BRP Evinrude E-Tec E200DPLSUR Manuals

Manuals and User Guides for BRP Evinrude E-Tec E200DPLSUR. We have 1 BRP Evinrude E-Tec E200DPLSUR manual available for free PDF download: Service Manual

BRP Evinrude E-Tec E200DPLSUR Service Manual

BRP Evinrude E-Tec E200DPLSUR Service Manual (443 pages)

115,150,175,200 HP, 60 V Models

Brand: BRP | Category: Outboard Motor | Size: 45.93 MB

Table of Contents

Safety Information

4
- Table of Contents
  4
  - Safety Information
    4
  - Table of Contents
    6
- Models Covered in this Manual
  8
- Identifying Model and Serial Numbers
  8
- Model Designation
  9
- Typical Page - a
  10
- Typical Page - B
  11
- Typical Page - C
  12
- Typical Page - D
  13
- Abbreviations Used in this Manual
  14
- Units of Measurement
  14
- List of Abbreviations
  14
- Engine Emissions Information
  15
- Manufacturer's Responsibility
  15
- Dealer's Responsibility
  15
- Owner's Responsibility
  15
- Epa Emission Regulations
  15
- Product Reference and Illustrations
  16
- Symbols
  16
- Electrical
  16
- Values
  17
- Notes
  18
Service Specifications and Special Tools 1

19
- Service Specifications and Special Tools
  20
- Technical Data
  20
- Standard Torque Specifications
  22
- Special Tools
  23
  - Diagnostics
    23
  - Universal
    23
  - Electrical / Ignition
    24
  - Fuel/Oil Systems
    25
  - Powerhead
    26
  - Gearcase
    27
  - Trim and Tilt
    29
- Shop Aids
  30
- Notes
  34
Installation and Predelivery

35
- Boat Rigging
  
  36
  - Remote Controls
    36
  - Battery Installation
    38
  - Battery Switches and Multiple Batteries
    39
  - Auxiliary Battery Charge Isolator
    40
  - Battery and Switch Wiring Diagrams
    41
  - Fuel System Requirements
    43
  - Oiling System Set-Up
    45
  - Cable and Hose Installation
    48
- Outboard Installation
  
  53
  - Hull Preparation
    53
  - Transom Measuring and Drilling
    54
  - Lifting the Outboard
    58
  - Steering Systems
    58
  - Outboard Mounting
    60
- Outboard Rigging
  
  61
  - Cable, Hose, and Wire Routing
    61
  - Control Cable Installation
    62
  - Electrical Harness Connections
    64
  - Water Pressure Gauge
    65
  - Canbus Connections
    65
- Fuel and Oil Priming
  
  67
  - Fuel Requirements
    67
  - Fuel System Priming
    68
  - Oil Requirements
    68
  - Oil Injection Rate
    69
  - Break-In Oiling
    69
  - Systemcheck Low Oil Warning
    70
  - Oil Supply Priming
    70
- Before Start-Up
  
  72
- Running Checks
  
  73
  - Systemcheck Operation
    73
  - Fuel System
    73
  - Emergency Stop / Key Switch
    73
  - Start-In-Gear Prevention
    73
  - Tachometer Pulse Setting
    74
  - Water Pump Overboard Indicator
    74
  - Operating Temperature
    74
  - Break-In
    74
  - Idle Speed
    74
- Propellers
  
  75
  - Propeller Selection
    75
  - Propeller Hardware Installation
    76
- Final Adjustments
  
  77
  - Tilt Limit Switch Adjustment
    77
  - Trim Sending Unit Adjustment
    78
  - Trim Tab Adjustment
    79
  - Dual-Outboard Alignment
    80
Maintenance

81
- Inspection and Maintenance Schedule
  
  82
- Anti-Corrosion Protection
  
  83
  - Sacrificial Anodes
    83
  - Testing Procedure - Continuity
    83
  - Metallic Component Protection
    83
  - Exterior Finishes
    83
- Cooling System
  
  84
  - Flushing
    84
  - Water Intake Screens
    85
  - Additional Maintenance
    85
- Lubrication
  
  85
  - Steering System
    85
  - Swivel Bracket and Trailering Bracket
    86
  - Tilt Tube
    86
  - Throttle and Shift Linkage
    86
  - Propeller Shaft
    87
  - Gearcase Lubricant
    87
  - Trim and Tilt
    88
- Fuel and Oil Systems
  
