BRP Evinrude E-TEC G2 Manuals

BRP Evinrude E-TEC G2 Manuals

Manuals and User Guides for BRP Evinrude E-TEC G2. We have 2 BRP Evinrude E-TEC G2 manuals available for free PDF download: Service Manual, Operator's Manual

BRP Evinrude E-TEC G2 Service Manual

BRP Evinrude E-TEC G2 Service Manual (460 pages)

Brand: BRP | Category: Outboard Motor | Size: 26.88 MB

Table of Contents

Service Manual

2
Routine Service

15
- Inspection and Maintenance Schedule
  16
- Batteries
  17
- Maintenance
  17
- Oetiker Clamp Servicing
  18
- Cooling System
  19
- Engine Flushing
  19
- Gearcase Lubricant
  20
- Propeller Shaft
  20
- Spark Plugs
  22
- Fuel and Oil Systems
  23
- Exhaust Pressure Fitting
  24
- Anti-Corrosion Protection
  25
- Storage
  26
- Lifting the Outboard
  28
- Pre-Season Service
  28
- Plug Installation
  29
- Rigging Information
  30
- Before Start-Up
  38
- Operational Checks
  39
- Propellers
  40
- Adjustments
  42
- Engine Mounting Height and Jack Plate Adjustment
  42
- Engine Water Pressure
  43
- Fuel System Vacuum
  43
- Tilt Limit Setting
  43
- Trim & Tilt
  43
- I-Trim
  44
- Trim Gauge Calibration
  44
- Dynamic Power Steering (DPS)
  45
- Multiple Outboard Alignment
  45
- Engine Submerged (in Salt Water)
  47
- Engine Submerged (Not Running)
  47
- Engine Submerged (Running)
  47
- Prolonged Submersion (Fresh or Salt Water)
  47
- Submerged Engines
  47
- Filling and Bleeding the Hydraulic Steering System
  48
- Hydraulic Steering Fluid
  48
- Single Station / Single Engine Steering Installations
  48
- Single Station / Multiple Engine Installations
  50
- Steering System Checks
  52
- Oetiker Clamp Chart
  54
Engine Cover and Frame Service

55
- Service Charts
  56
- Top Cover and Center Frame
  56
- Rear Cover, Starboard Cover and Starboard Frame
  57
- Port Cover and Frame, Front Cover and Frame
  58
- Rigging Center
  59
- Cover Removal
  60
- Cover Installation
  62
- Frame Removal
  64
- Starboard, Port, and Front Frame Removal
  64
- Center Frame Removal
  67
- Center Frame Installation Installation
  71
- Frame Installation
  71
- Front, Port, and Starboard Frame Installation
  73
Engine and Control Systems

77
- Engine Management Module (EMM)
  78
- EMM Inputs and Outputs Diagram
  79
- Barometric Pressure Sensor
  80
- Circuit Sensor
  80
- EMM Temperature Sensor
  80
- Engine Control Systems
  80
- Internal Sensors
  80
- Air Temperature Sensor
  81
- Engine Temperature Sensor
  81
- Exhaust Pressure Sensor
  81
- Exhaust Temperature Sensor
  81
- External Sensors
  81
- Low Oil Level Switch
  82
- Oil Level Sensor
  82
- Crankshaft Position Sensor
  83
- Dynamic Power Steering
  83
- Electronic Shift Controller
  83
- Electronic Throttle Controller
  83
- Idle Controller
  83
- Internal EMM Functions
  83
- Knock Sensor
  83
- ROM Verification
  83
- Start Assist Circuit (SAC)
  83
- Electronic Throttle Controller
  84
- Engine Monitor and Warning Systems
  84
- Fault Code Creation and Storage
  84
- Neutral RPM Limiter
  84
- RPM Limiter
  84
- Throttle, Shift and Steering Control Systems
  84
- Electronic Shift Controller
  86
- Engine Monitor System
  88
- Warning System
  89
- Diagnostic Software Functions
  90
- EMM Servicing
  96
System Analysis

101
- Diagnostic Procedures
  102
- Diagnostic Software Inspections
  102
- Visual Inspections
  102
- Operational Inspections
  103
- Troubleshooting
  104
- Fuel System Static Tests
  105
- Ignition System Static Test
  105
- Static Tests
  105
- Oil System Static Tests
  106
- Cylinder Drop Tests
  107
- Dynamic Tests
  108
- Fuel Control Adjustment
  108
Electrical and Ignition

