Evinrude E-TEC 200 Service Manual
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Evinrude E-TEC 200 Service Manual

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Summary of Contents for Evinrude E-TEC 200

  • Page 1 Main Menu...
  • Page 3 † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: ® Twist Grip™ Evinrude ® Nut Lock™ Johnson Screw Lock™...

  • Page 4: Table Of Contents

    9 COOLING SYSTEM ......183 10 EVINRUDE ICON REMOTE CONTROL SYSTEM ..193 11 POWERHEAD .
  • Page 5 REFERENCE INFORMATION REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE ..............4 ABBREVIATIONS USED IN THIS MANUAL .

  • Page 6: Safety Notice

    DO NOT perform any work until you have read trained technicians who are already familiar with and understood these instructions completely. the use of Evinrude/Johnson Special Tools. The Torque wrench tightening specifications must included information is not a substitute for work strictly be adhered to.
  • Page 7 DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 8: Abbreviations Used In This Manual

    REFERENCE INFORMATION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft.

  • Page 9: Emission-Related Installation Instructions

    EPA Emission Regulations Manufacturer’s Responsibility All new 1999 and more recent Evinrude/Johnson Beginning with 1999 model year outboards, man- outboards are certified to the EPA as conforming ufacturers of marine outboards must determine to the requirements of the regulations for the con-...

  • Page 10: Model Designation

    B = Blue Paint N = 2 C = Counter Rotation D = ICON model T = 3 ® D = Evinrude E-TEC R = 4 E = Electric Start w/Remote Steering O = 5 F = Direct-Injection D = 6...

  • Page 11: Models Covered In This Manual

    REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 200.1 cubic inch (3.3 L) and 210 cubic inch (3.4 L), 90° V Evinrude E-TEC models. Description Model Displacement Gearcase Height...

  • Page 12: Service Specifications

    Weight 25 in. (X) Models: 524 lbs. (238 kg) (may vary depending on model) 30 in. (Z) Models: 530 lbs. (240 kg) Evinrude/Johnson XD100 Oil Lubrication Refer to Recommended Lubricants on p. 164 Engine Type 90° V 6-Cylinder Loop-Charged Displacement 200.1 cu.
  • Page 13 REFERENCE INFORMATION SERVICE SPECIFICATIONS 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv- Alternator ery and Installation Guide for multiple battery applications.
  • Page 14 Weight 25 in. (X) Models: 528 lbs. (239 kg) (may vary depending on model) 30 in. (Z) Models: 534 lbs. (242 kg) Evinrude/Johnson XD100 Oil Lubrication Refer to Recommended Lubricants on p. 164 Engine Type 90° V 6-Cylinder Loop-Charged Displacement 210.0 cu.
  • Page 15 REFERENCE INFORMATION SERVICE SPECIFICATIONS 250 H 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv- Alternator ery and Installation Guide for multiple battery applications.

  • Page 16: Standard Torque Specifications

    Defi- nite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become Nautical Orientation 006411 weak, use only authorized Evinrude/ Johnson Genuine Parts.

  • Page 17: Index

    ROUTINE SERVICE ROUTINE SERVICE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 16 LIFTING THE OUTBOARD .

  • Page 18: Inspection And Maintenance Schedule

    ROUTINE SERVICE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides guidelines for inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre- quent inspections and maintenance.

  • Page 19: Lifting The Outboard

    ROUTINE SERVICE LIFTING THE OUTBOARD LIFTING THE OUTBOARD RIGGING OUTBOARD CONNECTIONS IMPORTANT: For complete outboard rigging WARNING and remote control installation information, refer to To avoid personal injury, make sure the the Predelivery and Installation Guide included lifting capacity of the hoist is at least twice with the service manual set.

  • Page 20: Routine Service

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable Retainer Clip Installation Cable, Hose, and Wire Routing When installing retainer clips on control arm link- CAUTION age pins, clips should be locked and must not be bent or deformed. To prevent accidental starting while servic- ing, disconnect the battery cables at the For proper installation, review the following steps: battery.
  • Page 21 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Refer to the following diagram to ensure proper same path to the starboard side of the powerhead. positioning of rigging components in grommet. Secure all cables with clamps. 003974 1. Fuel supply hose 000095 2. Fuel supply hose--alternate location 3.
  • Page 22 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Shift Cable Installation and Adjustment Throttle Cable Installation and Adjustment Place the shift cable on the shift lever pin and With remote control lever in NEUTRAL, pull firmly install the washer and retainer clip. Refer to Cable on throttle cable casing to remove slack.

  • Page 23: Battery Cable Connections

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Install trunnion cover and screw. Tighten screw to SystemCheck Harness a torque of 60 to 80 in. lbs. (7 to 9 N·m). Connections Remove harness connector cover. 1. Trunnion cover and screw, throttle cable 005039 003972 Battery Cable Connections Install battery cables on starter solenoid and main...

  • Page 24: I-Command Network Connections

    I-Command Digital networks do not use the following connections to supply informa- use this connection. tion to the network: If using an Evinrude ICON control system, the I- Command Engine Interface Cable, Power Supply Kit, and Ignition and Trim Harness are not required.

  • Page 25: Icon Network Connections

    007883 2. Small tabs ICON Network Connections If the outboard is equipped for an Evinrude ICON Do not rotate connectors until they align. This control system, connect the outboard to the net- could result in a mismatched connection. It is pos- work as follows.

  • Page 26: Water Pressure Gauge

    1. Water pressure hose fitting 005035 1. Water pressure transducer lead 004120 For an I-Command water pressure display, sev- 2. Engine harness connector eral water pressure sensor kits are available. Refer to the Evinrude/Johnson Genuine Parts and Accessories catalog.

  • Page 27: Battery And Battery Connections

    ROUTINE SERVICE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from CONNECTIONS accessories. Finish this connection with a hex nut. WARNING Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion.

  • Page 28: Oetiker Clamp Servicing

    ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide corrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
  • Page 29 IMPORTANT: Use only Oetiker recommended tools to close Oetiker stepless clamps. Oetiker pincers are available in the Evinrude/ Johnson Genuine Parts and Accessories Catalog. 000108 Method 2: Lift end of stepless clamp with screw- driver.

  • Page 30: Adjustments

    ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS Place the outboard in normal operating position. Rotate the LOWER adjustment tab UP to reduce Tilt Limit Switch Adjustment the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement.

  • Page 31: Trim Sending Unit Adjustment

    ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not show center position, tilt the outboard up and Tilt the outboard and engage the tilt support. adjust the sending unit by pivoting it up or down. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

  • Page 32: Trim Tab Adjustment

    ROUTINE SERVICE ADJUSTMENTS Trim Tab Adjustment Tighten the trim tab screw as follows: • 115 – 200 HP: 35 to 40 ft. lbs. (47 to 54 N·m). WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface.

  • Page 33: Dual-Outboard Alignment

    ROUTINE SERVICE ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.

  • Page 34: Operational Checks

    REVERSE. I-Command Try to restart the outboard. Outboard should not start. Turn key switch to ON. The Evinrude E-TEC screen should appear, fol- lowed by the tachometer display.

  • Page 35: Cooling System

    ROUTINE SERVICE COOLING SYSTEM COOLING SYSTEM Tachometer Pulse Setting Confirm accuracy of tachometer reading. Check the condition of cooling system compo- • Adjust dial on back of tachometer to required nents regularly: setting (the outboard should not be running). • water intake screens Outboard Model Tachometer Setting...