  89
  - Fuel Filter
    89
  - Oil Filters and Oil Reservoir
    90
  - Air Silencer
    90
  - Hoses and Connections
    90
- Battery and Battery Connections
  
  89
- Spark Plugs
  
  91
  - Indexing
    91
- Exhaust Pressure Fitting
  
  92
  - Operation Test
    92
  - Cleaning
    92
- Storage
  
  93
  - Fuel System Treatment
    93
  - Internal Engine Treatment
    93
  - Additional Recommendations
    94
- Pre-Season Service
  
  94
  - Outboard Mounting Bolts
    94
  - Gearcase Lubricant
    94
  - Battery(S)
    94
  - Power Trim and Tilt
    94
  - Operational Checks
    94
- Submerged Engines
  
  95
- Notes
  
  96
Maintenance Notes Notes

97
- Engine Management Module (Emm)
  97
- Description
  
  98
  - Emm Functions
    98
  - Emm Connections
    98
- Sensors and Functions
  
  99
  - Internal Sensors
    99
  - External Sensors
    100
  - Internal Functions
    103
- Emm Inputs and Outputs Diagram
  
  104
- Shutdown Mode
  
  105
- Warning System
  
  105
  - Initiation
    105
  - Recovery
    105
- Emm Diagnostics
  
  106
  - Led Indicators
    106
  - Diagnostic Software Program
    107
  - Communication
    107
  - Program Information
    108
  - Service Codes (Faults)
    108
  - Static Tests
    109
  - Dynamic Tests
    110
  - Oil Control
    111
  - Timing Verification
    111
  - Tps Calibration
    112
  - Fuel Injector Servicing
    112
  - Fuel Control Adjustment
    112
  - Reports
    113
  - Software Replacement
    113
  - Emm Transfer
    113
- Systemcheck Engine Monitor
  
  114
  - Gauges
    114
  - System Self-Test
    114
  - Service Mode
    114
  - Engine Running
    114
System Analysis

115
- Electrical Connections
  
  116
- Ground Circuits
  
  118
  - Test Procedure
    118
- Fuse
  
  118
- Emm Diagnostics
  
  119
  - Led Indicators
    119
  - Software Programs
    119
- Diagnostic Procedures
  
  120
  - Symptoms
    121
- Specialized Test Procedures
  
  122
  - Dynamic Tests
    122
  - Testing with Timing Light
    122
  - Inductive Amp Meter Test
    123
  - Engine Monitoring Information
    123
  - Voltage Testing
    124
- Start Circuit
  
  124
  - Electric Starter Operation
    124
  - Starter Solenoid Activation
    125
  - Start Circuit Diagram
    127
- Ignition and Electrical Circuits
  
  128
- Ignition Output
  
  129
  - Wiring Inspection
    129
  - Ignition Voltage
    129
  - System Voltage
    130
  - Static Spark Test
    130
  - Running Ignition Tests
    131
  - Ignition Primary Circuit Resistance Test
    132
  - Crankshaft Position Sensor (Cps) Test
    132
- Fuel Delivery
  
  133
  - Manifold Pressure Test
    133
  - Vapor Separator Checks
    134
  - Fuel Delivery to Lift Pump
    134
- Fuel Injector Operation
  
  134
  - Static Tests
    134
  - Dynamic Tests
    135
- Exhaust Valve
  
  136
Electrical and Ignition

137
- Service Chart
  138
- Dash Connections, Instrument Harness
  140
- Sensor Resistance Tests
  141
- Capacitor Test
  142
- Ignition Coil Tests
  143
- Stator Tests
  143
- Charging System Tests
  144
- Systemcheck Circuit Tests
  147
- Remote Control Switch Tests
  149
  - Key Switch Test
    149
  - Neutral Start Circuit Test
    150
  - Neutral Start Switch Test
    150
  - Emergency Stop Switch Test
    151
- Tachometer Circuit Tests
  151
- Electric Starter Tests
  152
  - Starter Solenoid Test
    152
  - Load Current Draw Test
    152
- Tilt/Trim Relay Test
  153
  - Operation
    153
  - Test Procedure
    154
- Exhaust Valve Relay Tests
  154
- Emm Servicing
  155
  - Removal
    155
  - Installation
    156
- Flywheel and Stator Servicing
  156
  - Flywheel Removal
    156
  - Stator Service
    158
  - Flywheel Installation
    158
- Timing Adjustments
  159
  - Timing Pointer
    159
  - Timing Verification
    161
- Tps Calibration
  161
- Spark Plugs
  162
  - Inspection
    162
  - Indexing
    162
- Electric Starter Servicing
  163
  - Removal
    163
  - Disassembly
    163
  - Cleaning and Inspection
    166
  - Assembly
    167
  - Installation
    169
- Connector Servicing
  170
Table of Contents

