Powerhead Assembly • A apply an even 1/8 inch (3 mm) bead of Three- Apply final torque of 60 to 65 ft. lbs. (81 to 88 bond 1217H sealant, P/N 768611, to the crank- N·m). case mating flange in the pattern shown below. The sealant must not come within 1/4 in.
Page 263: Final Powerhead Assembly
Powerhead Powerhead Assembly Install main bearing screws finger tight, no more Final Powerhead Assembly than 60 in. lbs. (7 N·m). Install the reed plate assemblies and plenum. Tighten main bearing screws in three stages: Refer to Intake Manifold Service on p. 180. •...
Page 264: Powerhead Installation
Powerhead Powerhead Installation Powerhead Installation Remove the replacement powerhead from the shipping container. Pre-Service Adjustments WARNING NOTICE To avoid personal injury, make sure the lifting capacity of the hoist is at least twice the After installing a new or rebuilt powerhead, weight of the outboard.
Page 265 Powerhead Powerhead Installation Apply a 1/4 in. (6 mm) bead of high-temperature Install the 12 washers and nuts to retain the pow- RTV, such as Permatex #26BR around the erhead to the exhaust adapter and exhaust hous- exhaust passage areas. ing.
Page 266 Powerhead Powerhead Installation Tighten the nuts in the sequence shown to a torque of 22 to 24 ft. lbs. (30 to 32 N·m). Torque Sequence 009235 Wait 5 minutes, then re-tighten the nuts. Use the same sequence and tighten to a torque of 22 to 24 ft.
Page 267 Powerhead Powerhead Installation Rear Install the following hoses and hose clamps: 2. Install the overboard indicator to the tee fitting, secure with a new 15.7 mm Oetiker clamp. 1. Install the supply hose to the oil pump, secure with a new 10.5 mm Oetiker clamp. 009176...
Page 268 Powerhead Powerhead Installation Port Install the following: 5. The thermostat hose to the exhaust adapter fit- ting, secure with a new 21.0 mm Oetiker 1. The DPS module and cooling hose assembly. clamp. Install the following hoses and hose clamps: 6.
Page 269 Powerhead Powerhead Installation Starboard Install the following: 6. The remote oil fill hose on to the oil tank, secure with a new 14.5 mm Oetiker clamp. 1. The oil tank. Install the three washers and retaining nuts on the oil tank. Tighten the nuts Connect the electrical connectors to the following: to a torque of 15 to 17 ft.
Page 270 Powerhead Powerhead Installation Install the rigging grommets on the powerhead Refer to Engine Cover and Frame Service on hoses and buss cables. p. 55. 1. Rigging grommets 009173 NOTICE Install plugs as indicated. Plugs MUST be installed to prevent water entry and/or engine performance issues.
Page 271: Powerhead Views
Powerhead Powerhead Views Powerhead Views Starboard 009375...
Page 272: Port - Non-Dps Models
Powerhead Powerhead Views Port – Non-DPS Models 009406...
Page 273: Port - Dps Models
Powerhead Powerhead Views Port – DPS Models 009374...
Page 274: Rear - 200, 225, 250 Hp Models
Powerhead Powerhead Views Rear – 200, 225, 250 HP Models 009407...
Page 275: Rear - 250 H.o., 300 Hp Models
Powerhead Powerhead Views Rear – 250 H.O., 300 HP Models 009376...
Page 276: Front - Frame Removed
Powerhead Powerhead Views Front – Frame Removed 009379...
Page 277: Front - Frame Installed
Powerhead Powerhead Views Front – Frame Installed 009378...
Page 278: Exhaust Water Valve
Powerhead Exhaust Water Valve Exhaust Water Valve Water Flow 1. Water Filter (Block Outlet) 2. Water Supply Hose to Exhaust Water Valve 3. Exhaust Water Valve 4. Water Tube and Fitting 5. Exhaust Water Fitting (Starboard) 6. Water Hose and Tee Fitting 7.
Page 279: Exhaust Water Valve Operation
Powerhead Exhaust Water Valve Exhaust Water Valve Operation water should flow from the hose while the test is running. During rapid acceleration, the EMM opens a valve that injects water into the exhaust. This water changes exhaust tuning, boosting midrange horsepower as the boat comes on plane.
Page 280: Water Valve Resistance Test
Powerhead Exhaust Water Valve Results: Use a digital multimeter with appropriate test probe leads to measure the resistance between ∞ • An infinite reading ( ) indicates an open circuit. the pins of the exhaust water valve connector. Isolate the faulty component. Check continuity of wiring and connections.
Page 281: Exhaust Water Valve Component Service
Powerhead Exhaust Water Valve Component Service Exhaust Water Valve Port: Remove the hose clamp from the exhaust water fitting. Remove the exhaust water fitting Component Service from the exhaust runner. Water Valve Remove the hose clamps from the water valve. Remove the two retaining screws from the bottom of the water valve, then remove the valve from the bracket.
Page 282 Powerhead Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 283 Exhaust Housing & Adapter Exhaust Housing & Adapter Table of Contents Service Charts ............. . . 284 Exhaust Housing .
Page 284: Service Charts
Exhaust Housing & Adapter Service Charts Service Charts Exhaust Housing 15 to 17 Ft. lbs. (20 to 23 N·m) 30 to 35 in. lbs. (3 to 4 N·m) 6 to 8 Ft. lbs. (8 to 10 N·m) 6 to 8 Ft. lbs. (8 to 10 N·m) 24 to 26 Ft.
Page 285: Adapter And Muffler
Exhaust Housing & Adapter Service Charts Adapter and Muffler 7 to 9 Ft. lbs. (9.5 to 12 N·m) 72 to 96 In. lbs. (8 to 11 N·m) 72 to 96 In. lbs. (8 to 11 N·m) 22 to 24 Ft. lbs. 18 to 20 Ft.
Page 286: Exhaust Housing Service
Exhaust Housing & Adapter Exhaust Housing Service Exhaust Housing Service Exhaust Housing Removal Cleaning and Inspection Before removing the exhaust housing, remove WARNING the: • Gearcase. Refer to Gearcase Removal starting Wear safety glasses to avoid personal injury, on p. 361. and set compressed air to less than 25 psi •...
Page 287: Exhaust Housing Installation
Exhaust Housing & Adapter Exhaust Housing Service Exhaust Housing Installation Remove one hose clamp and two tie straps. Then remove the hoses from the hose fittings. Align the exhaust housing and adapter onto the swivel bracket assembly. Next remove the muffler and hose from the exhaust pipe.
Page 288 Exhaust Housing & Adapter Exhaust Housing Service Lift the adapter and exhaust pipe from the exhaust Cooling Water Hose and Tube housing. Remove the hose clamps to service the hose and tube assembly. Installation is reverse of removal. If fitting is removed, apply Pipe Thread Sealant to the threads of the fitting.
Page 289: Exhaust Adapter Installation
Exhaust Housing & Adapter Exhaust Housing Service Exhaust Adapter Installation hoses onto the hose fittings. Secure with tie straps. Install the adapter and exhaust pipe into the exhaust housing. 1. Foam gasket 009343 2. Muffler 3. Hose clamp 4. Tie straps Install the two adapter screws.