  • Page 36: Engine Flushing

    ROUTINE SERVICE COOLING SYSTEM Engine Flushing Thread garden hose into flushing port. Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in cool- ing system passages. The outboard can be flushed on the trailer or at dockside;...

  • Page 37: Running The Outboard Using A Hose And Flushing Adapter

    ROUTINE SERVICE COOLING SYSTEM Running the Outboard Using a NOTICE Temporarily cover the small holes Hose and Flushing Adapter on the front of M2-Type gearcases with water- proof tape to make sure enough water travels to the powerhead. Water can drain from auxil- WARNING iary inlets, resulting in engine overheat.

  • Page 38: Lubrication

    ROUTINE SERVICE LUBRICATION LUBRICATION Swivel Bracket and Trailering Bracket Steering System Lubricate the swivel bracket with Triple-Guard grease. WARNING Apply grease until the grease begins to flow from Failure to regrease as recommended the upper or lower swivel bracket areas. could result in steering system corrosion.

  • Page 39: Propeller Shaft

    ROUTINE SERVICE LUBRICATION • Gearcase Lubricant Inner casings of both the throttle and shift cables. Draining WARNING Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precau- tions to avoid injury. IMPORTANT: Always check the fill level of the gearcase lubricant at the upper plug before...
  • Page 40 ROUTINE SERVICE LUBRICATION Inspection Remove the lubricant level plug and the lubricant drain/fill plug. Inspect the lubricant and the magnets on the plugs for metal chips. The presence of metal fuzz Use Gearcase Filler, P/N 501882, to slowly fill the can indicate normal wear of the gears, bearings, gearcase with HPF PRO lubricant through the or shafts within the gearcase.

  • Page 41: Trim And Tilt

    ROUTINE SERVICE LUBRICATION Trim and Tilt CAUTION Correct fluid level must be maintained to ensure operation of the impact protection built into the unit. Check reservoir fluid level every three years or every 300 operating hours. • System capacity is approximately 21 fl. oz. (620 ml).

  • Page 42: Spark Plugs

    ROUTINE SERVICE SPARK PLUGS SPARK PLUGS Apply Triple-Guard grease to the gasket surface of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m). Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged If the mark is in unshaded area do not tighten any- spark plugs.

  • Page 43: Fuel And Oil Systems

    ROUTINE SERVICE FUEL AND OIL SYSTEMS FUEL AND OIL SYSTEMS Air Silencer The air silencer on Evinrude outboards maximizes Routine replacement of filters reduces the possi- air flow while minimizing noise. bility of foreign material restricting the incoming fuel or oil supplies.

  • Page 44: Exhaust Pressure Fitting

    1. Barometric pressure reading 2. Exhaust pressure reading Operation Test Cleaning Use the Evinrude Diagnostics software Monitor screen to confirm: Cleaning with Engine Tuner maintenance product • barometric pressure reading; and can dissolve carbon build-up.

  • Page 45: Anti-Corrosion Protection

    ROUTINE SERVICE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.

  • Page 46: Storage

    Internal Engine Treatment Remove the propeller, attach garden hose to flushing port and turn on water. Evinrude E-TEC models are designed to be self- 1. Winterization start button 008077 winterizing using either of the following methods:...

  • Page 47: Additional Recommendations

    ROUTINE SERVICE STORAGE I-Command Method Additional Recommendations I-Command 3.5 inch digital gauges (with software • Top off oil reservoir. version 1.4.0 or higher) provide a winterize feature • inspect the fuel filter. If there is debris in the fuel for 2008 and newer V4 and V6 models. filter, it must be replaced.

  • Page 48: Pre-Season Service

    ROUTINE SERVICE PRE-SEASON SERVICE PRE-SEASON SERVICE SUBMERGED ENGINES If the outboard was removed from the boat for Once an outboard has been submerged in fresh storage, make sure it is reinstalled with factory or salt water, it must be serviced within three (3) specified hardware.
  • Page 49 Refer to Spark Plug Indexing on p. 40. Engine Dropped Overboard (In Salt Water) Reinstall all removed or disconnected parts. Follow the same procedures used for Engine Use Evinrude Diagnostics software to: Dropped Overboard (Not Running) and Engine • Start break-in oiling Dropped Overboard (Running). Disassemble •...
  • Page 50 ROUTINE SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 51 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 50 .

  • Page 52: Upper Cover Service

    ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Upper Cover Cap Replacement Place new upper cap into position. Latch Hook Installation Place hook into position on bracket. 006815 Tighten self-tapping screws to a torque of 24 to 36 006962 in.

  • Page 53: Lower Cover Service

    ENGINE COVER SERVICE LOWER COVER SERVICE LOWER COVER Lower Cover Installation Install the lower engine covers and tighten all SERVICE screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m). Lower Cover Removal Remove lower engine cover screws. 1.

  • Page 54: Latch Handle Installation

    ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006827 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
  • Page 55 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............54 EMM INPUTS AND OUTPUTS DIAGRAM .

  • Page 56: Description

    EMM by the stator. This section discusses the functions of the EMM and its various internal and external sensors. It also describes using Evinrude Diagnostics soft- ware to retrieve and adjust service information stored in the EMM EMM Functions 1.

  • Page 57: Emm Inputs And Outputs Diagram

    ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS J1-A J1-B OUTPUTS x 100 3550 MENU 008365 1. Engine Management Module (EMM) 10. Oil Pressure Sensor (component of 18) 19. Rear Oil Injector and Manifold 2.

  • Page 58: Internal Sensors

    311°F (155°C) a sensor circuit fault is detected and the EMM: Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude Stores service code 23 Diagnostics software to troubleshoot the sensors. EMM LED 3: OFF (Cranking)

  • Page 59: Circuit Sensor

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS 5 V Circuit Sensor Exhaust Pressure Sensor Monitors the EMM’s 5 V sensor circuit. The exhaust pressure sensor monitors exhaust pressure during all running conditions to compen- If sensor voltage is less than 4.75 volts, the EMM: sate for engine loads.

  • Page 60: External Sensors

    (90°C) above 2000 RPM for 3 seconds, the EMM: Sensor inputs and internal EMM controllers are Activates S.A.F.E. used to control outboard operation. Use Evinrude Diagnostics software to troubleshoot the sensors. If cylinder head temperature exceeds 248°F Refer to the EMM Service Code Chart at the (120°C) for 3 seconds, the EMM:...

  • Page 61: Oil Pressure Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Oil Pressure Sensor Throttle Position Sensor The oil pressure sensor monitors oil pressure in The throttle position sensor receives a voltage sig- the oil distribution manifold. nal from the EMM. As the throttle lever is rotated, the EMM receives a return voltage signal through If the sensor does not detect pressure for 150 a second wire.

  • Page 62: Crankshaft Position Sensor

    RPM. Approximate air gap between CPS and flywheel encoder ribs is 0.073 (1.85 mm). Use the Evinrude Diagnostics software Monitor screen to check CPS operation. The software should show an RPM reading while the outboard is cranking. If the CPS or its circuit fails, no RPM reading will appear and the outboard cannot run.

  • Page 63: Internal Emm Functions

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM RPM Limiter This feature of EMM programming prevents FUNCTIONS engine damage due to excessive RPM. At 6250 RPM, fuel and ignition to the cylinders is shut off. Start Assist Circuit (SAC) Normal operation resumes when engine RPM When the ignition key is ON, the EMM Start Assist returns to the specified range.

  • Page 64: Engine Monitor System

    ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITOR SYSTEM ENGINE MONITOR The EMM activates the warning horn and gauge displays as follows: SYSTEM • LOW OIL means that oil in the tank is at reserve level (about 1/4 full). All remote controlled outboards, 40 HP and •...

