BRP EVINRUDE E-TEC 115 HP 2011 Manuals

BRP EVINRUDE E-TEC 115 HP 2011 Manuals

Manuals and User Guides for BRP EVINRUDE E-TEC 115 HP 2011. We have 1 BRP EVINRUDE E-TEC 115 HP 2011 manual available for free PDF download: Service Manual

BRP EVINRUDE E-TEC 115 HP 2011 Service Manual

BRP EVINRUDE E-TEC 115 HP 2011 Service Manual (416 pages)

Brand: BRP | Category: Outboard Motor | Size: 40.92 MB

Table of Contents

S M Ervice Anual Contents

4
Routine Service

15
- Inspection and Maintenance Schedule
  16
- Lifting the Outboard
  17
- Outboard Rigging Connections
  17
- Control Cable Installation
  19
- Battery Cable Connections
  21
- Systemcheck Harness Connections
  21
- I-Command Network Connections
  22
- Icon Network Connections
  24
- Water Pressure Gauge
  25
- Battery and Battery Connections
  26
- Oetiker Clamp Servicing
  27
- Adjustments
  29
- Tilt Limit Switch Adjustment
  29
- Trim Sending Unit Adjustment
  30
- Trim Tab Adjustment
  31
- Dual-Outboard Alignment
  32
- Operational Checks
  33
- Cooling System
  34
- Engine Flushing
  34
- Running the Outboard Using a Hose and Flushing Adapter
  35
- Lubrication
  36
- Steering System
  36
- Tilt Tube
  36
- Propeller Shaft
  37
- Swivel Bracket and Trailering Bracket
  37
- Throttle and Shift Linkage
  37
- Gearcase Lubricant
  38
- Trim and Tilt
  39
- Indexing
  40
- Spark Plugs
  40
- Fuel and Oil Systems
  41
- Fuel Filter
  41
- Air Silencer
  42
- Hoses and Connections
  42
- Oil Filters and Oil Reservoir
  42
- Cleaning
  43
- Exhaust Pressure Fitting
  43
- Operation Test
  43
- Anti-Corrosion Protection
  44
- Storage
  45
- Pre-Season Service
  47
- Submerged Engines
  48
Engine Cover Service

49
- Latch Hook Installation
  50
- Upper Cover Cap Replacement
  50
- Upper Cover Service
  50
- Lower Cover Installation
  51
- Lower Cover Removal
  51
- Lower Cover Service
  51
- Latch Handle Installation
  52
- Trim Switch Installation
  52
Engine Management Module (Emm)

53
- Description
  54
- Emm Inputs and Outputs Diagram
  55
- 55 V Circuit Sensor
  56
- Emm Temperature Sensor
  56
- Internal Sensors
  56
- Barometric Pressure Sensor
  57
- Circuit Sensor
  57
- Exhaust Pressure Sensor
  57
- Air Temperature Sensor
  58
- Engine Temperature Sensor
  58
- External Sensors
  58
- Oil Pressure Sensor
  59
- Throttle Position Sensor
  59
- Crankshaft Position Sensor
  60
- Neutral Switch (V4 Models)
  60
- Engine Monitor and Warning Systems
  61
- Exhaust Valve (V4 Models)
  61
- Fault Code Creation and Storage
  61
- Idle Controller
  61
- Internal Emm Functions
  61
- Rom Verification
  61
- Rpm Limiter
  61
- Start Assist Circuit (Sac)
  61
- Engine Monitor System
  62
- Shutdown Mode
  63
- Warning System
  63
- Communication
  64
- Diagnostic Software Functions
  64
- Static Information
  64
- Dynamic Information
  65
- Hard Faults
  65
- Persistent Faults
  65
- Static Tests
  65
- Stored Service Codes (Faults)
  65
- Dynamic Tests
  66
- Oil Control Settings
  67
- Tiller/Remote Programming
  67
- Fuel Injector Servicing
  68
- Ignition Timing
  68
- Tps Calibration
  68
- Reports
  69
- Software Replacement
  69
- Emm Servicing
  70
- Emm Transfer
  70
System Analysis