Page 290: Exhaust Water Cooling Fitting
Exhaust Housing & Adapter Exhaust Housing Service Exhaust Water Cooling Fitting Correct indexing is achieved when one of the index marks is aligned with, or up to 30° past the Remove the hose clamp and cooling hose, then exhaust back pressure probe. remove the fitting.
Page 291: Upper Mount Service
Exhaust Housing & Adapter Exhaust Housing Service Upper Mount Service Remove the four screws and lower mount covers and inspect the lower mounts. Remove the exhaust housing and adapter from the swivel bracket. refer to Exhaust Housing Removal starting on p. 286. Remove the four screws from the upper mount plate, then remove the plate.
Page 292: Exhaust Relief Muffler Assembly
Exhaust Housing & Adapter Exhaust Housing Service Exhaust Relief Muffler Assembly The overboard indicator and flush port in the exhaust relief grommet connect to a water hose. The exhaust relief muffler is located at the rear of A tee-fitting distributes water to two hoses. One the adapter housing and concealed by the engine hose supplies flushing water to the vapor separa- covers and frames.
Page 293 Stern and Swivel Stern and Swivel Table of Contents Service Charts ............. . . 294 Stern &...
Page 294: Service Charts
Stern and Swivel Service Charts Service Charts Stern & Swivel 180 to 204 In. lbs. (20 to 23 N·m) 36 to 60 In. lbs. (4 to 6 N·m) 84 to 120 In. lbs. 84 In. lbs. (10 to 14 N·m) (10 N·m) 348 to 372 In.
Page 295: Spray Plate, Covers And Anode
Stern and Swivel Service Charts Spray Plate, Covers and Anode 84 to 120 In. lbs. (10 to 14 N·m) 15 to 23 Ft. lbs. (20 to 23 N·m) 84 to 106 In. lbs. (10 to 12 N·m) 15 to 23 Ft. lbs. (20 to 23 N·m) 36 to 60 In.
Page 296: Steering Arm, End Cap And Lower Bracket
Stern and Swivel Service Charts Steering Arm, End Cap and Lower Bracket 79 to 96 In. lbs. (9 to 10 N·m) 26 to 28 Ft. lbs. (36 to 38 N·m) 59 to 70 Ft. lbs. (80 to 94 N·m) 84 to 120 In. lbs. (10 to 14 N·m) 67 to 69 Ft.
Page 297: Stern & Swivel Bracket Attachments
Stern and Swivel Service Charts Stern & Swivel Bracket Attachments 22 to 30 in. lbs. (2.5 to 3 N·m) 18 to 24 in. lbs. 84 to 106 in. lbs. (2 to 2.7 N·m) (9.5 to 12 N·m) 84 to 106 in. lbs. (9.5 to 12 N·m) 36 to 60 in.
Page 298: Dps Manifold Assembly
Stern and Swivel Service Charts DPS Manifold Assembly 60 to 84 In. lbs. (7 to 10 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 84 to 108 In. lbs. (10 to 12 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 60 to 84 In.
Page 299: Dps Pressure Sensors
Stern and Swivel Service Charts DPS Pressure Sensors ABA Models (DPS-1) 144 to 168 In. lbs. (17 to 19 N·m) 84 to 108 In. lbs. (10 to 12 N·m) 144 to 168 In. lbs. AFA & Newer Models (DPS-2) (17 to 19 N·m) Red Ultra Lock 84 to 108 In.
Page 300: Trim & Tilt Manifold Assembly (Non-Dps Models)
Stern and Swivel Service Charts Trim & Tilt Manifold Assembly (Non-DPS Models) 60 to 84 In. lbs. (7 to 10 N·m) 22 to 30 In. lbs. (2.5 to 3 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 18 to 20 Ft.
Page 301: Dynamic Power Steering (Dps)
Stern and Swivel Dynamic Power Steering (DPS) Dynamic Power The helm pressure sensor signals the DPS mod- ule of an increase in hydraulic pressure in the direction of the turn. The DPS module then turns Steering (DPS) ON the DPS pump providing steering assistance. As the outboard approaches the steering system The DPS system consists of a hydraulic steering stop, the pump pressure sensor signals the DPS...
Page 302 Stern and Swivel Dynamic Power Steering (DPS) detects a pressure differential between the two pressure sensors and turns ON the DPS pump providing steering assistance. The DPS module also monitors the steering posi- tion sensor. As the outboard approaches the steering system stop, the DPS module turns OFF the DPS pump to maximize system efficiency.
Page 303: Dps Electrical Circuit Diagram
Stern and Swivel Dynamic Power Steering (DPS) DPS Electrical Circuit Diagram DPS – 2 SPLICE #9 BAT_GND 4X, AB SPLICE #43 21A, B, C DPS – 1 1. EMM 2. DPS Module 3. DPS Module to EMM Connections 4. Steering Position Sensor (DPS - 2 models only) 5.
Page 304: Dps System Tests
Stern and Swivel DPS System Tests DPS System Tests Connect the negative meter lead to engine ground. DPS Module Ground Circuit NOTICE Connector/ Wire Result Use appropriate test leads or adapters such Steering Position/ Black as Test Probe Kit, P/N 342677, when perform- Pressure Sensor 2 ing electrical tests.
Page 305: Steering Motor Circuits
Stern and Swivel DPS System Tests Steering Motor Circuits Connect the BLACK meter lead to the wire listed in the table, connect the RED meter lead to Use the diode test function of a digital multimeter engine ground. to check the steering motor circuit. DPS Module Sensor Circuits (Diode Test) Connector/Wire...
Page 306: Steering Position Sensor Test
Stern and Swivel Steering Position Sensor Service Steering Position Turn the steering wheel fully to PORT. While hold- ing the steering wheel against the stop, observe Port Pressure. Then turn the steering wheel fully Sensor Service to STARBOARD. While holding the steering wheel against the stop, observe Starboard Pressure.
Page 307: Dps Module Service
Stern and Swivel DPS Module Service IMPORTANT: Calibrate the DPS system after in- DPS Module Installation stalling the steering position sensor. Refer to DPS If installing the DPS module on an ABA engine System Calibration on p. 309. model, install the Connector and Seal Assembly, P/N 587328, on the steering position sensor con- DPS Module nector.
Page 308: Dps Software Installation
Stern and Swivel DPS Module Service Connect the electrical connectors to the DPS After the program connects to the network, select module. from the device list the Engine Controller (EMM). 1. Mounting screws 009393 1. Engine controller 009392 2. Ground screw 3.
Page 309: Dps System Calibration
Stern and Swivel DPS Module Service DPS System Calibration Use Evinrude Diagnostics software v 6.1 or higher to calibrate steering pressure sensors. WARNING Connect the MPI-2 and adapter cable to the lap- The DPS system of AFA and newer outboards top and the NMEA 2000 network.