109
- Service Charts
  110
- Electrical Harness Connections
  112
- Fuses
  115
- Ground Circuits
  115
- Air Temperature Sensor (AT) Test
  116
- Air Temperature Sensor Circuit Test
  116
- Sensor and Circuit Tests
  116
- CPS Circuit Test
  117
- Crankshaft Position Sensor (CPS) Operation Test
  117
- Crankshaft Position Sensor (CPS) Resistance Test
  117
- Engine Temperature Circuit Test
  118
- Engine Temperature Sensor Test
  118
- Exhaust Temperature Circuit (EGT) Test
  118
- Exhaust Temperature Sensor (EGT) Test
  118
- Knock Sensor Circuit Test
  119
- Knock Sensor Test
  119
- Ignition System
  120
- Required Systems
  120
- Ignition System Circuit Diagram
  121
- Ignition System Tests
  122
- Wiring Inspection
  122
- Ignition Circuit Tests
  123
- Ignition Coil Tests
  123
- Stator Tests
  125
- Charging System Tests
  127
- Electric Start Circuit
  129
- Start Circuit Diagram
  129
- Start Circuit Operation
  130
- Electric Starter Tests
  131
- Starter Voltage Drop Test
  131
- Starter Voltage Test
  131
- Tilt/Trim Relay Test
  132
- Flywheel and Stator Servicing
  133
- Ignition Coil Servicing
  135
- Timing Adjustments
  136
- Timing Pointer
  136
- Electric Starter Servicing
  138
- Timing Verification
  138
- Connector Servicing
  139
Fuel System

145
- Reed Plate Assembly and Throttle Body
  146
- Service Charts
  146
- Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails ABA & AFA Models
  147
- Fuel Pump and Vapor Separator, Fuel Filter and Fuel Rails AGA & Newer Models
  148
- Fuel Injectors
  149
- Fuel System Flow Diagram (AB, AF Models)
  150
- Fuel System Flow Diagram (AG & Newer)
  151
- Fuel System Circuit Diagram
  152
- Fuel Flow Requirements
  153
- Fuel System Requirements
  153
- Permanent Fuel Tanks
  153
- Portable Fuel Tanks
  153
- Regulations and Guidelines
  153
- Fuel Requirements
  154
- Components
  155
- Fuel Pump & Vapor Separator Assembly
  155
- Mechanical Fuel Lift Pump (AGA & Newer)
  155
- Fuel Filters
  158
- Fuel Rails
  158
- Fuel Injectors
  159
- Fuel System Pressure Tests
  160
- Fuel System Priming
  160
- Fuel System Tests
  160
- Fuel System Electrical Tests
  164
- Fuel Component Servicing
  168
- Fuel Filter Service
  168
- Relieving Fuel System Pressure
  168
- Mechanical Fuel Lift Pump Service
  169
- Vapor Separator Service
  170
- Fuel Rail Service
  172
- Fuel Injector Service
  174
- Intake Manifold Service
  180
- Throttle Valve Service
  180
Oiling System

185
- Oil Tank Assembly
  186
- Service Charts
  186
- Cylinder Oil Pump Assembly
  187
- Oiling System Circuit Diagram
  188
- Oil Recirculation Diagram
  189
- 200, 225, 250 HP, 250 H.O., 300 HP Models - Starboard
  190
- Oil Supply Diagrams
  190
- 200, 225, 250 HP, 250 H.O., 300 HP Models - Rear
  191
- Checking Oil Level
  192
- Components
  192
- Oil Requirements
  192
- Oil Tank Assembly
  192
- Optional Remote Oil Tank Kits
  192
- Recommended Lubricants
  192
- Crankcase Oil Pump
  193
- Cylinder Oil Pump
  193
- Oil Level Sender
  193
- Cylinder and Crankcase
  194
- LOW OIL Switch
  194
- Oil Warning System
  194
- Break-In Oiling
  195
- Oil Recirculation System
  195
- Oil Supply Priming
  196
- Oil Pump Electrical Tests
  198
- Oiling System Tests
  198
- Oil Pump Circuit Tests
  200
- Oil Pump Resistance Test
  201
- LOW OIL Switch Circuit Test
  202
- LOW OIL Switch Test
  202
- Oil Fittings Flow Test
  202
- Oil Pump Function Test
  202
- Oil Level Sender Circuit Test
  203
- Oil Level Sender Resistance Test
  203
- Oil Component Servicing
  204
- Oil Distribution Hoses
  204
- Oil Tank Servicing
  205
- Crankcase Oil Pump
  206
- Cylinder Oil Pump
  207
Cooling System