73
- Diagnostic Procedures
  74
- Operational Inspections
  74
- Visual Inspections
  74
- Troubleshooting
  75
- Cylinder Drop Tests
  76
- Dynamic Tests
  76
- Fuel Control Adjustment
  76
- Inductive Amp Meter Test
  76
- Emm Led Indicators
  77
- Key on
  77
- Starting
  77
- Running
  78
- Ignition Output Tests
  79
- Required Ignition Systems
  79
- Wiring Inspection
  79
- Crankshaft Position Sensor (Cps) Test
  80
- System Voltage Test
  80
- Static Ignition Test
  81
- Running Ignition Tests
  82
- Capacitor Test
  83
- Ignition Coil Tests
  83
- Ignition Control Circuit Tests
  83
- Fuel Delivery Tests
  84
- Fuel Injector Static Test
  84
- Fuel Pump Static Test
  84
- Running Fuel System Tests
  85
- Exhaust Valve (V4 Models)
  86
- Exhaust Valve Static Test
  86
Electrical and Ignition

87
- Service Chart
  88
- Ignition System Circuit Diagrams
  90
- Electrical Harness Connections
  92
- Fuse
  94
- Ground Circuits
  94
- Crankshaft Position Sensor (Cps) Test
  95
- Sensor Tests
  95
- Throttle Position Sensor (Tps) Test
  95
- Air Temperature Sensor (At) Test
  96
- Engine Temperature Sensor Test
  96
- Stator Resistance Tests
  97
- Stator Tests
  97
- Stator Voltage Output Test
  97
- 12 V Charging Circuit
  98
- Charging System Tests
  98
- 55 V Alternator Circuit
  99
- Auxiliary Battery Charge Wire
  99
- Electric Start Circuit
  100
- Electric Start Tests
  102
- Remote Control Switch Tests
  104
- Tilt/Trim Relay Test
  106
- Exhaust Valve Relay Tests
  107
- Systemcheck Circuit Tests
  109
- Tachometer Circuit Tests
  111
- Flywheel and Stator Servicing
  112
- Flywheel Removal
  112
- Flywheel Installation
  113
- Stator Service
  113
- Ignition Coil Installation
  115
- Ignition Coil Removal
  115
- Ignition Coil Servicing
  115
- Timing Adjustments
  116
- Timing Pointer
  116
- Timing Verification
  117
- Electric Starter Servicing
  118
- Starter Removal
  118
- Tps Calibration
  118
- Starter Disassembly
  119
- Starter Cleaning and Inspection
  121
- Starter Assembly
  122
- Connector Servicing
  125
- Starter Installation
  125
Fuel System

131
- Service Chart
  132
- Fuel System Hose Routing
  135
- Fuel System Circuit Diagram - V4
  136
- Fuel System Circuit Diagram - V6
  137
- Fuel Flow Requirements
  138
- Fuel System Requirements
  138
- Portable Fuel Tanks
  138
- Regulations and Guidelines
  138
- Fuel Requirements
  139
- Components
  140
- Fuel Filter
  140
- Fuel Lift Pump
  140
- Vapor Separator
  140
- Fuel Circulation Pump
  141
- Fuel Injectors
  142
- Fuel Manifolds
  142
- Fuel System Priming
  143
- Priming the Fuel System
  143
- Vent Line Clamp
  143
- Fuel System Pressure Test
  144
- Fuel System Tests
  144
- Fuel Injector Pressure Test
  145
- Pressure Regulator Test
  145
- Vapor Separator Vent Check
  145
- Circulation Pump Resistance Test
  146
- Fuel Injector Resistance Test
  146
- Lift Pump Pressure Test
  146
- Lift Pump Diaphragm Test
  147
- Lift Pump Vacuum Test
  147
- Anti-Siphon Valve Test
  148
- Fuel Component Servicing
  148
- Relieving Fuel System Pressure
  148
- Fuel Filter Service
  149
- Fuel Lift Pump Service
  150
- Vapor Separator Service
  150
- Fuel Manifold Service
  151
- Fuel Injector Service
  152
- Intake Manifold Service
  155
Oiling System

