BRP Evinrude E-TEC Manuals

Manuals and User Guides for BRP Evinrude E-TEC. We have 2 BRP Evinrude E-TEC manuals available for free PDF download: Manual, Operator's Manual

BRP Evinrude E-TEC Manual

BRP Evinrude E-TEC Manual (364 pages)

Brand: BRP | Category: Boat | Size: 44 MB

Table of Contents

Service Manual

2
- Table of Contents
  2
  - Table of Contents
    3
- Safety Notice
  4
- Abbreviations Used in this Manual
  6
- Units of Measurement
  6
- List of Abbreviations
  6
- Standard Torque Specifications
  7
- Product Reference and Illustrations
  7
- Emission-Related Installation Instructions
  8
- Manufacturer's Responsibility
  8
- Dealer's Responsibility
  8
- Owner's Responsibility
  8
- EPA Emission Regulations
  9
- Engine Identification
  10
- Model Designation
  10
- Models Covered
  11
- Service Specifications, 40 - 60 HP
  12
- Service Specifications, 60 H.O. - 90 HP
  14
- Wire Size Table
  16
- American Wire Gauge
  16
- Metric Wire Size
  16
Routine Service

17
- Inspection and Maintenance Schedule
  18
- Lifting the Outboard
  19
- Outboard Rigging Connections
  20
- Battery and Battery Connections
  26
- Oetiker Clamp Servicing
  28
- Adjustments
  29
- Steering Friction Adjustment
  29
- Throttle Friction Adjustment
  30
- Tilt Limit Switch Adjustment (3-Cylinder Models)
  30
- Trim Sending Unit Adjustment (2-Cylinder Models)
  31
- Trim Sending Unit Adjustment (3-Cylinder Models)
  32
- Trim Tab Adjustment
  33
- Dual-Outboard Alignment
  34
- Operational Checks
  35
- Cooling System
  36
- Engine Flushing
  36
- Water Intake Screens
  36
- Running the Outboard Using a Hose and Flushing Adapter
  37
- Lubrication
  38
- Steering System
  38
- Tiller Handle
  38
- Swivel Bracket and Trailering Bracket
  39
- Throttle and Shift Linkage
  39
- Tilt Tube
  39
- Gearcase Lubricant
  40
- Propeller Shaft
  40
- Trim and Tilt
  41
- Indexing
  43
- Spark Plugs
  43
- Fuel and Oil Systems
  44
- Fuel Filter
  44
- Hoses and Connections
  44
- Oil Filters and Oil Reservoir
  44
- Anti-Corrosion Protection
  45
- Gearcase Removal and Installation
  46
- Storage
  50
- Pre-Season Service
  52
- Submerged Engines
  53
- Oetiker Clamp Chart
  54
Engine Cover Service

55
- Latch Hook Installation
  56
- Lower Cover Installation
  56
- Lower Cover Removal
  56
- Lower Cover Service
  56
- Upper Cover Service
  56
- Latch Handle Installation
  57
- Trim Switch Installation
  58
Engine Management Module (Emm)

59
- Description
  60
- EMM Connections
  60
- EMM Functions
  60
- LED Indicators
  60
- EMM Inputs and Outputs Diagram
  61
- 55 V Circuit Sensor
  62
- EMM Temperature Sensor
  62
- Internal Sensors
  62
- 5 V Circuit Sensor
  63
- Air Temperature Sensor
  63
- Barometric Pressure Sensor
  63
- Engine Temperature Sensor
  63
- External Sensors
  63
- Low Oil Switch
  64
- Throttle Position Sensor
  64
- Crankshaft Position Sensor
  65
- Neutral Switch
  65
- Internal EMM Functions
  66
- Engine Monitor System
  67
- Shutdown Mode
  68
- Warning System
  68
- Communication
  69
- Diagnostic Software Functions
  69
- Static Information
  70
- Active Faults
  71
- Dynamic Information
  71
- Historical Faults
  71
- Occurred Fault Codes
  71
- Static Tests
  71
- Dynamic Tests
  72
- Oil Control Settings
  72
- Ignition Timing
  73
- Tiller/Remote Programming
  73
- Fuel Injector Servicing
  74
- Idle Speed Control
  74
- TPS Calibration
  74
- Reports
  75
- Software Replacement
  75
- EMM Transfer
  76
- EMM Servicing
  77
System Analysis