  • Page 65: Warning System

    Sensor or switch readings must be back within and ON again. limits • The EMM must be reset—stop and restart IMPORTANT: Shutdown related to code 57 or 33 requires the removal of the stored service code. Use Evinrude Diagnostics software to clear a code 57 or 33.

  • Page 66: Diagnostic Software Functions

    Identity screen must match the identifica- parts information, and for making adjustments to tion label on the outboard swivel bracket. the system. Use Evinrude Diagnostics software, version 4.5 or higher, and a laptop computer to access program information. IMPORTANT: For software help, refer to the “Help”...

  • Page 67: Dynamic Information

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Information Hard Faults Dynamic information is viewed while the outboard A hard fault is a service code that currently exists. is running. Changes in data, such as voltages or Hard faults become stored faults only if the out- temperatures, are shown as they happen.

  • Page 68: Dynamic Tests

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Test Dynamic Tests Use the diagnostics software to test each ignition Dynamic tests are performed with the outboard circuit. Refer to Static Ignition Test on p. 82. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.

  • Page 69: Oil Control Settings

    The XD100 setting provides an option to run the outboard at a reduced oil injection rate. This set- ting REQUIRES the use of Evinrude XD100 out- board lubricant and is not recommended for all applications. Use the XD100 setting for: •...

  • Page 70: Ignition Timing

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Timing TPS Calibration Use the Ignition Timing screen to check and TPS Calibration synchronizes throttle plate open- adjust EMM timing. EMM timing must be synchro- ing with throttle position sensor voltage. nized to crankshaft position. Refer to TPS CALIBRATION on p.

  • Page 71: Reports

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Reports Software Replacement Engine reports provide service records and can Engine Management Software is loaded into the be used to document the running history of an out- EMM at the factory. Periodically, a new program board.

  • Page 72: Emm Transfer Emm Servicing

    ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM Transfer EMM SERVICING EMM Transfer is used to save engine history data when the EMM must be replaced. IMPORTANT: If a new EMM is being installed, refer to EMM Transfer on p. 70. Select EMM Data Transfer from the Utilities menu.
  • Page 73 ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING Installation Align slots in starboard side of EMM case with iso- lator mounts on cylinder block. Slide EMM into position. 1. EMM mounting slots 006968 2. Isolator mounts Install two EMM retaining screws. Tighten screws 12 to 16 in.
  • Page 74 ENGINE MANAGEMENT MODULE (EMM) NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 75 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............74 .

  • Page 76: Diagnostic Procedures

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Diagnostic Software Inspections Before running the outboard, use Evinrude Diag- PROCEDURES nostics software to review historical information stored in the EMM. Visual Inspections Check the Hard Faults and Stored Faults screens Inspect wiring and electrical connections. Disas- for current service codes.

  • Page 77: Operational Inspections

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES • first on the list. As each new record is added, Check the Engine Temperature Profile for evi- the oldest record is removed. dence of cold running or overheating. Last Two Minutes Profile 008126 Engine Temperature Profile 008124 The Engine Identity Report provides a snap-shot •...

  • Page 78: Troubleshooting

    If there are multiple stored sensor codes, inspect all 5 V sensor circuits for broken or grounded wiring. • Perform a Static Ignition test using Evinrude Diagnostics software and an inductive timing light. Refer to Static Ignition Test on p. 82. •...

  • Page 79: Dynamic Tests

    Cylinder Drop Tests be too rich or too lean. This feature should not be used by itself to identify a faulty injector. Use the Evinrude Diagnostics software Dynamic Tests to momentarily disable one cylinder while Evinrude Diagnostics software allows temporary the outboard is running.

  • Page 80: Emm Led Indicators

    SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS LED 2 – CRANK POSITION OKAY – input from CPS, EMM powered ON. For NO LIGHT, check for: The EMM LED indicators provide a quick refer- • Code 16 – CPS, intermittent loss of sync ence to the status of several outboard systems.

  • Page 81: Running

    SYSTEM ANALYSIS EMM LED INDICATORS Running • Code 7 – PORT Knock sensor circuit fault • Code 8 – STBD Knock sensor circuit fault When the outboard is running, all of the LEDs • Code 12 – TPS circuit fault should be off.

  • Page 82: Ignition Output Tests

    Ignition Coil • Primary circuits are powered by system (55 V) Use the Evinrude Diagnostics software Stored voltage Faults screen to check for current service codes • EMM provides control signal to ignition coil before troubleshooting.

  • Page 83: Crankshaft Position Sensor (Cps) Test

    Use the Evinrude Diagnostics software Monitor screen to check system voltage. Use the Evinrude Diagnostics software CPS Sync and engine RPM displays to confirm a valid CPS signal while the outboard is cranking or running.

  • Page 84: Static Ignition Test

    Static Ignition Test IMPORTANT: You may need to remove shield- ing from wire if pickup does not read signal. Perform the static ignition test using Evinrude Diagnostics software and an inductive timing light. IMPORTANT: DO NOT use a spark checker tool.

  • Page 85: Running Ignition Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Running Ignition Tests Results: Steady voltage and strobe, engine misfires: Use Evinrude Diagnostics software to monitor • Inspect or replace spark plugs system voltage (55 V). • Refer to FUEL DELIVERY TESTS on p. 85.

  • Page 86: Ignition Control Circuit Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector and test the continuity of each ignition control cir- Use a digital multimeter to test the following: cuit (orange). Check resistance between J1-B •...

  • Page 87: Fuel Delivery Tests

    FIRST. Fuel Injector Static Test Inspect all fuel hoses, filters, and connections. Use the Evinrude Diagnostics software Fuel Injec- Check quality of fuel supply. tor Static Test to activate each fuel injector. Listen for an audible click from each injector when it is Fuel Pump Static Test actuated.

  • Page 88: Running Fuel System Tests

    Running Fuel System Tests Steady light activation on all injector wires and Run or crank the outboard. consistent voltage readings, EMM injector control Use the Evinrude Diagnostics software Monitor function is good: screen to check system voltage. If voltage is low, •...
  • Page 89 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............88 IGNITION SYSTEM CIRCUIT DIAGRAM .

  • Page 90: Service Chart

    ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 50-70 In. lbs. (5.6-8 N·m) 30-42 In. lbs. 30-42 In. lbs. (3-5 N·m) (3-5 N·m) 30-42 In. lbs. (3.5-4.7 N·m) 30-42 In. lbs. 140-160 Ft. lbs. (3.5-4.7 N·m) (190-217 N·m) 15-30 Ft.
  • Page 91 ELECTRICAL AND IGNITION SERVICE CHART 60-84 in. lbs (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 168-192 in. lbs (19-21.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 00803 Liquid Neoprene...

  • Page 92: Ignition System Circuit Diagram

    ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM CIRCUIT DIAGRAM FUSE 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Fuse Crankshaft position sensor Main harness ground Stator Capacitor +12 V from battery...

  • Page 93: Electrical Harness Connections

    ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
  • Page 94 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 1 Blue Injector, cylinder 2 Blue vacant Injector, cylinder 3 Purple Isolated B+ Red/Black Rear oil injector control (ground) Blue/Red Battery ground...

  • Page 95: Ground Circuits

    ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS Additional Ground Tests Check connections and continuity at the following All ground circuits are essential to reliable out- locations: board performance. Make sure all ground connec- • Trim and Tilt module ground at main ground ter- tions are clean and tight.

