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Evinrude E25DRSII Series
BRP Evinrude E25DRSII Series Manuals
Manuals and User Guides for BRP Evinrude E25DRSII Series. We have
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BRP Evinrude E25DRSII Series manual available for free PDF download: Service Manual
BRP Evinrude E25DRSII Series Service Manual (342 pages)
Brand:
BRP
| Category:
Outboard Motor
| Size: 24.52 MB
Table of Contents
S M Ervice Anual
4
Table of Contents
4
Safety Notice
6
Abbreviations Used in this Manual
8
Units of Measurement
8
List of Abbreviations
8
Emission-Related Installation Instructions
9
Manufacturer's Responsibility
9
Dealer's Responsibility
9
Owner's Responsibility
9
Epa Emission Regulations
9
Model Designation
10
Models Covered in this Manual
11
Service Specifications
12
Standard Torque Specifications
14
Product Reference and Illustrations
14
Table of Contents
15
Routine Service
15
Inspection and Maintenance Schedule
16
Lifting the Outboard
17
Outboard Rigging Connections
19
Control Cable Installation
20
Systemcheck Harness Connections
22
Battery and Battery Connections
23
Oetiker Clamp Servicing
24
Adjustments
26
Steering Friction Adjustment
26
Throttle Friction Adjustment
26
Tiller Height Adjustment
27
Tiller Handle Ratchet
27
Tiller Handle Friction
27
Neutral Switch Adjustment
27
Trim Sending Unit Adjustment
28
Trim Tab Adjustment
29
Operational Checks
30
Cooling System
31
Water Intake Screens
31
Idle Speed
31
Engine Flushing
32
Running the Outboard Using a Hose and Flushing Adapter
33
Lubrication
34
Steering System
34
Tiller Handle
34
Swivel Bracket and Trailering Bracket
34
Tilt Tube
34
Throttle and Shift Linkage
35
Propeller Shaft
35
Gearcase Lubricant
36
Trim and Tilt
37
Spark Plugs
38
Indexing
38
Fuel and Oil Systems
39
Fuel Filter
39
Oil Filters and Oil Reservoir
39
Air Silencer
39
Hoses and Connections
39
Anti-Corrosion Protection
40
Metallic Component Protection
40
Exterior Finishes
40
Storage
41
Fuel System Treatment
41
Internal Engine Treatment
41
Additional Recommendations
42
Pre-Season Service
42
Power Trim and Tilt
42
Submerged Engines
43
Engine Cover Service
45
Upper Cover Service
46
Latch Hook Installation
46
Lower Cover Service
47
Lower Cover Removal
47
Lower Cover Installation
47
Latch Handle Installation
49
Engine Cover Service Notes Notes
51
Engine Management Module (Emm)
51
Description
52
Emm Functions
52
Emm Connections
52
Led Indicators
52
Emm Inputs and Outputs Diagram
53
Internal Sensors
54
Emm Temperature Sensor
54
55 V Circuit Sensor
54
Circuit Sensor
55
Barometric Pressure Sensor
55
External Sensors
55
Air Temperature Sensor
55
Engine Temperature Sensor
56
Low Oil Switch
56
Throttle Position Sensor
57
Crankshaft Position Sensor
57
Neutral Switch
57
Engine Monitor System
58
Internal Emm Functions
58
Warning System
59
Diagnostic Software Functions
60
Communication
60
Static Information
61
Dynamic Information
62
Stored Service Codes (Faults)
62
Hard Faults
62
Persistent Faults
62
Static Tests
62
Dynamic Tests
63
Oil Control Settings
64
Tiller/Remote Programming
64
Ignition Timing
65
Tps Calibration
65
Fuel Injector Servicing
66
Reports
66
Software Replacement
67
Emm Transfer
67
Shutdown Mode
60
Emm Servicing
68
Removal
68
Installation
68
System Analysis
69
Diagnostic Procedures
70
Visual Inspections
70
Operational Inspections
70
Troubleshooting
71
Dynamic Tests
72
Cylinder Drop Tests
72
Fuel Control Adjustment
72
Inductive Amp Meter Test
72
Emm Led Indicators
73
Key on
73
Starting
73
Running
74
Ignition Output Tests
75
Required Ignition Systems
75
Wiring Inspection
75
Crankshaft Position Sensor (Cps) Test
76
System Voltage Test
76
Static Ignition Test
77
Running Ignition Tests
78
Ignition Control Circuit Tests
79
Ignition Coil Tests
79
Fuel Delivery Tests
80
Fuel Pump Static Test
80
Fuel Injector Static Test
80
Running Fuel System Tests