79
- Diagnostic Inspections
  80
- Diagnostic Procedures
  80
- Visual Inspections
  80
- Operational Inspections
  81
- Troubleshooting
  81
- Cylinder Drop Tests
  83
- Dynamic Tests
  83
- Fuel Control Adjustment
  83
- Inductive Amp Meter Test
  83
- EMM LED Indicators
  84
- Key on
  84
- Running
  84
- Starting
  84
- Cylinder Block / Cylinder Head Cooling 1
  85
- Ignition Output Tests
  85
- Required Ignition Systems
  85
- Crankshaft Position Sensor (CPS) Test
  86
- System Voltage Test
  86
- Wiring Inspection
  86
- Static Ignition Test
  87
- Ignition Control Circuit Tests
  88
- Running Ignition Tests
  88
- Capacitor Test
  89
- Ignition Coil Tests
  89
- Fuel Delivery Tests
  90
- Fuel Injector Static Test
  90
- Fuel Pump Static Test
  90
- Running Fuel System Tests
  91
- Exhaust Water Valve
  92
- Exhaust Water Valve Dynamic Test
  92
- Exhaust Water Valve Static Test
  92
Electrical and Ignition

93
- Service Charts
  94
- Ignition System Circuit Diagram, 2-Cylinder Models
  96
- Ignition System Circuit Diagram, 3-Cylinder Models
  97
- Electrical Harness Connections
  98
- Fuse
  100
- Ground Circuits
  100
- Crankshaft Position Sensor (CPS) Test
  101
- Sensor Tests
  101
- Throttle Position Sensor (TPS) Test
  101
- Air Temperature Sensor (AT) Test
  102
- Engine Temperature Sensor Test
  102
- Stator Tests
  103
- Charging System Tests
  104
- Electric Start Circuit
  106
- Electric Start Tests
  108
- Remote Control Switch Tests
  110
- Tilt/Trim Relay Test
  112
- Exhaust Water Valve Test
  113
- Systemcheck Circuit Tests
  113
- Flywheel and Stator Servicing
  116
- Flywheel Removal
  116
- Tachometer Circuit Tests
  116
- Flywheel Installation
  118
- Stator Service
  118
- Ignition Coil Servicing
  119
- Timing Adjustments
  119
- Timing Pointer
  119
- Timing Verification
  120
- Electric Starter Servicing
  121
- TPS Calibration
  121
- Connector Servicing
  122
- Deutsch Connectors
  122
- AMP Connectors
  124
- Packard Connectors
  126
Fuel System

129
- Service Chart
  130
- Fuel System Hose Routing
  134
- Fuel System Circuit Diagrams
  136
- 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
- Pressure Regulator Test
  144
- Fuel Injector Pressure Test
  145
- Fuel Injector Resistance Test
  145
- Vapor Separator Vent Check
  145
- Circulation Pump 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
  149
- Vapor Separator Service
  150
- Fuel Manifold Service
  151
- Fuel Injector Service
  152
- Intake Manifold Service
  156
Oiling System

159
- Service Charts
  160
- Oil Supply Diagrams
  162
- Oil Recirculation Diagrams
  164
- Oiling System Circuit Diagram
  165
- Components
  166
- Oil System Requirements
  166
- Oil Tank Assembly
  166
- Recommended Lubricants
  166
- Electrical Circuit (55 V)
  167
- LOW OIL Warning
  167
- NO OIL Warning
  167
- Oil Injection Pump
  167
- Cylinder and Crankcase
  168
- Oil Recirculation System
  168
- Oil Control Settings
  169
- Oil Injection Rate
  169
- Break-In Oiling
  170
- Oil Supply Priming
  171
- Oil Injection Pump Voltage Tests
  172
- Oiling System Tests
  172
- Oil Injection Pump Function Test
  173
- Oil Injection Pump Resistance Test
  173
- LOW OIL Sending Unit Test
  174
- Oil Component Servicing
  174
- Oil Distribution Hoses
  174
- Oil Injection Fittings Flow Test
  174
- Oil Tank Assembly
  175
- Oil Injection Pump
  177
Cooling System