  • Page 96: Sensor Tests

    Crankshaft Position Sensor (CPS) Test Throttle Position Sensor (TPS) Test Use the Evinrude Diagnostics software CPS Sync Use Evinrude Diagnostics software to monitor and engine RPM displays to confirm a valid CPS TPS voltage while the outboard is running. Volt- signal while the outboard is cranking or running.

  • Page 97: Engine Temperature Sensor Test

    004216 Knock Sensor Test There are no tests for the knock sensor. If Evinrude Diagnostics reports Service Code 7 or 8, replace with a new sensor. Make sure sensor retaining screw is tightened to a torque of 14 to 16 ft. lbs. (19 to 22 N·m).

  • Page 98: Stator Tests

    ELECTRICAL AND IGNITION STATOR TESTS STATOR TESTS To check for a grounded winding, connect one meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The stator consists of 3 windings (6 poles each) read no continuity.

  • Page 99: Charging System Tests

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS 12 V Charging Circuit To test the operation of the regulator in the EMM, you must be able to run the outboard continuously at approximately 5000 RPM, such as in a test tank or on a marine dynamometer.

  • Page 100: Auxiliary Battery Charge Wire

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Auxiliary Battery Charge Wire With outboard running at 1000 RPM, voltage must read higher than with key OFF and increase The auxiliary battery charge feature requires aux- steadily to approximately 14.5 V as the outboard iliary battery charge kit, P/N 5006253 (or equiva- RPM increases.

  • Page 101: Electric Start Circuit

    ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 004112 1. Marine battery 10. 26-pin J1-B EMM connector 2. RED wire (POS) 11. 34-pin J1-A EMM connector 3. BLACK wire (NEG) 12. Engine Management Module (EMM) 4.
  • Page 102 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The starter must engage and turn the flywheel. • Red/purple wire provides 12 V to key switch ter- The outboard must crank a minimum of 100 RPM minal “B”.

  • Page 103: Electric Start Tests

    ELECTRICAL AND IGNITION ELECTRIC START TESTS ELECTRIC START TESTS Key Switch, START Position Key switch START: Starter Solenoid Test • Switches 12 V to terminal “S” of key switch and to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- •...
  • Page 104 ELECTRICAL AND IGNITION ELECTRIC START TESTS Starter Voltage Drop Test • Observe voltage reading. STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to To prevent accidental starting of outboard, starter motor terminal. disconnect crankshaft position sensor •...

  • Page 105: Remote Control Switch Tests

    ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or continuity light to test the SWITCH TESTS continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
  • Page 106 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Switch Test Emergency Stop Switch Test Use an ohmmeter or a continuity light to test neu- This switch can be part of the key switch or tral start switch operation. installed as a separate switch. Either style con- nects the “M”...

  • Page 107: Tilt/Trim Relay Test

    ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST Test Procedure Make sure red and black wires are connected to The tilt and trim (TNT) module contains the cir- 12 V battery power supply. cuitry and relays required for power trim and tilt operation.

  • Page 108: Systemcheck Circuit Tests

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS SystemCheck CIRCUIT instrument harness terminal 1 (purple wire) and terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...
  • Page 109 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test gauge. The tan wire of engine harness and the MWS har- ness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head.

  • Page 110: Tachometer Circuit Tests

    ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS LOW OIL Circuit Test TACHOMETER CIRCUIT Turn the key switch ON. Using a jumper wire, con- TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW Check voltage at the battery.

  • Page 111: Flywheel And Stator Servicing

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING FLYWHEEL AND Apply Moly Lube grease to the threads of the puller pressing screw, P/N 307637, and the center STATOR SERVICING hole of the crankshaft. Place the puller on flywheel with body flat side up. IMPORTANT: Weak flywheel...

  • Page 112: Flywheel Installation

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Flywheel Installation IMPORTANT: DO NOT over apply Nut Lock on flywheel taper. This prevents Nut Lock from CAUTION migrating into upper seal of crankshaft. To avoid injury, keep hands and fingers Align the flywheel keyway and install the flywheel. clear from underside of flywheel.

  • Page 113: Ignition Coil Servicing

    ELECTRICAL AND IGNITION IGNITION COIL SERVICING IGNITION COIL Remove four screws and bracket. SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil. Disconnect ignition coil electrical connector. Remove two ignition coil retaining screws. Do not lose the rubber washers between coil and bracket.

  • Page 114: Timing Adjustments

    1. Timing pointer 005025 Always check timing pointer adjustment before Rotate the flywheel clockwise until the piston using the Evinrude Diagnostics software Timing contacts the tool. Mark the flywheel directly across Verification procedure. from the pointer. Label this mark “B.” Rotate fly- wheel counterclockwise slightly to release tool Disconnect the battery cables at the battery.

  • Page 115: Timing Verification

    DR1233 TPS CALIBRATION 2. Mark “B” 3. Mark “C” Use Evinrude Diagnostics software to tell the EMM what throttle position sensor voltage is when Repeat the entire adjustment process to make the throttle plates begin to open. sure pointer is aligned correctly.
  • Page 116 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Use Ball Socket Remover, P/N 342226, to remove While holding the throttle plates closed, advance throttle link from actuator arm. the throttle linkage until it stops. The “Measured TPS Calibration” field on the screen will increase. Click the “Working”...

  • Page 117: Electric Starter Servicing

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Remove the screws, lock washers, and pinion housing. SERVICING Starter Removal IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator.
  • Page 118 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Hit the socket with a mallet to lower the spacer Remove pinion and plastic weather cover from and expose the retaining ring under the spacer. pinion shaft. 30368 Remove the driven gear and thrust washer. 30371 30367 30360...
  • Page 119 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the two thru-bolts. Mark the end cap ori- Note the alignment marks by the positive terminal entation, and remove the cap. stud. Hold the armature in place, and slide the frame away from the gear housing. 30365 Gently tap the starter frame with a rubber mallet to loosen it.

  • Page 120: Starter Cleaning And Inspection

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Starter Cleaning and Inspection matter which could contribute to failure of wind- ings. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. TYPICAL 24058 Check permanent magnets. Make sure they 30349 strongly attract any steel or iron object held inside frame.

  • Page 121: Starter Assembly

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Starter Assembly Align the starter frame and make sure the long alignment mark matches the mark next to the pos- IMPORTANT: itive terminal stud on the gear housing. If removed, apply Locquic Primer and Screw Lock to the brush card screws before Push the armature down firmly and slide the installing.
  • Page 122 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Install the two thru-bolts. Tighten to a torque of 50 Guard grease. Install the thrust washer and driven to 65 in. lbs. (5.6 to 7.3 N·m). gear. 30362 30363 Install the weather cover. Lightly coat the drive gear with Triple-Guard grease, and install it on the armature shaft.

  • Page 123: Starter Installation

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Lightly coat the pinion shaft splines (helix) with Install the bracket. Apply Nut Lock to the thru- Starter Bendix Lube. Lower the pinion into place bolts. Install the nuts and tighten to a torque of 50 without displacing the driven gear or thrust to 65 in.