159
- Service Chart
  160
- Oiling System Circuit Diagram
  161
- Oil Supply Diagrams - V4
  162
- Oil Supply Diagrams - V6
  164
- Oil Recirculation Diagrams - V4
  166
- Oil Recirculation Diagrams - V6
  168
- Components
  170
- Oil System Requirements
  170
- Oil Tank Assembly
  170
- Recommended Lubricants
  170
- Oil Injection Pump
  171
- Oil Pressure Sensor
  171
- Rear Oil Manifold
  171
- Cylinder and Crankcase
  172
- Electrical Circuit (55 V)
  172
- Low Oil Warning
  172
- NO OIL Warning
  172
- Oil Recirculation System
  173
- Oil Control Settings
  174
- Oil Injection Rate
  174
- Break-In Oiling
  175
- Oil Supply Priming
  175
- Oil Injection Pump Static Test
  177
- Oil Injection Pump Voltage Tests
  177
- Oiling System Tests
  177
- Oil Injection Pump Circuit Resistance Test
  178
- Oil Supply Vacuum Test
  179
- Low Oil Sending Unit Test
  180
- Oil Injection Fittings Flow Test
  180
- Oil Injection Pump Function Test
  180
- Oil Component Servicing
  181
- Oil Distribution Hoses
  181
- Oil Injection Pump
  182
Cooling System

185
- Hose Routing and Water Flow Diagrams
  186
- Adapter/Inner Exhaust Housing
  188
- Components
  188
- Water Pump and Intakes
  188
- Water Supply Tube
  188
- Block Venting
  189
- Pressure Relief Valve
  189
- Thermostats
  189
- Cylinder Block / Cylinder Head Cooling
  190
- Emm and Vapor Separator Cooling
  190
- Operation
  190
- Engine Temperature Check
  191
- Pyrometer Method
  191
- Software Method
  191
- Idle Operating Temperature Troubleshooting (below Range)
  192
- Disassembly
  193
- Installation
  193
- Removal
  193
- Temperature Sender Servicing
  193
- Thermostat Servicing
  193
- Assembly
  194
- Disassembly
  194
- Inspection
  194
- Pressure Relief Valve Servicing
  194
Powerhead

195
- Service Chart
  196
- Compression Testing
  198
- Powerhead Removal
  198
- Powerhead Disassembly
  200
- Systems Removal
  200
- Crankcase Disassembly
  201
- Shift Linkage Removal
  201
- Throttle Linkage Removal
  201
- Connecting Rods and Pistons
  202
- Cylinder Head Removal
  202
- Crankshaft Removal
  203
- Cylinder Block Cleaning
  206
- Powerhead Inspection
  207
- Crankshaft Assembly
  209
- Powerhead Assembly
  209
- Pistons and Connecting Rods
  211
- Cylinder Head Installation
  213
- Crankshaft and Connecting Rods
  214
- Crankcase Assembly
  217
- Shift Linkage Installation
  218
- Final Powerhead Assembly
  219
- Throttle Linkage Installation
  219
- Upper Mount Servicing
  220
- Powerhead Installation
  221
- Powerhead Views
  225
- V4 Port - Hose Routings
  225
- V4 Starboard - Hose Routings
  225
- V4 Port
  226
- V4 Starboard
  226
- V4 Front
  227
- V4 Rear
  228
- V4 - V6 Top - Hose Routings
  229
- V4 - V6 Top
  230
- V6 Starboard - Hose Routings
  231
- V6 Port - Hose Routings
  232
- V6 Starboard
  233
- V6 Port
  234
- V6 Front
  235
- V6 Rear
  236
Midsection

237
- Service Chart
  238
- Removal
  242
- Tilt Tube
  242
- Installation
  243
- Exhaust Housing Removal
  244
- Exhaust Housing Service
  244
- Lower Mount Service
  244
- Exhaust Housing Installation
  245
- Exhaust Housing Disassembly - V4 Models
  246
- Exhaust Housing Disassembly - V6 Models
  246
- Cleaning and Inspection
  247
- Exhaust Housing Assembly - V6 Models
  247
- Exhaust Housing Assembly - V4 Models
  248
- Extension Service - V4 Models
  250
- Installation
  250
- Removal
  250
- Stern Bracket
  250
- Stern Bracket Disassembly
  250
- Stern Bracket Assembly
  253
- Exhaust Relief Muffler Assembly
  256
Gearcase