179
- Hose Routing and Water Flow Diagrams
  180
- Adapter/Inner Exhaust Housing
  182
- Components
  182
- Exhaust Housing
  182
- Water Pump and Intakes
  182
- Water Supply Tube
  182
- Pressure Relief Valve
  183
- Thermostat
  183
- Block Venting
  184
- Water Pressure Connection
  184
- EMM and Vapor Separator Cooling
  185
- Operation
  185
- Engine Temperature Check
  186
- Pyrometer Method
  186
- Software Method
  186
- Idle Operating Temperature Troubleshooting (below Range)
  187
- Temperature Sender Servicing
  188
- Thermostat Servicing
  189
- Pressure Relief Valve Servicing
  190
Powerhead

191
- Service Charts
  192
- Piston Pin Retainer Tool
  196
- 2-Cylinder Models
  197
- Compression Testing
  197
- Powerhead Removal
  197
- 3-Cylinder Models
  199
- Powerhead Disassembly
  200
- Systems Removal
  200
- Shift Linkage Removal
  201
- Throttle Linkage Removal
  201
- Crankcase Disassembly
  202
- Connecting Rods and Pistons
  203
- Cylinder Head Removal
  203
- Crankshaft Removal
  204
- Cylinder Block Cleaning
  207
- Powerhead Inspection
  208
- Crankshaft Assembly
  210
- Powerhead Assembly
  210
- Pistons and Connecting Rods
  211
- Cylinder Head Installation
  214
- Crankshaft and Connecting Rod Installation
  215
- Crankcase Assembly
  218
- Shift Linkage Installation
  220
- Throttle Linkage Installation
  220
- Final Powerhead Assembly
  221
- Upper Mount Servicing (3-Cylinder)
  222
- Powerhead Installation
  224
- Powerhead Mounting - 2-Cylinder Models
  224
- Powerhead Mounting - 3-Cylinder Models
  226
- Final Adjustments
  228
- Shift Linkage Adjustment
  228
- 2-Cylinder Models
  229
- Powerhead Views
  229
Midsection

241
- Service Charts
  242
- 3-Cylinder Models
  248
- Tilt Tube, 3-Cylinder Models
  248
- Exhaust Housing Removal
  250
- Exhaust Housing, 2-Cylinder Models
  250
- Exhaust Relief Muffler
  251
- Exhaust Water Valve (40 H.O. /60 HP 2-Cylinder Models)
  251
- Exhaust Housing Installation
  252
- Exhaust Housing Removal
  253
- Exhaust Housing, 3-Cylinder Models
  253
- Lower Mount Service
  253
- Exhaust Housing Disassembly
  254
- Exhaust Housing Installation
  254
- Cleaning and Inspection
  255
- Exhaust Housing Assembly
  256
- Stern Bracket Disassembly
  258
- Stern Bracket, 2-Cylinder Models with Power Tilt
  258
- Stern Bracket Assembly
  259
- Stern Bracket Disassembly
  260
- Stern Bracket, 3-Cylinder Models
  260
- Stern Bracket Assembly
  262
- Clamp Screw Service
  265
- Stern Bracket Disassembly
  265
- Stern Bracket, 2-Cylinder Manual Tilt
  265
- Stern Bracket Assembly
  268
- Tilt Assist Cylinder
  271
- Removal
  272
- Tiller Handle Service - Standard
  272
- Disassembly
  273
- Assembly
  275
- Inspection
  275
- Installation
  277
- Throttle Cable Adjustment
  278
- Removal
  279
- Tiller Handle Service - Long Handle
  279
- Disassembly
  280
- Assembly
  283
- Inspection
  283
- Installation
  287
- Control Cable Installation
  288
Trim and Tilt

291
- Service Charts
  292
- Manual Adjustment
  294
- System Description
  294
- Trailering Bracket and Tilt Support
  294
- General
  295
- Manual Release Valve
  295
- Reservoir Fluid
  295
- Routine Inspections
  295
- Stern Brackets
  295
- Electrical Circuit Tests
  296
- Relay Testing
  296
- Trim and Tilt Motor Current Draw Tests
  296
- Troubleshooting
  296
- Trim and Tilt Motor no Load Test
  297
- Trim Gauge Test
  298
- Trim Sender Test
  298
- Trim and Tilt Replacement
  299
- Manual Release Valve
  303
- Trim and Tilt Service
  303
- Piston Seal and End Cap
  305
- Trim Motor
  311
Manual Starter