81
System Analysis Notes Notes
83
Electrical and Ignition
83
Service Chart
84
Ignition System Circuit Diagram
86
Diagrams
87
Electrical Harness Connections
87
Fuse
88
Ground Circuits
88
Sensor Tests
89
Crankshaft Position Sensor (Cps) Test
89
Throttle Position Sensor (Tps) Test
89
Engine Temperature Sensor Test
90
Air Temperature Sensor (At) Test
90
Stator Tests
91
Charging System Tests
93
Electric Start Circuit
96
Electric Start Tests
98
Remote Control Switch Tests
100
Key Switch Test
100
Neutral Start Circuit Test
100
Neutral Start Switch Test
101
Emergency Stop Switch Test
101
Tilt/Trim Relay Test
102
Systemcheck Circuit Tests
103
Flywheel and Stator Servicing
105
Flywheel Removal
105
Stator Service
106
Flywheel Installation
106
Tachometer Circuit Tests
105
Ignition Coil Servicing
107
Ignition Coil Removal
107
Ignition Coil Installation
107
Timing Adjustments
108
Timing Pointer
108
Timing Verification
108
Tps Calibration
108
Electric Starter Servicing
109
Starter Removal
109
Starter Disassembly
109
Starter Cleaning and Inspection
110
Starter Assembly
111
Starter Installation
113
Connector Servicing
113
Fuel System
117
Service Chart
118
Fuel System Hose Routing
120
Fuel System Circuit Diagram
121
Fuel System Requirements
122
Regulations and Guidelines
122
Portable Fuel Tanks
122
Fuel Flow Requirements
122
Fuel Requirements
123
Components
124
Fuel Lift Pump
124
Fuel Filter
124
Vapor Separator
124
Fuel Circulation Pump
125
Fuel Manifold
126
Fuel Injectors
126
Fuel System Priming
127
Vent Line Clamp
127
Priming the Fuel System
127
Fuel System Tests
128
Fuel System Pressure Test
128
Vapor Separator Vent Check
129
Fuel Injector Pressure Test
129
Fuel Injector Resistance Test
129
Circulation Pump Resistance Test
130
Lift Pump Pressure Test
130
Lift Pump Vacuum Test
131
Lift Pump Diaphragm Test
131
Anti-Siphon Valve Test
132
Fuel Component Servicing
132
Relieving Fuel System Pressure
132
Fuel Filter Service
133
Fuel Lift Pump Service
134
Vapor Separator and Fuel Injector Service
134
Intake Manifold Service
140
Oiling System
143
Service Chart
144
Oil Supply Diagrams
145
Oil Recirculation Diagram
146
Oiling System Circuit Diagram
147
Components
148
Oil Tank Assembly
148
Oil Injection Pump
148
Electrical Circuit (55 V)
149
Low Oil Warning
149
NO OIL Warning
149
Cylinder and Crankcase
150
Oil Recirculation System
150
Oil System Requirements
148
Recommended Lubricants
148
Oil Control Settings
151
Oil Injection Rate
151
Break-In Oiling
152
Oil Supply Priming
152
Oiling System Tests
153
Oil Injection Pump Voltage Test
153
Oil Injection Pump Resistance Test
154
Oil Injection Pump Function Test
155
Oil Injection Fittings Flow Test
155
Low Oil Sending Unit Test
155
Oil Component Servicing
156
Oil Distribution Hoses
156
Oil Tank Assembly
157
Oil Injection Pump
158
Cooling System
159
Hose Routing and Water Flow Diagrams
160
Components
161
Water Pump and Intakes
161
Exhaust Housing
161
Pressure Relief Valve
162
Thermostat
162
Operation
163
Cylinder Block / Cylinder Head Cooling
163
Vapor Separator, Emm and Battery Charge Module Cooling
163
Engine Temperature Check
164
Software Method
164
Pyrometer Method
164
Idle Operating Temperature Troubleshooting (below Range)
165
Thermostat and Pressure Relief Valve Servicing
166
Disassembly
166
Inspection
167
Assembly
167
Temperature Sender Servicing
166
Removal
166
Installation
166
Cooling System Notes Notes
169
Powerhead
169
Service Chart
170
Powerhead Removal
172
Compression Testing
172
Powerhead Disassembly
174
Systems Removal
174
Throttle Linkage Removal
175
Shift Linkage Removal
175
Cylinder Head Removal
175
Crankcase Disassembly
175
Crankshaft Assembly Removal
176
Connecting Rods and Pistons
176
Crankshaft Service
177
Cylinder Block Cleaning
179
Powerhead Inspection
180
Cylinder Head
180
Bearings
180
Cylinder Bore
180
Pistons
181
Piston Rings
181