257
- Service Charts
  259
- Gearcase Types
  265
- Propeller Service
  267
- Gearcase Leak Test
  269
- Gearcase Removal and Installation
  270
- Assembly
  273
- Disassembly
  273
- Inspection
  273
- Water Pump Service
  273
- Shift Rod Adjustment
  276
- Gearcase - Standard Rotation
  277
- Gearcase Disassembly
  277
- Pre-Disassembly Inspection
  277
- Propeller Shaft Bearing Housing Removal - "S2" and "O" Type
  278
- Propeller Shaft Bearing Housing Removal - "L2" and "M2" Type
  279
- Pinion Gear and Driveshaft Removal - "S2" Type
  280
- Pinion Gear and Driveshaft Removal - "O", "L2", and "M2" Type
  283
- Driveshaft Service
  284
- Shift Housing, Gear and Propeller Shaft Removal
  285
- Water Intake Screens
  285
- Gearcase Housing Inspection
  286
- Pinion Bearing Installation
  287
- Pinion Bearing Removal
  287
- Shifter, Bearing and Seal Service
  287
- Shift Housing Disassembly
  288
- Shift Housing Assembly
  290
- Driveshaft Bearing Housing Service
  292
- Propeller Shaft Bearing Housing Service
  293
- Driveshaft Shimming
  295
- Gearcase Assembly
  297
- Shift Housing, Gear, and Propeller Shaft Installation
  297
- Water Intake Screens
  297
- Shift Rod Housing Installation
  298
- Pinion Gear and Driveshaft Installation - "S2" Type
  299
- Pinion Gear and Driveshaft Installation - "O", "L2", and "M2" Type
  303
- Propeller Shaft Bearing Housing and Gear Installation - "S2" and "O" Type
  304
- Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
  305
- Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
  307
- Final Assembly and Adjustment
  308
- Gearcase Disassembly
  309
- Pre-Disassembly Inspection
  309
- Propeller Shaft Bearing Housing Removal - "M2" Type
  309
- Propeller Shaft Bearing Housing Removal - "O" Type
  309
- Pinion Gear Removal and Driveshaft Servicing
  310
- Gearcase Housing Inspection
  311
- Shift Housing, Gear and Propeller Shaft Removal
  311
- Water Intake Screens
  311
- Shift Housing Disassembly
  312
- Shifter, Bearing and Seal Servicing
  312
- Shift Housing Assembly
  313
- Pinion Bearing
  315
- Propeller Shaft Bearing Housing and Forward Gear - "O" Type
  315
- Propeller Shaft Bearing Housing and Forward Gear - "M2" Type
  319
- Driveshaft Shimming
  322
- Gearcase Assembly
  323
- Shift Housing, Gear, and Propeller Shaft Installation
  323
- Water Intake Screens
  323
- Pinion Gear and Driveshaft Installation
  324
- Propeller Shaft Bearing Housing and Gear Installation - "O" Type
  324
- Shift Rod Cover
  324
- Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
  325
- Final Assembly and Adjustment
  326
Trim and Tilt

327
- Service Chart
  328
- System Description
  330
- Modes of Operation (Three Piston System)
  331
- General
  337
- Manual Release Valve
  337
- Reservoir Fluid
  337
- Routine Inspections
  337
- Single Piston System
  337
- Stern Brackets
  337
- Troubleshooting
  337
- Three Piston System
  338
- Electrical Circuit Tests
  341
- Relay Testing
  341
- Trim and Tilt Motor Current Draw Tests
  341
- Trim and Tilt Motor no Load Test
  342
- Trim Gauge Test
  343
- Removal
  344
- Trim and Tilt Replacement
  344
- Trim Sender Test
  344
- Installation
  346
- Disassembly
  347
- Servicing-Single Piston System
  347
- Assembly
  348
- Disassembly
  349
- Servicing - Three Piston System
  349
- Tilt Piston Removal
  352
- Tilt Piston Assembly
  353
- Tilt Piston Identification
  353
- Tilt Rod Assembly
  354
- Trim Rod Removal
  355
- Trim Rod Assembly
  356
- Manifold and Reservoir Installation
  357
- Trim Rod Installation
  358
- Motor Installation
  359
- Tilt Rod Installation
  359
Safety

363

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