BRP Evinrude E25DTSLII Series Manuals

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BRP Evinrude E25DTSLII Series Service Manual (342 pages)

Brand: BRP | Category: Outboard Motor | Size: 24.52 MB

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
- 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 - Manual Tilt Models
  
  218
- 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
- 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
- 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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BRP Evinrude E25DTSLII Series Manuals

BRP Evinrude E25DTSLII Series Service Manual (342 pages)

Table of Contents

S M Ervice Anual

Safety Notice

Abbreviations Used in this Manual

Units of Measurement

List of Abbreviations

Emission-Related Installation Instructions

Manufacturer's Responsibility

Dealer's Responsibility

Owner's Responsibility

Epa Emission Regulations

Model Designation

Models Covered in this Manual

Service Specifications

Standard Torque Specifications

Product Reference and Illustrations

Table of Contents

Inspection and Maintenance Schedule

Lifting the Outboard

Outboard Rigging Connections

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Engine Cover Service Notes Notes

System Analysis

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

System Analysis Notes Notes

Fuel System

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Oiling System

Cooling System

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat and Pressure Relief Valve Servicing

Temperature Sender Servicing

Cooling System Notes Notes

Service Chart

Powerhead Removal

Compression Testing

Powerhead Disassembly

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Powerhead Installation

Powerhead Views

Midsection

Service Chart

Exhaust Housing Service

Extension Service - 25” Models

Stern Bracket - Power Tilt Models

Stern Bracket - Manual Tilt Models

Tiller Handle Service

Gearcase

Service Chart

Propeller Service