Page 310 Stern and Swivel DPS Module Service Bleed the steering system. Refer to Filling and 2. Press Reset Limits. Then be SURE to select End Points. Bleeding the Hydraulic Steering System on p. 48. Steering Position Sensor Calibration (AFA and Newer Models Only) IMPORTANT: Calibrate the steering position sensor when:...
Page 311 Stern and Swivel DPS Module Service Test the steering system. See Steering System Connect the MPI-2 and adapter cable to the lap- Test on p. 313. top and the NMEA 2000 network. Turn the key switch to the ON position, then start the diagnostic Multiple Outboard Installations program.
Page 312 Stern and Swivel DPS Module Service IMPORTANT: Make sure outboards do not con- 8. Repeat steps 1 through 7 for the SECOND DPS outboard. tact. Slowly turn the steering wheel, while an assis- tant manually moves the disconnected outboards. After completing end points calibration, calibrate the turn limits.
Page 313 Stern and Swivel DPS Module Service Wait for the button to activate BEFORE con- screen of Evinrude Diagnostics software to moni- tinuing. tor the pump Current and Duty Cycle. 4. Select Disable Calibration to save the settings and re-enable the power steering pump. 1.
Page 314: Dps Manifold Service
Stern and Swivel DPS Manifold Service DPS Manifold swivel bracket to pivot. After the shipping bracket is installed, close the bleed valves Service NOTICE Service procedures of hydraulic manifolds MUST occur in a clean, dust-free environ- ment. When cleaning components use lint-free shop towels.
Page 315 Stern and Swivel DPS Manifold Service pass through the area shown. Do NOT attempt to retaining the trim manifold. The DPS and trim remove wiring at this time. manifolds are removed as one assembly. 1. Wiring pass-through area 009446 Remove the four screws retaining the plate to the stern brackets.
Page 316: Cleaning And Inspection
Stern and Swivel DPS Manifold Service Remove the four DPS manifold o-rings from the Cleaning and Inspection swivel bracket. NOTICE Remove the four trim manifold o-rings from the swivel bracket. Apply cleaning solvent to lint-free shop tow- els to clean hydraulic oil residue from all sur- faces.
Page 317 Stern and Swivel DPS Manifold Service • Continue to push the filter into the oil passage 3 O-rings, P/N 326956, which are 0.299 in. (7.6 mm) inside diameter, x 0.103 in (2.6 mm) until the filter is just below the mating surface. thick.
Page 318 Stern and Swivel DPS Manifold Service Carefully install leads and cables through the port Install the two cap screws and washers into the side of the swivel bracket in this order: DPS manifold and the four hex screws into the •...
Page 319: Disassembly
Stern and Swivel DPS Manifold Service Install the plate to the stern brackets with four Calibrate the steering pressure sensors on AFA screws. Tighten screws to a torque of 18 to 24 in. and newer models. lbs. (2 to 2.7 N·m). Refer to Steering Pressure Sensor Calibration (AFA and Newer Models Only) on p.
Page 320: Assembly
Stern and Swivel DPS Manifold Service Remove the tube and o-rings from the bottom of the DPS manifold. Then remove the filter. Top of DPS Manifold 009455 1. Screw 1. Tube and o-rings 009457 Carefully separate the manifolds. 2. Filter Clean and dry all parts thoroughly.
Page 321: Steering Pressure Sensors
Stern and Swivel DPS Manifold Service Align the sleeves, and tube and o-rings of the DPS manifold with the screw bosses, and fluid passage of the trim manifold. Top of DPS Manifold 009455 1. Screw Tighten the screws to a torque of 60 to 84 In. lbs. (7 to 10 N·m).
Page 322: Electric Motor
Stern and Swivel DPS Manifold Service Install tie strap, P/N 320107 to secure sensor lead Electric Motor to sensor as shown. Remove the four screws and washers retaining the electric motor to the manifold housing. 1. Tie strap 009455 IMPORTANT: DPS-2 Pressure sensors use a 1.
Page 323: Trim & Tilt System Service
Stern and Swivel Trim & Tilt System Service Trim & Tilt System Outboard Removed from Boat If the outboard is removed from the boat, remove Service the four screws retaining the plate to the stern brackets. Then remove the plate. Trim &...
Page 324 Stern and Swivel Trim & Tilt System Service Use a strap and an appropriate hoist to support Remove the four hex screws retaining the trim the outboard by the gearcase. The outboard will manifold. drop when the trim and tilt manifold is removed. 1.
Page 325 Stern and Swivel Trim & Tilt System Service Remove the four trim manifold o-rings from the • 3 O-rings, P/N 326956, which are 0.299 in. swivel bracket. (7.6 mm) inside diameter, x 0.103 in (2.6 mm) thick • 1 O-ring P/N 318372, which is 0.306 in (7.8 mm) inside diameter x 0.179 in.
Page 326 Stern and Swivel Trim & Tilt System Service Install four filters and o-rings into the swivel Install the four hex screws into the trim manifold. bracket. Install the large diameter o-ring in the position shown. 1. Large o-ring 009433 Position the manifold assembly close to the swivel bracket.
Page 327 Stern and Swivel Trim & Tilt System Service If removed, install the plate to the stern brackets Manifold Disassembly with four screws. Tighten screws to a torque of 18 Service of the trim and tilt manifold requires to 24 in. lbs. (2 to 2.7 N·m). removal from the outboard.
Page 328 Stern and Swivel Trim & Tilt System Service Carefully separate the reservoir from the manifold. Manifold Assembly Apply a drop of Power Trim/Tilt Fluid, P/N 767969, to the o-rings of a new tube and o-ring assembly. Install the tube and o-rings into the manifold. 1.
Page 329 Stern and Swivel Trim & Tilt System Service Assemble the manifolds: Electric Motor • Install two screws and washers from the bottom Remove the four screws and washers retaining of the trim manifold the electric motor to the manifold housing. •...
Page 330: Trim Rod Service
Stern and Swivel Trim & Tilt System Service Trim Rod Service Place an appropriate pan under the outboard to catch spilled hydraulic fluid. NOTICE Use Spanner Wrench, P/N 912084, or Spanner Wrench, P/N 359080, to remove the trim rod end Service procedures of hydraulic trim and tilt caps.
Page 331 Stern and Swivel Trim & Tilt System Service Slide both trim rod assemblies out of the trim cyl- Use lint-free shop towels to wipe up spilled inders at the same time. hydraulic fluid. ENVIRONMENTAL NOTE Dispose of spilled hydraulic fluid or contaminated shop towels in an environmentally responsible manner, or according to local regulations.
Page 332: Filling The Trim And Tilt System
Stern and Swivel Trim & Tilt System Service Slide both trim rod assemblies into of the trim cyl- Filling the Trim and Tilt System inders at the same time. Push the assemblies into Place an appropriate container under the out- the bore approximately 1.5 inches (38 mm).
Page 333 Stern and Swivel Trim & Tilt System Service Clean the reservoir cap. Verify that the o-ring seal NOTICE is installed in the cap. Lubricate the o-ring with Over-filling of the trim and tilt reservoir can clean hydraulic fluid. Carefully install the cap. Do damage seals or o-rings resulting in trim fluid NOT cross-thread the cap.