  • Page 124: Connector Servicing

    ELECTRICAL AND IGNITION CONNECTOR SERVICING CONNECTOR Release terminal latch and gently pull on wire. SERVICING DEUTSCH Connectors IMPORTANT: Electrical Grease recom- mended. Incorrect grease application can cause electrical or warning system problems. 1. Terminal latch (receptacle) 423293 2. Terminal latch (plug) To disconnect the connector, press the latch and pull the connectors apart.
  • Page 125 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors IMPORTANT: Always appropriate meter test probes and adapters when testing com- ponents fitted with these terminals. Electrical grease is NOT used on AMP connectors. UPERSEAL Disconnect Lift latch. Pull connectors apart. 1. Locking tab, plug 002447 2.
  • Page 126 ELECTRICAL AND IGNITION CONNECTOR SERVICING UPER OWER IMER ERIES The J1-A and J1-B connectors of the EMM are The J2 connector of the EMM is a AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOTH latches and pull connector from Use a screw driver to open latch.
  • Page 127 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back side of the terminal engages a terminal with seal into connector housing until shoulder in the connector housing to hold the ter- seated.
  • Page 128 ELECTRICAL AND IGNITION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 129 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............128 FUEL SYSTEM HOSE ROUTING .

  • Page 130: Service Chart

    FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 30-42 In. lbs. (3.5-4.7 N·m) 60-84 In. lbs. (7-9.5 N·m) 100-110 In. lbs. (11-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) (Lower screw only) Hand tighten to seal contact then 1/2 - 1 turn 60-84 In.
  • Page 131 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Important: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 60-84 in. lbs. (7-9.5 N·m) Start at center and use a spiral torque pattern 60-80 in. lbs. (7-9.5 N·m) 30-42 in.

  • Page 132: Fuel System

    FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Tighten in 3 stages 60-84 in. lbs. (6.8-9.5 N·m) 120 in. lbs. (14 N·m) 24-26 Ft. lbs. 24-36 in. lbs (33-35 N·m) (2.7-4 N·m) S = Supply R = Return Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...

  • Page 133: Fuel System Hose Routing

    FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Return 3.3 L Models 003985 Fuel Supply Fuel Return 3.4 L Models 006977 Fuel supply from boat fuel system Electric fuel circulation pump (20 to 35 psi) Fuel lift pump (2 to 8 psi) Fuel supply manifold Pulse hose(s) from cylinder/crankcase...

  • Page 134: Fuel System Circuit Diagram

    FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM J1-A J1-B 007109 Injectors Capacitor High pressure fuel pump Grounds (neg) Fuel filter/water separator 55 V circuit (white/red) Fuel Injector grounds...

  • Page 135: Fuel System Requirements

    FUEL SYSTEM FUEL SYSTEM REQUIREMENTS FUEL SYSTEM Portable Fuel Tanks REQUIREMENTS WARNING If engine is equipped with a quick-discon- Regulations and Guidelines nect fuel hose, you MUST disconnect the Vessel manufacturer, and/or installer of an EPA fuel hose from the engine and the fuel tank certified outboard, must meet minimum specifica- to prevent fuel leaks: tions for boat fuel systems established by:...

  • Page 136: Fuel Requirements

    Do not smoke, allow open flames or IMPORTANT: sparks, or use electrical devices such as The only fuel additives approved cellular phones in the vicinity of a fuel leak ® for use in Evinrude outboards are 2+4 fuel condi- or while fueling. tioner Evinrude/Johnson Fuel System Cleaner.

  • Page 137: Components

    FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The fuel system includes the following compo- high-pressure components of the fuel system from nents: contaminants. Refer to INSPECTION AND MAIN- • Fuel Lift Pump TENANCE SCHEDULE on p.

  • Page 138: Fuel Circulation Pump

    FUEL SYSTEM COMPONENTS Fuel Reservoir to flow to the intake manifold through the vent hose. The vapor separator accumulates fuel in an inter- nal fuel reservoir and supplies fuel to the electric As the vapor pressure in the vapor separator circulation pump.

  • Page 139: Fuel Manifolds

    FUEL SYSTEM COMPONENTS Fuel Manifolds The EMM is programmed to compensate for vari- ations in fuel flow. Each injector and its location on The fuel supply and return manifolds route fuel the outboard is identified by the EMM. DO NOT through the high pressure side of the fuel system.

  • Page 140: Fuel System Priming

    FUEL SYSTEM FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System Vent Line Clamp WARNING Federal Regulations require that all outboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp installed.

  • Page 141: Fuel System Tests

    FUEL SYSTEM FUEL SYSTEM TESTS FUEL SYSTEM TESTS Shut OFF outboard. Monitor pressure gauge. Pressure should not drop below 15 psi (103 kPa). WARNING IMPORTANT: If outboard does not run, prime fuel system and crank outboard; check circulation Use caution when working on any pres- pump operation;...

  • Page 142: Pressure Regulator Test

    FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 146 to This test requires Injector Test Fitting kit, remove vapor separator. P/N 5005844. Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.

  • Page 143: Fuel Injector Resistance Test

    FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Resistance Test Circulation Pump Resistance Test Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter with appropriate adapter coil resistance.

  • Page 144: Lift Pump Vacuum Test

    FUEL SYSTEM FUEL SYSTEM TESTS Results: START outboard and run at FULL THROTTLE for at least two minutes. Monitor clear vinyl hose for Normal pressure the presence of air. Air bubbles indicate a faulty • Perform the Lift Pump Vacuum Test on p. 142. hose, connection, or fuel tank pick-up.

  • Page 145: Anti-Siphon Valve Test

    FUEL SYSTEM FUEL COMPONENT SERVICING FUEL COMPONENT Anti-Siphon Valve Test Remove anti-siphon valve from fuel tank. Install SERVICING adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve. WARNING Gasoline is extremely flammable and highly explosive under certain conditions.

  • Page 146: Fuel Filter Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Filter Service Wrap a shop towel completely around the pres- sure test valve while connecting fitting from Fuel Removal Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly. Disconnect the battery cables at the battery. Use an appropriate filter wrench to turn the filter in a counterclockwise direction.

  • Page 147: Fuel Lift Pump Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Installation Place fuel pump bracket, with rubber isolator The fuel lift pump is serviceable as a complete mounts, in front of the throttle body. assembly. Refer to parts catalog for service parts. Apply Nut Lock to screws and install screws into Removal throttle body.

  • Page 148: Vapor Separator Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Vapor Separator Service Fuel Manifold Service Removal Removal Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Relieve fuel system pressure. Refer to Relieving Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p.

  • Page 149: Fuel Injector Service

    NOTICE Fuel injectors must be installed in Both fittings must be fully seated into the injector the correct cylinder locations. Use Evinrude fuel ports. Diagnostics Software to make sure that EMM programming matches injector positioning.
  • Page 150 FUEL SYSTEM FUEL COMPONENT SERVICING Remove injector screws. tor filter. Install new crush ring and O-rings. Lubri- † cate O-rings with STP Oil Treatment. 1. Injector screws 008195 1. Adaptor 002196 Remove fuel injector and insulator. Crush Ring Replacement NOTICE Injector crush rings...
  • Page 151 If a disk is not included with the injector, coefficient data can be downloaded from the Evinrude/Johnson dealer website. Refer to the instructions provided with the injector kit. Upload Coefficient Files to EMM Use the Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM.
  • Page 152 FUEL SYSTEM FUEL COMPONENT SERVICING Install Injector Tighten screws in stages, starting with the lower screw. The following items and their mating surfaces • First torque is 5 ft. lbs. (7 N·m) must be cleaned before reassembly: • Second torque is 10 ft. lbs. (14 N·m) •...