Powerhead Assembly
181
Crankshaft Assembly
181
Pistons and Connecting Rods
183
Crankshaft Assembly Installation
184
Crankcase Assembly
185
Cylinder Head Installation
186
Megaphone and Inner Exhaust Housing Installation
187
Shift Linkage Installation
188
Throttle Linkage Installation
189
Final Powerhead Assembly
189
Powerhead Installation
190
Powerhead Mounting
190
Shift Linkage Adjustment
191
Final Adjustments
192
Powerhead Views
193
Port Electric Start Models
193
Starboard Electric Start Models
193
Port Rope Start Models
194
Starboard Rope Start Models
194
Front
195
Rear
196
Top
197
Midsection
199
Service Chart
200
Exhaust Housing Service
205
Exhaust Housing Removal
205
Exhaust Housing Installation
205
Mount Service
206
Exhaust Relief Muffler
208
Extension Service - 25” Models
209
Extension Service - 25" Models
209
Removal
209
Installation
209
Stern Bracket - Power Tilt Models
210
Stern Bracket Disassembly (Power Tilt)
210
Stern Bracket Assembly (Power Tilt)
212
Trim Sending Unit Removal
216
Trim Sending Unit Installation
217
Stern Bracket - Manual Tilt Models
218
Clamp Screw Service
218
Stern Bracket Disassembly (Manual Tilt)
218
Stern Bracket Assembly (Manual Tilt)
223
Tiller Handle Service
229
Removal
229
Disassembly
230
Inspection
234
Assembly
234
Installation
241
Control Cable Installation
242
Gearcase
245
Service Chart
246
Propeller Service
247
Inspection
247
Propeller Selection
247
Propeller Hardware Installation
248
Gearcase Leak Test
249
Trim Tab Service
249
Removal
249
Installation
249
Gearcase Removal and Installation
250
Gearcase Removal
250
Gearcase Installation
250
Water Pump Service
252
Disassembly
252
Inspection
252
Assembly
252
Gearcase Disassembly
255
Pre-Disassembly Inspection
255
Propeller Shaft Bearing Housing Removal
256
Shifter, Gear and Propeller Shaft Removal
257
Bearing and Seal Removal
258
Driveshaft Seals
258
Driveshaft Bearing
258
Pinion Bearings
259
Forward Bearing
259
Shift Rod Bushing and O-Ring
259
Propeller Shaft Bearing Housing Seals and O-Ring
260
Bearing and Seal Installation
260
Propeller Shaft Bearing Housing Bearings
260
Propeller Shaft Bearing Housing Seals and O-Ring
261
Shift Rod Bushing and O-Ring
261
Forward Bearing
261
Pinion Bearings
262
Driveshaft Bearing
262
Driveshaft Seals
263
Gearcase Assembly
263
Propeller Shaft, Gear and Shifter Installation
263
Propeller Shaft Bearing Housing Installation
266
Table of Contents
269
Service Chart
270
System Description
271
Manual Adjustment
271
Trailering Bracket and Tilt Support
271
Routine Inspections
272
General
272
Reservoir Fluid
272
Manual Release Valve
272
Stern Brackets
272
Troubleshooting
272
Electrical Circuit Tests
273
Relay Testing
273
Trim and Tilt Motor Current Draw Tests
273
Trim and Tilt Motor no Load Test
274
Trim Gauge Test
274
Trim Sender Test
275
Trim and Tilt Replacement
275
Removal
275
Installation
276
Trim and Tilt Service
277
Disassembly
277
Assembly
278
Manual Starter
281
Service Chart
282
Recoil Starter Removal
283
Recoil Starter Installation
284
Recoil Starter Disassembly
285
Safety
285
Recoil Starter Cleaning and Inspection
287
Recoil Starter Assembly
288
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
291
Marine Products and the Safety of People Who Use Them
293
Outboard Shift Systems and Safety
294
Outboard Speed Control System and Safety
295
Outboard Steering Control System and Safety
296
Outboard Fuel, Electrical System, and Safety
298
Outboard Mounting System and Safety
301
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
303
Outboard Emergency Stop System and Safety
304
Summing up
306
Marine Products and the Safety of People Who Fix Them
307
Handling Outboards
307
Handling Lead/Acid Batteries
311
Gasoline - Handle with Care
312
Hazardous Products
313
Safety Awareness Test
314
Index
315
Trouble Check Chart
323
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