Page 334: Stern & Swivel Bracket
Stern and Swivel Stern & Swivel Bracket Stern & Swivel be cycled through the entire range to continue fill- ing it with fluid and to purge air from the system. Bracket Removal IMPORTANT: Trim the engine to the vertical po- sition BEFORE beginning the stern and swivel bracket removal procedure.
Page 335 Stern and Swivel Stern & Swivel Bracket Use shop towels to clean up spilled steering fluid. Disconnect the electrical connectors for the trim Install plug and nut assembly in the hose fittings of motor and trim sender. the stern and swivel assembly. 1.
Page 336 Stern and Swivel Stern & Swivel Bracket Then remove the thread protector from the fly- Use the off-set lifting eye to support the engine. wheel threads. Fasten an appropriate chain hook to the off-set lift- ing eye. 1. 4 inch plug 009425 2.
Page 337: Installation
Stern and Swivel Stern & Swivel Bracket Separate the supported engine from the stern & Apply marine sealer under hex heads of bolts, on swivel assembly. the mounting plates, and to the bolt shanks. Install the stern and swivel assembly with the four mounting bolts.
Page 338 Stern and Swivel Stern & Swivel Bracket Install the 4 lower mount bolts. Route the harnesses for the trim motor and trim sender to the starboard side of the engine. Con- nect the electrical connectors. 1. Lower mount bolts (port side shown) 009275 Tighten the nuts to a torque of 67 to 69 ft.
Page 339: Stern Bracket Service
Stern and Swivel Stern & Swivel Bracket Remove the Lifting Fixture, P/N 357667, from the release valve. Make sure the trim rollers are NOT flywheel. touching the ramps. NOTICE If the trim rollers are touching the ramps, hydraulic pressure will make removal of the stern bracket(s) Install plugs as indicated.
Page 340 Stern and Swivel Stern & Swivel Bracket plate and anode. Remove the spray plate and Remove the two screws and o-rings from the anode. stern bracket cover. Remove the cover and large o-ring. 1. Bottom screws 009629 2. Upper screws 1.
Page 341 Stern and Swivel Stern & Swivel Bracket Remove the stern bracket from the tilt shaft. the ramp bracket. The screw will be tightened Remove the thrust washer and o-ring. later. 1. Stern bracket 009634 1. Ramp bracket 009635 2. Thrust washer 2.
Page 342 Stern and Swivel Stern & Swivel Bracket Install the locking washer on the tilt shaft. Make Tighten screws to a torque of 30 to 60 in.lbs. (4 to sure the locating tab is inserted into the locating 6 N·m). hole. 1.
Page 343 Stern and Swivel Stern & Swivel Bracket Install the stern bracket plate. Install the four Tighten the bottom screws to a torque of 30 to 60 screws and tighten to a torque of 18 to 24 in.lbs. in.lbs. (4 to 6 N·m). (2 to 2.7 N·m).
Page 344: Trim Sender Service
Stern and Swivel Stern & Swivel Bracket Trim Sender Service Tighten both screws to a torque of 22 to 30 in. lbs. (2.5 to 3 N·m). Removal Apply No-Ox Grease, P/N 768230 over the ring Disconnect the trim sender electrical connector. terminal, washer and nut.
Page 345 Stern and Swivel Stern & Swivel Bracket Remove the cover and o-ring Remove the steering arm from the steering shaft. 1. Cover 009645 1. Steering arm 009647 2. O-ring End Cap Removal Use Spanner Socket, P/N 359224, to remove the spanner nut.
Page 346 Stern and Swivel Stern & Swivel Bracket Remove the large o-ring from the end cap bore. Install the end cap assembly and install the eight Remove the two small o-rings from the steering screws hand-tight. shaft. 1. Screws 009648 1. Large o-ring 009649 2.
Page 347 Stern and Swivel Stern & Swivel Bracket Install the steering position sensor with two If installing a new service replacement part, align screws. Tighten the screws to a torque of 35 to 60 the mounting surface of the steering arm with the In.lbs.
Page 348 Stern and Swivel Stern & Swivel Bracket Place the locking washer over the steering shaft Install the three screws in the steering arm cover. with the locating tab in the hole at the rear of the Tighten screws to a torque of 79 to 96 In.lbs. steering arm.
Page 349 Stern and Swivel Stern & Swivel Bracket Make an alignment mark on the splined steering Lower Bracket Installation shaft and lower bracket to aid re-assembly. Install a new o-ring on the shaft. 1. Alignment mark 009661 1. O-ring 00963 Use a soft-faced mallet or soft-faced dead-blow Install the lower bracket on the steering shaft.
Page 350 Stern and Swivel Stern & Swivel Bracket If installing a new service replacement part, align Use a bent-jaw retaining ring pliers to install the the mounting surface of the lower bracket with the retaining ring. mounting surface of the steering arm. 1.
Page 351 Gearcase Gearcase Table of Contents Service Charts ............. . . 353 Propeller Hardware .
Page 352 Gearcase Driveshaft Shimming ............391 Gearcase Assembly .
Page 353: Service Charts
Gearcase Service Charts Service Charts Propeller Hardware 70 to 80 Ft. lbs. (95 to 105 N·m) 15 to 17 Ft. lbs. (20 to 23 N·m) 009314...
Page 354: Water Pump And Gearcase Housing
Gearcase Service Charts Water Pump and Gearcase Housing 106 to 127 In. lbs. (12 to 14 N·m) 18 to 24 In. lbs. 15 to 17 Ft. lbs. (2 to 2.7 N·m) (20 to 23 N·m) 18 to 24 In. lbs. (2 to 2.7 N·m) 10 to 14 In.
Page 355: Driveshaft And Shift Actuator
Gearcase Service Charts Driveshaft and Shift Actuator 60 to 84 In. lbs. (7 to 10 N·m) 144 to 168 In. lbs. (16 to 19 N·m) 15 to 17 Ft. lbs. (20 to 23 N·m) 100 to 110 Ft. lbs. (136 to 149 N·m) Triple-Guard Grease Gasket Sealing Compound Moly Lube...
Page 356: Standard Rotation Propeller Shaft
Gearcase Service Charts Standard Rotation Propeller Shaft 2 to 4 in. lbs. (0.25 to 0.45 N·m) 82 to 92 Ft. lbs. (111 to 125 N·m) Triple-Guard Grease Gasket Sealing Compound 84 to 106 In. lbs. Moly Lube (10 to 12 N·m) Red Ultra Lock 009311C Needle Bearing Grease...
Page 357: Counter Rotation Propeller Shaft
Gearcase Service Charts Counter Rotation Propeller Shaft 100 to 110 Ft. lbs. (136 to 149 N·m) 2 to 4 in. lbs. (0.25 to 0.45 N·m) 82 to 92 Ft. lbs. (111 to 125 N·m) Triple-Guard Grease 84 to 106 In. lbs. Gasket Sealing Compound (10 to 12 N·m) Moly Lube...