  • Page 153: Intake Manifold Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Intake Manifold Service Disassembly All reed plate assembly and reed valve assem- Removal blies must be cleaned before reassembly. DO Disconnect vapor separator vent hose, throttle NOT use strong carburetor cleaner or the hot position sensor connector, and throttle link arm. soaking tank method for cleaning.
  • Page 154 FUEL SYSTEM FUEL COMPONENT SERVICING Inspect the intake manifold. All gasket surfaces Installation must be cleaned, smooth, and free of nicks. Use a Install gasket on reed plate assembly. DO NOT machinist’s straight-edge and a feeler gauge to use sealer on the gasket. check flatness in all directions.
  • Page 155 FUEL SYSTEM FUEL COMPONENT SERVICING Connect throttle linkage and throttle position sen- Position clamps as shown. sor connector. IMPORTANT: DO NOT lubricate TPS to throttle shaft surface. 1. Throttle linkage 004248 2. TPS electrical connector 3. Vapor separator vent hose 1.
  • Page 156 FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 157: Diagrams

    OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............156 OILING SYSTEM CIRCUIT DIAGRAM .

  • Page 158: Service Chart

    P/N 351520 P/N 351520 *IMPORTANT* This outboard has been programmed XD 100 for the use of Evinrude ® /Johnson ® XD100 ™ outboard oil ONLY. Boat Label Failure to use Evinrude/Johnson XD100 outboard oil may harm engine performance and shorten engine life.

  • Page 159: Oiling System Circuit Diagram

    OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM 1 2 3 4 5 1 2 3 4 5 J1-A J1-B 008364 Crankcase Oil Injection Pump Oil Pressure Sensor Signal (TAN/WHITE) Cylinder Oil Injection Pump Rear Oil Injector control (BLUE/RED) Rear Oil Injector +12 V (RED/YELLOW) 55 V Circuit (WHITE/RED) Low Oil Switch (TAN/BLACK)

  • Page 160: Oil Supply Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 200 – 250 HP (3.3 L) M ODELS Rear oil manifold delivers oil to cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4. Cylinder 1 5. Cylinder 3 6. Cylinder 5 Oil tank assembly Oil pick-up Oil supply hose...

  • Page 161: Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS Port View Starboard View 008208...

  • Page 162: Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS 250 – 300 HP (3.4 L) M ODELS Rear oil pump delivers oil to cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4. Cylinder 1 5. Cylinder 3 6. Cylinder 5 Oil tank assembly Oil pick-up Oil supply hose In-line oil filters...

  • Page 163: Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS Port View Starboard View 008432...

  • Page 164: Oil Recirculation Diagrams

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMs Complete View 008205 Top View 1. Recirculation fitting 008206...

  • Page 165: Diagrams

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS Port View Starboard View 008207...

  • Page 166: Oil System Requirements

    • Oil injection pump and manifold assembly Evinrude/Johnson XD100, XD50, or XD30 out- • Oil pressure sensor board oils are recommended for use in Evinrude • Electrical circuit E-TEC outboards. If these oils are not available, • LOW OIL and NO OIL warning systems you must use a TC-W3 certified oil.

  • Page 167: Oil Injection Pump

    OILING SYSTEM COMPONENTS Oil Injection Pump Oil Pressure Sensor The oil injection pump is an electric (55 V) actua- The oil pressure sensor reacts to changes in oil tor style pump. It draws oil from the oil tank manifold pressure. The EMM supplies and moni- through the oil supply hose [25 ft.

  • Page 168: Rear Oil Manifold (3.3 L Models)

    OILING SYSTEM COMPONENTS Rear Oil Manifold (3.3 L models) Electrical Circuit (12 V) The rear oil manifold receives oil from the primary The rear oil pump is powered by the 12 V electri- manifold and distributes it to the cylinder sleeves. cal circuit.

  • Page 169: Cylinder And Crankcase

    OILING SYSTEM COMPONENTS Cylinder and Crankcase Oil Recirculation System The primary oil distribution manifold provides External hoses fittings, internal cylin- crankcase lubrication through oil distribution der/crankcase passages, and intake manifold pas- hoses and pressed-in fittings at the front of the sages are used to recirculate any accumulation of crankcase, port side.

  • Page 170: Oil Control Settings

    This set- and hoses, and an in-line check valve. ting REQUIRES the use of Evinrude XD100 out- board lubricant and is not recommended for all Both center main bearings receive oil through applications.

  • Page 171: Break-In Oiling

    • 90° V6: First two hours above 2000 RPM Follow these steps for outboard set-up: Use Evinrude Diagnostics software to make sure 1. Evinrude/Johnson XD30 outboard lubricant (TC-W3) 004964 the break-in program has been started on a new YELLOW label outboard.

  • Page 172: Oil Supply Priming

    Use Evinrude Diagnostics software to make sure oil pump. the EMM is programmed for the type of oil being used.
  • Page 173 OILING SYSTEM OIL SUPPLY PRIMING • Observe oil flow through all oil distribution hoses. The pump assembly cannot prime itself until it has been filled with oil. Air must be purged during the priming procedure. 1. Cylinder oil pump 008391 1.

  • Page 174: Hp (3.3 L) Models

    OILING SYSTEM OIL SUPPLY PRIMING 200 – 250 HP (3.3 L) M Make sure that oil flows through the rear oil distri- ODELS bution manifold to the cylinder block fittings. Start the outboard. Use the oil priming function in the software to make sure the system is com- pletely primed.

  • Page 175: Oiling System Tests

    30 V on the system voltage (55 V) circuit. The start assist circuit (SAC) of the EMM converts bat- Use the Oil Injector test of Evinrude Diagnostic tery voltage (12 V) to 30 V of system voltage. Bat- software Static Test screen to activate the oil tery must be fully charged and connections must pump.

  • Page 176: Oil Injection Pump Circuit Resistance Test

    OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Circuit Observe voltage at pin 2. • Voltage at pin 2 should drop as the oil pump Resistance Test cycles. IMPORTANT: The complete oil injection pump Check the control signal while the Oil Injector test electrical circuit includes EMM alternator output, is running.

  • Page 177: Cylinder Oil Pump Circuit Resistance Test

    OILING SYSTEM OILING SYSTEM TESTS Cylinder Oil Pump Voltage Tests Use the Cylinder Oiler Test function of Evinrude Diagnostic software Static Test screen to activate The EMM controls the pump by providing ground the cylinder oil pump. through pin 4 (blue/red wire) of the J1-A connector and pin A (blue/red wire) of the oil pump connec- tor.

  • Page 178: Oil Injection Pump Function Test

    OILING SYSTEM OILING SYSTEM TESTS Cylinder Oil Pump Resistance Oil Supply Vacuum Test Test WARNING Disconnect the battery cables at the battery. Wear safety glasses to avoid personal Disconnect the electrical connector from the oil injury, and set compressed air pressure to injection pump.

  • Page 179: Oil Distribution Hoses

    Repair or Static Test replace any leaking components. Reinstall the oil Use the Evinrude Diagnostics software oil injector hose. test to activate injector. Confirm that a small amount of oil is discharged while injection pump is Check height of pickup assembly.

  • Page 180: Oil Component Servicing

    OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Once hose is removed from the manifold, make sure hose support is in the end of the hose. SERVICING WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery. Oil Distribution Hoses The oil distribution hoses from each manifold MUST be the same length.

  • Page 181: Oil Injection Pump

    OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Route oil distribution hoses from the oil distribu- Removal tion manifold to the crankcase oil delivery fittings Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP- PLY DIAGRAMS on p.
  • Page 182 OILING SYSTEM OIL COMPONENT SERVICING Install oil pump on bracket with clamp and retain- Rear Oil Pump ing screw. Tighten to a torque of 24 to 36 in. lbs. (3 Removal to 4 N·m). Disconnect the battery cables at the battery. Remove engine cover.