315
- Service Chart
  316
- Recoil Starter Disassembly
  317
- Recoil Starter Removal
  317
- Recoil Starter Assembly
  319
- Recoil Starter Cleaning and Inspection
  319
- Recoil Starter Installation
  323
Safety

325
- Marine Products and the Safety of People Who Use Them
  327
- Outboard Shift Systems and Safety
  328
- Outboard Speed Control System and Safety
  329
- Outboard Steering Control System and Safety
  330
- Outboard Fuel, Electrical System, and Safety
  332
- Outboard Mounting System and Safety
  335
- If Weakened, Parts Could Fail Later on the Water, When Not Expected
  336
- Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
  337
- Outboard Emergency Stop System and Safety
  338
- Summary
  340
- Handling Outboards
  341
- Marine Products and the Safety of People Who Fix Them
  341
- Handling Lead/Acid Batteries
  345
- Gasoline - Handle with Care
  346
- Hazardous Products
  347
- Safety Awareness Test
  348
- Outboard will Not Start
  358
- Outboard Hard to Start
  360
- Outboard Starts and Stalls
  361
- Outboard will Not Shut off
  361
- Excessive Smoking
  362
- Outboard Starts, Low Maximum RPM
  362
- Outboard Surges, Runs Rough
  363

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BRP Evinrude E-TEC Operator's Manual

BRP Evinrude E-TEC Operator's Manual (72 pages)

OUTBOARD

Brand: BRP | Category: Outboard Motor | Size: 3.14 MB

Table of Contents

Table of Contents
6
About this Guide
8
Important Safety Messages
9
Product References, Illustrations and Specifications
11
Declaration of Conformity
12
Using Your Evinrude E-Tec Outboard
13
Safety Information on the Outboard
14
Warning Symbols
14
Hang Tag
14
Remote Control Decals
15
Component Identification
16
Oil and Fuel
18
Oil Requirements
18
Oiling System
18
Filling the Oil Tank
19
Priming the Oil System
19
Fuel Requirements
19
Fuel Additives
20
Fuel System Operation
20
Operation
21
Safety Information
21
Engine Starting
21
Engine Stopping
22
Remote Controls - Evinrude Icon™ Control System
23
Remote Controls - Evinrude/Johnson (Brp) Controls
25
Fuel Economy
27
Power Trim and Tilt
27
Trailering
29
Impact Damage
30
Salt Water
31
Weedy Water
31
High Altitude
32
Freezing Weather
32
Shallow Water
32
Dual Outboard Operation
32
Under Tow
32
Fuse
32
Routine Inspection Checklist
33
Engine Monitoring
34
Engine Overheating
36
Maintenance
37
Engine Emissions Information
38
Maintenance Schedule
39
Storage
40
Transportation
40
Flushing
40
Short-Term Storage (between Uses)
41
Long-Term Storage (Winterization)
41
Pre-Season Check
44
Spark Plugs
44
Outboard External Finish
45
Scratch Repair
45
Hull Finish
45
Submerged Outboard
45
Troubleshooting
46
Product Information
47
Rigging and Accessories
48
Propeller
48
Battery
49
Accessory Battery Connection
50
Water Pressure
50
Adjustments
51
Specifications
52
Product Warranty Information
56
Bombardier Recreational Products Limited Warranty for 2010 Evinrude Outboard Engines Sold in the United States and Canada
56
California Emission Control Warranty Statement
59
Product Warranty Information
61
Brp Limited Warranty for 2010 Evinrude Outboard Engines Used in European Union Member States, Turkey, Australia, New Zealand and Japan
61
Product Warranty Information
64
Brp Limited Warranty for 2010 Evinrude Outboard Engines Used
64
In Africa, Middle East, Latin America, Pacific Islands, Asia, Albania
64
Former Yugoslavian Republic of Macedonia, Serbia and Montenegro
64
Bosnia and Herzegovina and the Commonwealth of Independent States
64
Readiness Test
67
Frequently Asked Questions
68
Change of Address / Change of Ownership
69
Confirmation of Receipt
71

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