Page 358: Gearcase Type
Gearcase Gearcase Type Gearcase Type Housing Outboard Model Description of Features Gear Ratio Type Standard Rotation Front water inlets and straight leading edge, pressed 20 in. in propeller shaft bearing housing with retaining 13:24 (.542) 25 in. spanner nut and locking ring, heavy duty standard 30 in.
Page 359: Propeller Service
Gearcase Propeller Service Propeller Service point of the RPM operating range at full throttle. Refer to Service Specifications on p. 12. WARNING Peak HP When servicing the propeller, always shift the 100% outboard to NEUTRAL position, turn the key switch OFF and remove the key, so the out- board cannot be started accidentally.
Page 360: Propeller Hardware Installation
Gearcase Propeller Service ward, the propeller rotates in a left-hand (coun- When installing a propeller with an interchange- terclockwise) direction as viewed from the rear. able hub, follow the instructions provided with the propeller. 2 3 4 5 1. Anode screw 5008933-05 2.
Page 361: Gearcase Leak Test
Gearcase Gearcase Leak Test Gearcase Leak Test Gearcase Removal and Installation Remove the drain/fill screw and drain the lubricant before testing. Refer to Gearcase Lubricant on p. Gearcase Removal WARNING Install Gearcase Pressure Tester, P/N 507977, into the gearcase drain/fill. During service, the outboard may drop unex- pectedly.
Page 362 Gearcase Gearcase Removal and Installation Disconnect the shift actuator cable from the Remove the eight gearcase mounting nuts. engine harness. 1. Gearcase mounting nuts (Port side shown) 5008933-12 5008933-10 Remove the gearcase assembly and the upper driveshaft. If the upper driveshaft does not come off with the gearcase, remove it from the exhaust CAUTION housing.
Page 363 Gearcase Gearcase Removal and Installation Install the upper driveshaft on to the lower drive- The oil hose is routed to starboard, the actuator shaft. cable to port. 009326 Shift the gearcase into FORWARD gear: • Temporarily connect the shift actuator cable to 1.
Page 364 Gearcase Gearcase Removal and Installation WARNING Failure to properly tighten gearcase nuts with a torque wrench could lead to gearcase dam- age or loss, resulting in loss of control and possible personal injury. Nut torque should be checked regularly, especially in high-speed applications, or any time propeller damage has occurred.
Page 365: Water Pump Service
Gearcase Water Pump Service Water Pump Service Install the oil reservoir vent hose to the top of the oil reservoir, secure with spring clamp. Install the oil hose on to the bottom of the oil reservoir with a Disassembly new 15.7 mm Oetiker clamp. Remove the four impeller housing screws.
Page 366: Inspection
Gearcase Water Pump Service Inspection Install the o-ring in the impeller housing. Check impeller for overheating, hub separation, and other wear or damage. Check liner and wear plate for scoring, distortion, and impeller material transfer. Inspect the housing for cracks or melting. Make sure gasket surface is clean and smooth.
Page 367 Gearcase Water Pump Service Apply Gasket Sealing Compound to the housing slide water pump down over key. Be sure impeller seal and install it into the impeller housing. key does not fall out of position. Rotation Rotation 1. Seal 5008933-22 5008933-24 Apply Gasket Sealing Compound to both sides of NOTICE...
Page 368: Shift Rod Adjustment
Gearcase Shift Rod Adjustment Shift Rod Adjustment Alternate Adjustment Method If the Shift Rod Installer, P/N 358162, is not avail- Use Shift Rod Installer, P/N 358162, to check shift able, this alternate method may be used. rod height. Make sure the gearcase is in the NEUTRAL posi- Install the plate on the gearcase housing with two tion.
Page 369: Shift Actuator
Gearcase Shift Actuator Shift Actuator Shift Actuator Circuit Diode Test Wire Result Control Circuit Tests Yellow/Blue approximately 0.5 VDC NOTICE Yellow/Green approximately Use appropriate test leads or adapters such 0.5 VDC as Test Probe Kit, P/N 342677, when perform- Red/White 0.11 to 0.125 ing electrical tests.
Page 370: Shift Actuator Service
Gearcase Shift Actuator Service Shift Actuator Service Remove the shift actuator seal and discard it. Shift Actuator Removal Remove the gearcase, refer to Gearcase Removal on p. 361. Remove the six screws retaining the shift actuator to the gearcase housing. 1.
Page 371 Gearcase Shift Actuator Service IMPORTANT: The shift actuator MUST be in Apply Gasket Sealing Compound to a new shift NEUTRAL. Make SURE: actuator seal and install the seal. • STANDARD rotation gearcase is in FORWARD • COUNTER-ROTATION gearcase REVERSE 1. Verify the correct gear position. Rotate the pro- peller shaft while lifting the lower shift rod.
Page 372: Shift Actuator Calibration
Gearcase Shift Actuator Calibration Rotate the propeller shaft while carefully pushing Install a gearcase pressure tester and pressurize down on the actuator to shift the gearcase into to 16 to 18 PSI for 5 to 10 minutes. If the shift neutral.
Page 373: Gearcase Disassembly
Gearcase Gearcase Disassembly (Standard Rotation) Gearcase Disassembly procedure is complete. · Select the Calibrate Shift Actuator button. (Standard Rotation) Pre-Disassembly Inspection WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa). IMPORTANT: Clean and inspect all parts during disassembly.
Page 374: Propeller Shaft Bearing Housing And Reverse Gear Removal
Gearcase Gearcase Disassembly (Standard Rotation) • ventilation ring up, then remove the ventilation Gearcase Anodes — If anodes have eroded to ring. two-thirds their original size, they must be replaced. 1. Pry tab inward 009529 2. Pry ventilation ring up 1.
Page 375 Gearcase Gearcase Disassembly (Standard Rotation) Once the spanner nut is loose, use the wrench to and turn the nut clockwise to remove the bearing remove the spanner nut by hand. housing. 1. Spanner Nut Wrench, P/N 358165 009531 009533 Use the Propeller Shaft Bearing Housing Puller Pull the propeller shaft and bearing housing far Kit, P/N 354060, with Puller Stud, P/N 358294, to enough to loosen the PRESSED bearing housing...
Page 376: Pinion Gear And Lower Driveshaft Removal
Gearcase Gearcase Disassembly (Standard Rotation) Pinion Gear and Lower Driveshaft Remove the driveshaft from the gearcase. The bearing housing, shims, thrust bearing, and thrust Removal washer will come out with the driveshaft. Use the Shift Rod Installer Tool, P/N 358162, to lift the shift rod and move the clutch dog as far for- ward as possible.
Page 377: Oil Pump Service
Gearcase Gearcase Disassembly (Standard Rotation) inserted between the puller and the gearcase until If the pinion bearing will not be removed, use a the driveshaft pops loose from the pinion. Slide Hammer, P/N 432128, or P/N 391008, with Puller Jaws, P/N 432129, to remove the oil pump. Locate the hole in the oil pump.