175
- Service Chart
  
  176
- Components
  
  179
  - Fuel Lift Pump
    179
  - Fuel Filter
    179
  - Vapor Separator
    180
  - Fuel Circulation Pump
    181
  - Fuel Manifolds
    181
  - Fuel Injectors
    182
- Fuel System Hose Routing
  
  183
- Direct Injection Electrical Circuits
  
  184
  - Injector / Circulation Pump Circuits Diagram
    185
- Fuel Component Tests
  
  186
  - Fuel Injectors
    186
  - Fuel Supply
    187
- Fuel Component Servicing
  
  191
  - Relieving Fuel System Pressure
    191
  - In-Line Fuel Filter
    192
  - Optional Fuel Filter
    192
  - Fuel Lift Pump
    193
  - Vapor Separator
    193
  - Fuel Manifolds
    194
  - Fuel Injectors
    195
- Intake Manifold
  
  198
  - Removal
    198
  - Disassembly
    198
  - Inspection
    199
  - Assembly
    199
  - Installation
    199
Oiling System

201
- Service Chart
  
  202
- Components
  
  203
  - Oil Tank
    203
  - Oil Injection Pump
    203
  - Oil Pressure Sensor
    204
  - Electrical Circuit (55 V)
    204
  - Oil Injection Pump Diagram
    205
  - Oiling System Electrical Diagram
    206
  - Systemcheck, I-Command and Emm Oiling System Warnings
    207
  - Cylinder and Crankcase
    207
  - Oil Supply and Distribution Diagrams - V6
    208
  - Oil Supply and Distribution Diagrams - V4
    210
  - Oil Recirculation System
    212
  - Recirculation Hose Routings and Check Valve Diagrams - V6
    213
  - Recirculation Hose Routings and Check Valve Diagrams - V4
    215
- Priming
  
  217
  - Oil Hose Connections
    217
  - Oil Distribution Manifold Priming
    217
- Oiling Rates
  
  219
  - Oil Injection Rate
    219
  - Xd100 Outboard Oil Decal
    219
  - Break-In Oiling
    219
- Oiling System Tests
  
  220
  - Oil Injection Pump Static Test
    220
  - Oil Injection Pump Voltage Test
    220
  - Oil Injection Pump Circuit Resistance Test
    221
  - Oil Supply Vacuum Test
    222
  - Oil Injection Pump Function Test
    222
  - Oil Injection Fittings Flow Test
    223
  - Low Oil Sending Unit Test
    223
- Oil Component Servicing
  
  224
  - Oil Distribution Hoses
    224
  - Oil Injection Pump
    225
Cooling System

227
- Hose Routing and Water Flow Diagrams
  
  228
- Engine Temperature Check
  
  230
  - Software Method
    230
  - Pyrometer Method
    230
  - Idle Operating Temperature Troubleshooting (below Range)
    231
- Components
  
  232
  - General Description
    232
  - Water Pump and Intakes
    232
  - Water Supply Tube
    232
  - Adapter/Inner Exhaust Housing
    233
  - Pressure Relief Valve
    233
  - Thermostats
    233
  - Block Venting
    233
- Operation
  
  234
  - Cylinder Block / Cylinder Head Cooling
    234
  - Vapor Separator and Emm Cooling
    234
- Thermostat Servicing
  
  235
  - Disassembly
    235
  - Inspection
    235
  - Assembly
    235
- Pressure Relief Valve Servicing
  
  235
  - Inspection
    236
  - Assembly
    236
Powerhead

237
- Service Chart
  
  238
- General
  
  240
  - Cylinder Compression Testing
    240
  - Retaining Ring Pliers
    240
- Removal
  
  241
- Disassembly
  
  243
  - General
    243
  - Crankcase
    244
  - Cylinder Head
    245
  - Connecting Rods and Pistons
    245
  - Crankshaft
    247
- Cleaning
  
  249
- Inspection
  
  250
  - Cylinder Head
    250
  - Crankshaft
    250
  - Cylinder Bore
    251
  - Pistons
    251
  - Piston Rings
    251
  - Bearings
    252
- Assembly
  
  252
  - Crankshaft
    252
  - Pistons and Connecting Rods
    254
  - Cylinder Head
    256
  - Crankshaft and Connecting Rods
    257
  - Crankcase
    260
  - General
    261
- Upper Mount Servicing
  