  • Page 183: Diagrams

    OILING SYSTEM OIL COMPONENT SERVICING Remove two screws to remove oil pump assembly Connect oil hoses to cylinder sleeve oil fittings on from mounting bracket. the crankcase and fasten with tie straps. 1. Screws 008476 1. Cylinder sleeve oil fittings – port 008456 Installation Clean threads of screws and apply Nut Lock to...
  • Page 184 OILING SYSTEM OIL COMPONENT SERVICING Make sure oiling system is primed. Check oil flow through oil distribution hoses. Check oil system operation and routing of oil hoses. Refer to OIL SUPPLY PRIMING on p. 170. Run the outboard and check for leaks. Repair any oil leaks and any kinked or misrouted hoses.
  • Page 185 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAM ......... 184 COMPONENTS .

  • Page 186: Hose Routing And Water Flow Diagram

    Port Rear Water intake screens Water pump Hose Routing & Water Flow Diagram Water tube 200-250HP/90ºV6- Evinrude E-TEC Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) 1. Water intake screens Water supply, EMM to vapor separator 2.

  • Page 187: Components

    COOLING SYSTEM COMPONENTS COMPONENTS Water Supply Tube The water pump outlet connects with the water Water Pump and Intakes supply tube located in the outboard’s midsection. Grommets seal the water tube to the water pump External water intakes mounted in the gearcase housing and the inner exhaust housing.

  • Page 188: Pressure Relief Valve

    COOLING SYSTEM COMPONENTS Pressure Relief Valve Thermostats A pressure relief valve is used to control water Thermostats control water flow and operating flow and operating temperature at higher speeds temperature at lower speeds (below 1200 RPM). (above approximately 1200 RPM). The pressure Overheating: A restricted or faulty thermostat typ- relief valve opens as water pressure increases.

  • Page 189: Operation

    COOLING SYSTEM OPERATION OPERATION At low speed, the pressure valve is against the seat and the thermostats are closed. Warm water from the cylinder block gradually migrates to the All models use a two-stage cooling system thermostat pocket at the top of each cylinder design.

  • Page 190: Emm And Vapor Separator Cooling

    COOLING SYSTEM ENGINE TEMPERATURE CHECK adapter. The water reduces inner exhaust temper- ENGINE TEMPERATURE atures and cools the propeller hub. CHECK IMPORTANT: The engine temperatures listed below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and place outboard in a test tank or in the water.

  • Page 191: Software Method

    ENGINE TEMPERATURE CHECK Software Method Typical pyrometer readings at IDLE speed should be 143°F ± 15°F (62°C ± 8°C) Use Evinrude Diagnostics software to read tem- perature displays. IMPORTANT: If you get low or inaccurate read- ings with a digital pyrometer, coat the probe loca- tion with Thermal Joint Compound, P/N 322170.
  • Page 192 If IDLE temperature is too low, pinch off the water Start the outboard and check IDLE operating tem- outlet hoses from pressure relief valve to cylinder perature using Evinrude Diagnostics software pro- heads. gram. If IDLE temperature increases to specific operat- ing range, 160°F ±...

  • Page 193: Temperature Sender Servicing

    COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 007209 004338 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.

  • Page 194: Pressure Relief Valve Servicing

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Inspection Inspect all parts for cracks, heat damage, or signs VALVE SERVICING of corrosion. Replace damaged parts. Clean debris from housing and parts. The pressure relief valve assembly should be ser- viced at the same time as the thermostats. Assembly Disassembly Assembly is the reverse of disassembly.
  • Page 195 EVINRUDE ICON REMOTE CONTROL SYSTEM EVINRUDE ICON REMOTE CONTROL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............194 COMPONENTS .

  • Page 196: Service Chart

    EVINRUDE ICON REMOTE CONTROL SYSTEM SERVICE CHART SERVICE CHART 60 to 84 in. lbs. (7 to 9.5 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 18 to 20 ft. lbs. (24.5 to 27 N·m) ESM to EMM connector...

  • Page 197: Components

    EVINRUDE ICON REMOTE CONTROL SYSTEM COMPONENTS COMPONENTS Shift Actuator The shift actuator converts electronic signals from The ICON remote control system consists of the the ESM into the mechanical motion required to following components: shift the outboard into and out of gear.

  • Page 198: Throttle Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM COMPONENTS Throttle Actuator If the throttle cannot move toward open position, the FORWARD or REVERSE indicator LED The throttle actuator converts electronic signals flashes (depending on gear position when fault from the ESM into the mechanical motion required occurred).

  • Page 199: Icon Component Servicing

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING ICON COMPONENT Installation Install grommets on ESM. Apply soapy water to SERVICING grommets and push assembly on to studs. WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
  • Page 200 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Continue harness routing under pressure relief NOTICE Make sure the oil recirculation hose valve hoses to EMM connector. Clip connector to is not pinched during assembly. fuel rail. Make sure harness is not strained and does not rub against EMM mounting boss.
  • Page 201 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Secure shift actuator harness with tie strap, Install copper crush washer over ESM positive P/N 317893. ring terminal. Then, install star washer, battery cable, and nut. Tighten nut to a torque of 60 to 84 in.

  • Page 202: Shift Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Route all ESM harnesses as shown and secure to Shift Actuator shift actuator with tie straps, P/N 907833. Removal Disconnect the battery cables at the battery. Remove electrical bracket cover. Observe and note all wire routings before disas- sembling.
  • Page 203 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Remove the shift actuator connector from the clip Installation on the mounting plate. Disconnect the shift actua- Remove old adhesive from clamp retaining screw tor harness. and shift actuator retaining screws. Apply Nut Lock to the threads of the screws.

  • Page 204: Throttle Actuator

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Connect the shift actuator harness. Attach to clip Throttle Actuator on mounting plate. Removal Disconnect the battery cables at the battery. Remove the flywheel cover. Remove the electrical bracket cover. Observe and note all wire routings before disas- sembling.
  • Page 205 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Remove the clamp retaining screw. Installation Remove old adhesive from clamp retaining screw and shift actuator retaining screws. Apply Nut Lock on the threads of the screws. Install throttle actuator on mounting plate with three long screws and one short screw.
  • Page 206 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Secure ESM to throttle actuator harness with tie Route the throttle actuator harness behind and strap, P/N 320107. over the oil recirculation hose as shown. Connect the throttle actuator harness. Attach to clip on Route ESM to shift actuator harness behind throt- mounting plate.

  • Page 207: Icon System Settings

    Each identity plug is stamped with its instance To calibrate the actuators, use the EST Calibra- number. tion tab of the Evinrude Diagnostics Settings screen. In a multi-engine application, all outboards can be calibrated through one connection by changing the engine instance setting on the screen.
  • Page 208 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS linkage. Evinrude Diagnostics reports when the • Click the Forward button under Shift Calibration process is complete. on the EST Calibration screen. The actuator arm will move forward. • Use the Nudge buttons to move the actuator arm forward or backward until the shift link aligns with the actuator arm and shift lever pins.
  • Page 209 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS • After forward and reverse strokes have been cali- With the shift link disconnected, rotate the pro- brated, the ESM calculates neutral position. peller and manually shift the outboard into reverse gear with the shift lever.

  • Page 210: Icon Remote Control System Troubleshooting Chart

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON REMOTE CONTROL SYSTEM TROUBLESHOOTING CHART ICON Remote Control System Troubleshooting Chart Note: Items listed in this chart will not result in setting of ICON fault codes. Observation Possible Cause Troubleshooting Procedure • Turn battery switch ON.
  • Page 211 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON REMOTE CONTROL SYSTEM TROUBLESHOOTING CHART Observation Possible Cause Troubleshooting Procedure Master trim and tilt switch • Check master trim and tilt switch. does not operate power trim Master trim and tilt switch or •...