Page 378: Propeller Shaft And Forward Gear Removal
Gearcase Gearcase Disassembly (Standard Rotation) Installation Propeller Shaft and Forward Gear Removal IMPORTANT: Make sure the pinion bearing is in- stalled BEFORE installing the oil pump. NOTICE Use Installer, P/N 358521, to install the oil pump. This procedure REQUIRES replacement of Align the oil pump with the hole to the STAR- the shift lever and shift cradle.
Page 379: Shift Housing Removal
Gearcase Gearcase Disassembly (Standard Rotation) and turn the nut clockwise remove the propeller Align the puller jaws beneath the shifter housing in shaft. the position shown. 009533 Remove propeller shaft assembly, then remove the forward gear from the gearcase. Shifter Housing FORWARD view 009528 1.
Page 380: Water Intake Screens
Gearcase Shifter, Bearing and Seal Servicing When the shifter housing is released from the Shifter, Bearing and Seal gearcase housing, use the puller tool to remove Servicing the bearing housing from the gearcase. Pinion Bearing Removal Assemble the following components of the Pinion Bearing Remover and Installer, P/N 5005927, in the gearcase as follows: 009540...
Page 381: Propeller Shaft Disassembly
Gearcase Shifter, Bearing and Seal Servicing the following components of the Pinion Bearing Remove the tool. Remover and Installer, P/N 5005927, as shown: Propeller Shaft Disassembly Insert a suitable tool under one end of the clutch dog spring and remove it from its groove by unwrapping it from around the clutch dog.
Page 382: Shift Housing Disassembly
Gearcase Shifter, Bearing and Seal Servicing Shift Housing Disassembly NOTICE Discard the shift cradle and shift lever. New WARNING parts MUST be used during installation. Wear safety glasses to avoid injury. During removal the shift lever will bend and the cradle will crack and could break. IMPORTANT: The shifter housing and forward Even if parts appear to be in good condition,...
Page 383: Shift Housing Assembly
Gearcase Shifter, Bearing and Seal Servicing Shift Housing Assembly Rotate the shifter detent 90° to position the detent to engage the ball in the NEUTRAL position. IMPORTANT: Clean and inspect all parts before beginning assembly procedures. Replace any damaged parts. Lightly coat the detent ball and spring with Needle Bearing grease.
Page 384 Gearcase Shifter, Bearing and Seal Servicing With shifter detent in NEUTRAL, install arms of ing. Insert the gear, bearing, and washer into the shift lever into detent slots. Align the pivot holes bearing housing. and insert the retaining pin. Push shifter detent NOTICE down.
Page 385: Shift Rod Bushing Service
Gearcase Shifter, Bearing and Seal Servicing of the pin, MAKING SURE NONE OF THE COILS 4. Align the plate across the top of the gearcase OVERLAP OR ARE LOOSE. so the threaded rod pulls the bushing straight, as the nut is tightened. 5.
Page 386: Driveshaft Bearing Housing Service
Gearcase Shifter, Bearing and Seal Servicing slightly below the surface at the bottom of the shift Seal Installation actuator cavity. Lightly apply Gasket Sealing Compound to a new O-ring. Install the O-ring in top groove of the bear- ing housing. Do not allow sealant in oil passage. NOTICE Do not install the O-ring in the bearing hous- ing’s bottom groove.
Page 387: Propeller Shaft Bearing Housing Service
Gearcase Shifter, Bearing and Seal Servicing ing housing. Apply Triple-Guard grease to seal Propeller Shaft Bearing Housing lips. Service Rear Seal Removal - Early Models Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.
Page 388 Gearcase Shifter, Bearing and Seal Servicing Remove seals as described in Rear Seal Remove bearing as described in Bearing Removal - Early Models. Removal - Early Models. Inspect the bearing housing anode. Replace Bearing Removal - Early Models anode if it is reduced to two-thirds of original size. Tighten screws to a torque of 108 to 132 in.
Page 389 Gearcase Shifter, Bearing and Seal Servicing Bearing Installation Counter Rotation 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 bearing installer, then press the bearing into the housing until the tool seats.
Page 390 Gearcase Shifter, Bearing and Seal Servicing Rear Seal Installation Sparingly apply Loc-Tite 7649 Primer to the seal bore of the bearing housing. Sparingly apply Loc- Tite 609 to metal casings of the seals before installing. Use Seal Installation Tool to install new seals back to back in bearing housing.
Page 391: Driveshaft Shimming
Gearcase Driveshaft Shimming Driveshaft Shimming Select collar, P/N 341440, and the correct shim gauge bar: • “SLX”: Shim gauge bar, P/N 358164 NOTICE If a new pinion gear is needed, replace gear Slide the collar onto the driveshaft with large end set before shimming.
Page 392: Gearcase Assembly
Gearcase Gearcase Assembly Check squareness of the bearing housing mount- Gearcase Assembly ing surface by holding the shim gauge bar against the pinion while rotating just the bearing hous- Water Intake Screens ing. Use a feeler gauge to measure clearance Install water intake screens.
Page 393: Pinion Gear And Driveshaft Installation
Gearcase Gearcase Assembly ward to assist in the installation of the shaft Bearing Press Fixture, P/N 358163, over propeller assembly. shaft and into gearcase housing. Align and level the gearcase assembly in the fix- ture as shown. Secure the fixture to a floor press. 009542 Be sure the thrust bearing and the thrust washer are in the proper position.
Page 394 Gearcase Gearcase Assembly Using Driveshaft Seal Protector, P/N 318674, of the drive shaft bearing housing is facing FOR- slide the driveshaft bearing housing onto the WARD or AFT. driveshaft and into position in the gearcase. 1. Oil passage 009527 1. Thrust bearing 009511 2.
Page 395: Propeller Shaft Bearing Housing And Gear Installation
Gearcase Gearcase Assembly Use Driveshaft Holding Socket, P/N 311875, Pin- the housing. Grease both machined side surfaces ion Nut Wrench, P/N 334455, and Wrench of bearing housing. Retainer, P/N 341438, to tighten the pinion nut to a torque of 100 to 110 ft. lbs. (136 to 149 N·m). Pad handle of holder to prevent damage to gear- case.
Page 396 Gearcase Gearcase Assembly Align and level gearcase assembly in fixture as Install a new locking ring with the alignment tab in shown. Secure fixture to floor press. the hole at the top of the housing. Locking Ring Installation 0099548 1. Locking ring 2.
Page 397: Final Assembly And Adjustment
Gearcase Gearcase Disassembly (Counter Rotation) Gearcase Disassembly Use an appropriate tool to bend one locking tab into the spanner nut. (Counter Rotation) IMPORTANT: Counter rotation (CR) gearcases use unique components and require different ser- vice procedures. Use care when working on count- er rotation gearcases.
Page 398 Gearcase Gearcase Disassembly (Counter Rotation) Use a punch to bend the tab of the locking ring Use the Propeller Shaft Bearing Housing Puller down. Use Spanner Nut Wrench, P/N 358165, to Kit, P/N 354060, with Puller Stud, P/N 358294, to remove the spanner nut.