209
- Water Flow
  210
- Water Flow and Hose Routing Diagrams
  210
- Cooling Hose Routing Diagram - Port
  212
- Cooling Hose Routing Diagram - Starboard
  213
- Cooling Hose Routing Diagram - Rear
  214
- Cooling Hose Routing Diagram - Top
  215
- Components
  216
- Exhaust Adapter
  216
- Pressure Relief Valve
  216
- Water Pump and Intakes
  216
- Water Supply Tube
  216
- Block Venting
  217
- Cylinder Block / Cylinder Head Cooling
  217
- Operation
  217
- Thermostats
  217
- EMM and Vapor Separator Cooling
  218
- Engine Temperature Check
  218
- Idle Operating Temperature Troubleshooting (below Range)
  219
- Pyrometer Method
  219
- Software Method
  219
- Component Servicing
  221
- Temperature Sensor Servicing
  221
- Thermostat Servicing
  221
- Pressure Relief Valve Servicing
  222
Evinrude Icon II Remote Control System

223
- Components
  224
- ICON II Remote Control
  224
- NMEA 2000 Network
  225
- Outboard EMM
  225
- Remote Control (Private) Network
  225
- Shift Actuator
  225
- Multiple Engine Instancing
  226
- System Settings and Diagnostics
  226
- Throttle Valve Assembly
  226
- Fluid Level Configuration
  229
- Remote Control Configuration
  229
- Remote Control Identity
  229
- Remote Control Faults
  230
- Remote Control Monitor
  230
- Remote Control Software
  230
- ICON II System Fault Detection
  231
Powerhead

233
- Cylinder Head
  234
- Service Charts
  234
- Crankshaft and Pistons
  235
- Cylinder and Crankcase (Port, Starboard, Front)
  236
- Cylinder and Crankcase (Bottom, Top, Rear)
  237
- Cylinder and Crankcase to Exhaust Adapter and Exhaust Housing
  238
- Compression Testing
  239
- Powerhead Removal
  239
- Powerhead Disassembly
  244
- Systems Removal
  244
- Crankcase Disassembly
  245
- Cylinder Head Removal
  245
- Connecting Rods and Pistons
  246
- Crankshaft Removal
  247
- Powerhead Studs
  249
- Cylinder Block Cleaning
  250
- Powerhead Inspection
  251
- Crankshaft Assembly
  254
- Powerhead Assembly
  254
- Pistons and Connecting Rods
  256
- Installing Pistons
  257
- Cylinder Head Installation
  258
- Crankshaft and Connecting Rods
  259
- Deck Cover Installation
  259
- Crankcase Assembly
  262
- Final Powerhead Assembly
  263
- Powerhead Installation
  264
- Pre-Service Adjustments
  264
- Powerhead Views
  271
- Starboard
  271
- Port - Non-DPS Models
  272
- Port - DPS Models
  273
- Rear - 200, 225, 250 HP Models
  274
- Rear - 250 H.O., 300 HP Models
  275
- Front - Frame Removed
  276
- Front - Frame Installed
  277
- Exhaust Water Valve
  278
- Water Flow
  278
- Circuit Tests
  279
- Dynamic Test
  279
- Exhaust Water Valve Operation
  279
- Exhaust Water Valve Tests
  279
- Static Test
  279
- Water Valve Resistance Test
  280
- Exhaust Water Valve Component Service
  281
Exhaust Housing & Adapter

283
- Exhaust Housing
  284
- Service Charts
  284
- Adapter and Muffler
  285
- Cleaning and Inspection
  286
- Exhaust Housing Removal
  286
- Exhaust Housing Service
  286
- Exhaust Adapter Removal
  287
- Exhaust Housing Installation
  287
- Exhaust Adapter Installation
  289
- Exhaust Water Cooling Fitting
  290
- Lower Mount Service
  291
- Upper Mount Service
  291
- Exhaust Relief Muffler Assembly
  292
Stern and Swivel