  263
- Installation
  
  264
- Powerhead Views
  
  268
  - V4 Starboard - Hose Routings
    268
  - V4 Port - Hose Routings
    269
  - V4 Starboard
    270
  - V4 Port
    271
  - V4 Front
    272
  - V4 Rear
    273
  - Top - Hose Routings
    274
  - V4 - V6 Top
    275
  - V6 Starboard - Hose Routings
    276
  - V6 Port - Hose Routings
    277
  - V6 Starboard
    278
  - V6 Port
    279
  - V6 Front
    280
  - V6 Rear
    281
- Notes
  
  282
Powerhead Notes Notes

283
- Midsection
  283
- Service Chart
  
  284
- Tilt Tube
  
  287
  - Removal
    287
  - Installation
    288
- Exhaust Housing
  
  289
  - Removal
    289
  - Disassembly
    290
  - Cleaning and Inspection
    291
  - Assembly
    291
  - Installation
    294
- Stern Bracket
  
  295
  - Removal
    295
  - Disassembly
    295
  - Assembly
    297
- Exhaust Relief Muffler Assembly
  
  300
Gearcase

301
- Service Chart
  302
- Gearcase Types
  307
- Propeller
  308
- Shift Interrupt Switch
  308
- Lubricant
  309
- Leak Test
  310
- Removal and Installation
  310
- Water Pump
  313
- Disassembly
  316
  - Pre-Disassembly Inspection
    316
  - Propeller Shaft Bearing Housing Removal
    317
  - Pinion Gear and Driveshaft Removal
    318
  - Driveshaft Service
    322
  - Shift Housing, Gear and Propeller Shaft Removal
    325
  - Water Intake Screens
    325
- Shift Rod Adjustment
  316
- Gearcase Housing Inspection
  325
- Bearing and Seal Removal
  326
  - Shift Housing
    326
  - Pinion Gear Bearing
    327
  - Driveshaft Bearing Housing
    328
  - Propeller Shaft Bearing Housing
    328
- Bearing and Seal Installation
  329
  - Shift Housing
    329
  - Pinion Gear Bearing
    331
  - Driveshaft Bearing Housing
    332
  - Propeller Shaft Bearing Housing
    333
- Driveshaft Shimming
  334
- Assembly
  336
- Counter Rotation
  343
- Notes
  356
Gearcase Notes Notes

357
- Service Chart
  
  358
- System Description
  
  360
  - Manual Adjustment
    360
  - Trailering Bracket and Tilt Support
    360
- Modes of Operation (Three Piston System)
  
  361
  - Trim-Out / Tilt-Up Mode
    361
  - Tilt-Down / Trim-In Mode
    362
  - Impact Relief
    363
  - Shallow Water Drive Tilt Relief
    364
  - Thermal Expansion Relief
    364
  - Manual Release - up
    365
  - Manual Release - down
    366
- Routine Inspections
  
  367
  - General
    367
  - Reservoir Fluid
    367
  - Manual Release Valve
    367
  - Stern Brackets
    367
- Troubleshooting
  
  368
  - Three Piston System
    368
  - Single Piston System
    371
- Electrical Circuit Tests
  
  372
  - Relay Testing
    372
  - Trim and Tilt Motor Current Draw Tests
    372
  - Trim and Tilt Motor no Load Test
    373
  - Trim Gauge Test
    374
  - Trim Sender Test
    374
- Removal and Installation
  
  375
- Servicing - Three Piston System
  
  378
  - Disassembly
    378
  - Tilt Piston Removal
    380
  - Tilt Piston Identification
    381
  - Tilt Piston Assembly
    382
  - Tilt Rod Assembly
    382
  - Trim Rod Removal
    384
  - Trim Rod Assembly
    385
  - Manifold and Reservoir Installation
    386
  - Trim Rod Installation
    387
  - Tilt Rod Installation
    387
  - Motor Installation
    388
- Servicing-Single Piston System
  
  390
  - Disassembly
    390
  - Safety
    390
  - Assembly
    391
- Adjustments
  
  392
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety

393
- Marine Products and the Safety of People Who Use Them
  395
- Marine Products and the Safety of People Who Fix Them
  409
  - Handling Outboards
    409
  - Handling Lead/Acid Batteries
    413
  - Gasoline - Handle with Care
    414
  - Hazardous Products
    415
  - Safety Awareness Test
    416
  - Index
    417
  - Trouble Check Chart
    425

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