Page 399: Pinion Gear Removal And Driveshaft Servicing
Gearcase Gearcase Disassembly (Counter Rotation) Pull the propeller shaft and bearing housing far Clutch Shaft and Reverse Gear enough to loosen the PRESSED bearing housing Removal from the gearcase housing. WARNING Wear safety glasses to avoid personal injury. The detent balls and spring can come out with great force.
Page 400 Gearcase Gearcase Disassembly (Counter Rotation) sleeve from the gearcase. Then remove the wrench and tighten the nut to remove the clutch detent balls and spring from the clutch shaft. shaft. 1. Large detent ball 009553 Counter Rotation Models 009551 1. Pin through holes in puller adapter and clutch shaft 2.
Page 401: Shift Housing Removal
Gearcase Shifter, Bearing and Seal Servicing Shifter, Bearing and Seal Shift Housing Removal Servicing Refer to Shift Housing Removal on p. 379. Shift Housing Disassembly Water Intake Screens WARNING Remove and clean side water intake screens. Replace if damaged. Wear safety glasses to avoid injury. IMPORTANT: The shift housing and bearing are serviced as an assembly.
Page 402 Gearcase Shifter, Bearing and Seal Servicing Push the pin out of the clutch dog. Remove all Remove the magnet, shift shaft, cradle and shift parts. lever. Move shifter detent as needed to help ease removal of parts. 1. Pin 009559 1.
Page 403: Shift Housing Assembly
Gearcase Shifter, Bearing and Seal Servicing Insert shifter detent into the housing. Position the WARNING NEUTRAL detent at a 90° angle as shown. Wear safety glasses to avoid personal injury. The detent ball and spring and come out with great force. Wrap the housing with a shop cloth to catch the ball and spring.
Page 404 Gearcase Shifter, Bearing and Seal Servicing Install the magnet into the shift lever, aligning the TRAL position to hold the cradle and shaft in hole in the magnet with the holes on the shift place. lever. 1. Cradle 009525 2. Shift shaft 1.
Page 405: Pinion Bearing
Gearcase Shifter, Bearing and Seal Servicing ing. Insert the gear, bearing, and washer into the of the pin, MAKING SURE NONE OF THE COILS bearing housing. OVERLAP OR ARE LOOSE. NOTICE Bearing and washer must be installed in the correct order. 1.
Page 406 Gearcase Shifter, Bearing and Seal Servicing Remove the shim(s). Remove the thrust washer and thrust bearing. 006852 1. Thrust washer 009563 2. Thrust bearing Inspect the forward gear and bearing housing Inspect the bearing housing anode. Replace assembly for excessive wear or damage. anode if it is reduced to two-thirds of original size.
Page 407 Gearcase Shifter, Bearing and Seal Servicing Remove any nicks or burrs on front of bearing Apply Needle Bearing grease to the thrust washer. housing. Place washer in recess of bearing housing. 1. O-ring groove 009568 1. Thrust bearing 009565 2. Thrust washer For seal and bearing service refer to Propeller Coat bearing surfaces of propeller shaft with gear- Shaft Bearing Housing Service on p.
Page 408: Driveshaft Shimming
Gearcase Driveshaft Shimming Install forward gear assembly with correct shims Driveshaft Shimming in bearing housing. NOTICE If a new pinion gear is needed, replace gear set before shimming. Pinion gear backlash is achieved by using shims between the driveshaft bearing housing and the thrust washer.
Page 409 Gearcase Driveshaft Shimming Select collar, P/N 341440, and the correct shim Check squareness of the bearing housing mount- gauge bar: ing surface by holding the shim gauge bar against • the pinion while rotating just the bearing hous- “SLX”: Shim gauge bar, P/N 358164 ing.
Page 410: Gearcase Assembly
Gearcase Gearcase Assembly Gearcase Assembly ment pin on the shifter housing is aligned with the hole in forward end of gearcase housing. Water Intake Screens Install water intake screens. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1.
Page 411 Gearcase Gearcase Assembly P/N 358163, over propeller shaft and into gear- Align and level the gearcase assembly in the fix- case housing. ture as shown. Secure the fixture to a floor press. 1. Installer, P/N 359079 009584 2. Pin 3. Forward Bearing Press Fixture, P/N 358163 1.
Page 412: Pinion Gear And Driveshaft Installation
Gearcase Gearcase Assembly tool. Slowly release pressure on the tool and in the housing. Grease the machined side sur- remove the tool from the gearcase. faces of bearing housing. 009512 Place the bearing housing into the gearcase. Align the vertical ribs of the propeller shaft bearing housing with the gearcase back rib and skeg, as shown.
Page 413 Gearcase Gearcase Assembly Align and level gearcase assembly in fixture as Install a new locking ring with the alignment tab in shown. Secure fixture to floor press. the hole at the top of the housing. Locking Ring Installation 0099548 1. Locking ring 2.
Page 414: Final Assembly And Adjustment
Gearcase Gearcase Assembly Final Assembly and Adjustment Use an appropriate tool to bend one locking tab into the spanner nut. To complete gearcase assembly, refer to: • Gearcase Leak Test on p. 361 • Water Pump Service on p. 365 •...
Page 415 Safety Table of Contents Safety Table of Contents Marine Products and the Safety of People Who Use Them ......417 Outboard Shift Systems and Safety .
Page 416 S–416...
Page 417: Marine Products And The Safety Of People Who Use Them
Safety Marine Products and the Safety of People Who Use Them Marine Products and the Safety of People Who Use Them WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always fol- low common shop safety practices.
Page 418: Outboard Shift Systems And Safety
Safety Marine Products and the Safety of People Who Use Them 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.
Page 419: Outboard Speed Control System And Safety
Safety Marine Products and the Safety of People Who Use Them 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 420: Outboard Steering Control System And Safety
Safety Marine Products and the Safety of People Who Use Them 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: •...
Page 421 Safety Marine Products and the Safety of People Who Use Them How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When •...
Page 422: Outboard Fuel, Electrical System, And Safety
Safety Marine Products and the Safety of People Who Use Them 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.
Page 423 Safety Marine Products and the Safety of People Who Use Them 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 •...
Page 424 Safety Marine Products and the Safety of People Who Use Them 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 under engine cover Whenever possible, remove hose from outboard and from tank.
Page 425: Outboard Mounting System And Safety
Safety Marine Products and the Safety of People Who Use Them 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...
Page 426: If Weakened, Parts Could Fail Later On The Water, When Not Expected
Safety Marine Products and the Safety of People Who Use Them If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only When rigging or fixing any boat, if transom looks weak, tell the owner.
Page 427: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety
Safety Marine Products and the Safety of People Who Use Them 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. •...
Page 428: Outboard Emergency Stop System And Safety
Safety Marine Products and the Safety of People Who Use Them 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? •...
Page 429 Safety Marine Products and the Safety of People Who Use Them 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.
Page 430: Summary
Safety Marine Products and the Safety of People Who Use Them Summary 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 “ ”...
Page 431: Marine Products And The Safety Of People Who Fix Them
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 432 Safety Marine Products and the Safety of People Who Fix Them 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.