293
- Service Charts
  294
- Stern & Swivel
  294
- Spray Plate, Covers and Anode
  295
- Steering Arm, End Cap and Lower Bracket
  296
- Stern & Swivel Bracket Attachments
  297
- DPS Manifold Assembly
  298
- DPS Pressure Sensors
  299
- Trim & Tilt Manifold Assembly (Non-DPS Models)
  300
- ABA Models (DPS-1)
  301
- AFA & Newer Models (DPS-2)
  301
- Dynamic Power Steering (DPS)
  301
- DPS Electrical Circuit Diagram
  303
- DPS System Tests
  304
- Steering Ground Circuits
  304
- Steering Supply Circuits
  304
- Canbus Circuit
  305
- Steering Motor Circuits
  305
- Steering Pressure Sensor Tests
  305
- Steering Sensor Circuits
  305
- Steering Position Sensor Service
  306
- Steering Position Sensor Test
  306
- DPS Module Installation
  307
- DPS Module Removal
  307
- DPS Module Service
  307
- DPS Software Installation
  308
- DPS System Calibration
  309
- DPS Manifold Service
  314
- Removal
  314
- Cleaning and Inspection
  316
- Installation
  316
- Disassembly
  319
- Assembly
  320
- Steering Pressure Sensors
  321
- Electric Motor
  322
- Trim & Tilt Manifold Service
  323
- Trim & Tilt System Service
  323
- Trim Rod Service
  330
- Filling the Trim and Tilt System
  332
- Trim and Tilt Fluid Level
  332
- Removal
  334
- Stern & Swivel Bracket
  334
- Installation
  337
- Stern Bracket Service
  339
- Steering Arm, End Cap and Lower Bracket Service
  344
- Trim Sender Service
  344
Gearcase

351
- Propeller Hardware
  353
- Service Charts
  353
- Water Pump and Gearcase Housing
  354
- Driveshaft and Shift Actuator
  355
- Standard Rotation Propeller Shaft
  356
- Counter Rotation Propeller Shaft
  357
- Gearcase Type
  358
- Housing Profile
  358
- Inspection
  359
- Propeller Selection
  359
- Propeller Service
  359
- Propeller Hardware Installation
  360
- Gearcase Leak Test
  361
- Gearcase Removal and Installation
  361
- Disassembly
  365
- Water Pump Service
  365
- Assembly
  366
- Inspection
  366
- Shift Rod Adjustment
  368
- Control Circuit Tests
  369
- Neutral Circuit
  369
- Shift Actuator
  369
- Shift Actuator Ground Circuit
  369
- Shift Actuator Installation
  370
- Shift Actuator Removal
  370
- Shift Actuator Service
  370
- Shift Actuator Calibration
  372
- Gearcase Disassembly
  373
- Pre-Disassembly Inspection
  373
- Propeller Shaft Bearing Housing and Reverse Gear Removal
  374
- Pinion Gear and Lower Driveshaft Removal
  376
- Oil Pump Service
  377
- Propeller Shaft and Forward Gear Removal
  378
- Shift Housing Removal
  379
- Pinion Bearing Installation
  380
- Pinion Bearing Removal
  380
- Shifter, Bearing and Seal Servicing
  380
- Water Intake Screens
  380
- Propeller Shaft Disassembly
  381
- Shift Housing Disassembly
  382
- Shift Housing Assembly
  383
- Shift Rod Bushing Service
  385
- Driveshaft Bearing Housing Service
  386
- Propeller Shaft Bearing Housing Service
  387
- Driveshaft Shimming
  391
- Gearcase Assembly
  392
- Shift Housing, Gear, and Propeller Shaft Installation
  392
- Water Intake Screens
  392
- Pinion Gear and Driveshaft Installation
  393
- Propeller Shaft Bearing Housing and Gear Installation
  395
- Final Assembly and Adjustment
  397
- Gearcase Disassembly
  397
- Pre-Disassembly Inspection
  397
- Propeller Shaft, Propeller Shaft Bearing Housing and Forward Gear Removal
  397
- Clutch Shaft and Reverse Gear Removal
  399
- Pinion Gear Removal and Driveshaft Servicing
  399
- Shift Housing Disassembly
  401
- Shift Housing Removal
  401
- Shifter, Bearing and Seal Servicing
  401
- Water Intake Screens
  401
- Shift Housing Assembly
  403
- Pinion Bearing
  405
- Propeller Shaft Bearing Housing and Forward Gear
  405
- Driveshaft Shimming
  408
- Gearcase Assembly
  410
- Shift Housing, Gear, and Propeller Shaft Installation
  410
- Water Intake Screens
  410
- Pinion Gear and Driveshaft Installation
  412
- Propeller Shaft, Propeller Shaft Bearing Housing and Gear Installation
  412
- Final Assembly and Adjustment
  414
Safety

415

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BRP Evinrude E-TEC G2 Operator's Manual

BRP Evinrude E-TEC G2 Operator's Manual (82 pages)

Brand: BRP | Category: Outboard Motor | Size: 6.39 MB

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