Page 433 Safety Marine Products and the Safety of People Who Fix Them Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM.
Page 434 Safety Marine Products and the Safety of People Who Fix Them Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off.
Page 435: Handling Lead/Acid Batteries
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 436: Gasoline - Handle With Care
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 437: Hazardous Products
Safety Marine Products and the Safety of People Who Fix Them 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 •...
Page 438: Safety Awareness Test
Safety Marine Products and the Safety of People Who Fix Them Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual?
Page 439 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 440 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 441 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 442 Trouble Check Chart Outboard Will Not Shut Off Outboard Will Not Shut Off OBSERVATION POSSIBLE CAUSE PROCEDURE Key switch or wire harness Check key switch and ground to key switch, refer to System Analysis and Electrical and Ignition ground Outboard starts and Check EMM LED indicators.
Page 443 Trouble Check Chart Outboard Starts, Low Maximum RPM Outboard Starts, Low Maximum RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM fault codes and check SystemCheck SystemCheck light Outboard is in S.A.F.E. warning Refer to specifications, check recommended WOT Incorrect propeller RPM; water test and install correct pitch propeller Setup or rigging change Incorrect outboard mounting...
Page 444 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 445 Index Index Break-In EMM Programming 195, 264 Abbreviations 6 Gearcase 397, 414 Accessories Oiling Auxiliary Battery Charge Kit, P/N 5009079 Procedure Fuel Filter Kit P/N 174176 Oil Tank Pick-up Kit, P/N 767686, for 10 gal. (37.8 liters) oil tank Calibration Remote Oil Tank Kits: DPS System 1.8 gal.
Page 446 Index Connecting Rods Cylinder Head 259, 260 Installation on Crankshaft Inspection Installation on Piston Installation Orientation Removal Removal from Crankshaft Cooling Hose Routing Diagrams Port Deutsch Connector Servicing 139 Rear Diagnostic Procedures Starboard Data Logging Dynamic Tests Cooling System Ignition Tests Components Operational Inspections Cylinder Block / Cylinder Head Cooling...
Page 447 Index 92, 138 Timing Verification Electrical Harness Water Pressure Transducer 36, 45 AMP Connectors Driveshaft Connector Servicing Bearing Housing, Seal Installation Deutsch Connectors Bearing Housing, Seal Removal EMM J1-A Connector Installation EMM J1-B Connector Removal 376, 399 EMM J2 Connector Shimming EMM J3 Connector Special Removal Procedures...
Page 448 Model Number Designations Water Flow Model Number Location Water Valve Resistance Test Serial Number Location Exterior Finish Protection 26 Engine Installation Evinrude E-TEC G2 Installation and Predelivery Guide Flushing, Cooling System 19, 20 Engine Monitor Flywheel Description Installation LOW OIL Warning...
Page 449 Index Electrical Circuit Tests Pressure Test Gearcase Resistance Test Assembly: Fuel System Counter Rotation Additives Standard Rotation Description Counter Rotation Service Dynamic Test Disassembly: Electrical Circuit Diagram Counter Rotaton Filters Standard Rotaton Fuel Circulation Pump Driveshaft Shimming Fuel Control Adjustment Gearcase Type Fuel Cooling Housing Identification...
Page 450 Index NMEA 2000 (Public) Network Outboard EMM Jack Plates Remote Control Adjustment Remote Control (Private) Network Shift Actuator System Diagnostics Knock Sensor System Settings Circuit Test Throttle Valve Assembly Description ICON II System Faults Test Fault Code Chart Fault Detection System Failsafe Mode LOW OIL Switch Using Diagnostic Software...
Page 451 Index NO OIL Warning Oiling System Networks Components Diagnostic Software Electrical Circuit Diagram Electronic Shift Controller (ESC) Engine Lubricant Electronic Throttle Controller (ETC) LOW OIL Switch Test ICON II Remote Controls Oil Distribution Hose Replacement NMEA 2000 (Public) Network Oil Filters Oil Level Sender 189, 195 Oil Recirculation...
Page 452 Studs Counter Rotation Views Predelivery Adjustments Before Start-Up Relays Engine Oil Level 55 V System Evinrude E-TEC G2 Installation and Engine Predelivery Guide 13, 129, 130 Starter Gearcase Lubricant Level Trim and Tilt Propellers Rigging Center 35 Trim and Tilt Fluid Level...
Page 453 Index Sensors and Sensor Tests Settings 81, 116 Air Temperature Sensor Power Steering Assist Levels Barometric Pressure Sensor Tilt Limit 83, 117 Crankshaft Position Sensor Trim Gauge Calibration Description Water Pressure Transducer Shift Actuator Engine Temperature Sensor 81, 118 Cable Routing Engine Temperature Sensor Servicing Calibration 24, 81...
Page 454 Index Starter Disassembly Inspection Circuit Diagram Temperature Installation Throttle, Shift and Steering Control Servicing Voltage Drop Test Systems 84 Start-In-Gear Protection 39 Dynamic Power Steering Stator Shift Controller Throttle Controller Resistance Test Timing Adjustments Servicing Voltage Output Test Timing Lead, P/N 587316 Steering Lock Tool, P/N 357717 49, 50, 51, 52 Timing Pointer Timing Verification...
Page 455 Index 395, 412 Installer Handle, P/N 345822 Temperature Gun, P/N 772018 Installer, P/N 358521 Terminal Release Tool, P/N 351413 Installer, P/N 359079 Test Probe Kit, P/N 342677 304, 369 Large Puller Jaws, P/N 432129 377, 379, 386, Thermal Joint Compound, P/N 322170 Timing Lead, P/N 587316 246, 261 MPI-2 Adapter, P/N 767994...
Page 456 Index Outboard Surges, Runs Rough Outboard Will Not Start Outboard Won’t Shut Off Strategy Timing Light Test Trouble Check Chart Vapor Separator Fuel Level Regulation Fuel Vapor Venting Voltage Drop Test 131 Warning System Activation Description Recovery Recovery from shutdown mode Water Intake Screens 19 Inspection 392, 410...
Page 457 Fault Code Tables & DPS Troubleshooting Flow Charts Fault Code Tables & DPS Troubleshooting Flow Charts Table of Contents Remote Control Fault Codes ........... . . 1 Outboard Fault Codes .
Page 458 Fault Code Tables & DPS Troubleshooting Flow Charts Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 459 Diagrams Diagrams Table of Contents Evinrude E-TEC G2 Engine Wiring Code Chart ICON II Start / Stop Panels ICON II Concealed Side Mount Control Harness ICON II Single Binnacle Mount Control Harness ICON II Dual Binnacle Mount Control Harness (Twin Outboards)
Page 460 Diagrams Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

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BRP Evinrude E-TEC G2 Service Manual

Service Manual

Routine Service

Engine Cover and Frame Service

Engine and Control Systems

System Analysis

Electrical and Ignition

Fuel System

Oiling System

Cooling System

Evinrude Icon II Remote Control System

Powerhead

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Troubleshooting

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Summary of Contents for BRP Evinrude E-TEC G2