  • Page 212: Icon Remote Control System Fault Messages

    EVINRUDE ICON REMOTE CONTROL SYSTEM ICON REMOTE CONTROL SYSTEM FAULT MESSAGES ICON Remote Control System Fault Messages Note: ICON fault codes are grouped by fault type. Fault Code: Fault Description/ Possible Cause Description Indicators Troubleshooting Procedure 108:RPM Reduction, ICON System Fail-...
  • Page 213 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON REMOTE CONTROL SYSTEM FAULT MESSAGES Fault Code: Fault Description/ Possible Cause Description Indicators Troubleshooting Procedure RFI due to excessive All LED indicators spark plug gap, dam- • Check spark plug condition. 151: Shift Actuator...
  • Page 214 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON REMOTE CONTROL SYSTEM FAULT MESSAGES Fault Code: Fault Description/ Possible Cause Description Indicators Troubleshooting Procedure All LED indicators 109: Control Hard- flash until control • Turn master power/ ware Fault (fault levers and shift actua-...
  • Page 215 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............214 TAPER PIN TOOL .

  • Page 216: Service Chart

    POWERHEAD SERVICE CHART SERVICE CHART Triple-Guard Grease Gasket Sealing Compound 60-84 In. lbs. (7-9.5 N·m) Moly Lube Red Ultra Lock 60-84 In. lbs. Blue Nut Lock (7-9.5 N·m) Outboard Engine Lubricant 30-42 In. lbs. Thermal Grease (3.5-5 N·m) Pipe Thread Sealing Compound 120-144 In.
  • Page 217 POWERHEAD SERVICE CHART 96-120 In. lbs. (11-13.5 N·m) 60-65 Ft. lbs. (81-88 N·m) 96-120 In. lbs. (11-13.5 N·m) 96-120 In. lbs. ( 1 1-13.5 N·m ) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Extreme Pressure Grease See Service Manual Text...

  • Page 218: Taper Pin Tool

    POWERHEAD TAPER PIN TOOL TAPER PIN TOOL Scale: FULL SIZE – Hole for Storage COMPRESSION TESTING Start and run outboard until it achieves operating If engine shows a variation greater than 15 psi temperature, then shut OFF. (100 kPa) between cylinders, check for: •...

  • Page 219: Powerhead Removal

    POWERHEAD POWERHEAD REMOVAL POWERHEAD REMOVAL Remove water hoses and exhaust back pressure hose from adapter. WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 143. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.
  • Page 220 POWERHEAD POWERHEAD REMOVAL Remove trim/tilt harness from clamp. Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist. 1. Trim harness 005041 2. Clamp 48758 Remove pin and washer from shift rod lever to Remove all powerhead retaining screws and nuts. release the lower shift rod.

  • Page 221: Powerhead Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Throttle Linkage Removal Remove throttle cam and throttle lever. DISASSEMBLY Systems Removal To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p.

  • Page 222: Crankcase Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY Crankcase Disassembly Remove the upper crankcase head screws. Use the TAPER PIN TOOL, or equivalent, to push the crankcase taper pins toward the front side of the engine. IMPORTANT: Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin.

  • Page 223: Cylinder Head Removal

    POWERHEAD POWERHEAD DISASSEMBLY Separate crankcase and cylinder block. It may be Connecting Rods and Pistons necessary to tap on crankshaft with a rawhide or Use a permanent marker to identify each connect- rubber mallet to loosen. ing rod cap, connecting rod, and piston by cylinder number.

  • Page 224: Crankshaft Removal

    POWERHEAD POWERHEAD DISASSEMBLY Use one hand to support the piston, and remove Remove wrist pin retaining rings. Discard retaining the rod cap screws with your other hand. Remove rings. each piston and rod assembly. 000689 Use Wrist Pin Pressing Tool, P/N 396747, to 49432 remove wrist pin.
  • Page 225 POWERHEAD POWERHEAD DISASSEMBLY Use a punch to remove the upper crankshaft seal. Remove the O-ring from crankshaft sleeve and Remove and discard two crankcase head O-rings. inspect it. Replace the O-ring if it is not in good condition. 0865 30057 If the lower crankcase head is to be resealed or the lower main bearing replaced, remove the four Inspect the crankshaft sleeve and replace, if nec-...
  • Page 226 POWERHEAD POWERHEAD DISASSEMBLY IMPORTANT: Remove center main bearings and split sleeves If the lower main bearing is for inspection. DO NOT mix parts. Note location of removed from the crankshaft, it must be dis- bearings for reassembly. carded. DO NOT reuse it. Use a bearing separator to support the bearing, and press off the crankshaft.

  • Page 227: Cylinder Block Cleaning

    POWERHEAD CYLINDER BLOCK CLEANING CYLINDER BLOCK Use Gel Seal and Gasket Remover to remove all traces of gaskets, adhesives, and Gel-Seal II™ CLEANING sealant from the cylinder block and crankcase. WARNING IMPORTANT: Before inspecting or assembling powerhead, all internal components must be com- To avoid personal injury, wear eye protec- pletely clean and free of contaminants.

  • Page 228: Powerhead Inspection

    POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diameter of each crankpin and main INSPECTION bearing journal. The lower main bearing journal would only be measured if the bearing was For dimensions, refer to SERVICE SPECIFICA- removed for another reason. TIONS on p. 10. IMPORTANT: Before any inspection process can begin, all internal components must be com-...

  • Page 229: Cylinder Bore

    POWERHEAD POWERHEAD INSPECTION Cylinder Bore Pistons Visually inspect pistons for signs of abnormal Use a Cylinder Bore Gauge to inspect each cylin- wear, scuffing, cracks, or burning. der bore for an out-of-round, oversize, or tapered condition. Be sure the gauge is perfectly square in Piston Rings the bore when measuring.

  • Page 230: Bearings

    POWERHEAD POWERHEAD ASSEMBLY Bearings POWERHEAD Inspect center main bearing and split sleeves for ASSEMBLY excess wear, nicks, or scratches. Replace if nec- essary. IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant.
  • Page 231 POWERHEAD POWERHEAD ASSEMBLY new sleeve onto the crankshaft until the installer Use retaining ring pliers to install bearing retaining contacts the lower main bearing. ring with sharp edge facing away from bearing. 30061 Lubricate a new driveshaft O-ring and lightly lubri- 30074 cate crankshaft splines with Moly Lube.
  • Page 232 POWERHEAD POWERHEAD ASSEMBLY Lightly coat the outside edge of a new crankshaft Install new seals on the four bearing retainer seal with Gasket Sealing Compound. Use Seal screws. Apply Nut Lock to the threads of the Installation Tool, P/N 325453, to install seal in screws and tighten to a torque of 96 to 120 in.

  • Page 233: Pistons And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Lightly coat two new O-rings with Gasket Sealing Apply outboard lubricant to the wrist pin bearings. Compound, and install on upper crankcase head. Install the bearings in the wrist pin bore. Keep sealer away from oil passage. Oil the wrist pin bore and wrist pin.

  • Page 234: Cylinder Head Installation

    POWERHEAD POWERHEAD ASSEMBLY in each wrist pin hole. Gap of retaining ring faces NOTICE Before continuing, make sure that away from notch in piston. all Gel-Seal II has been removed from the cyl- inder block and crankcase mating flanges. If traces of hardened Gel-Seal II are left, main bearings could be misaligned.

  • Page 235: Crankshaft And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Install cylinder head with the thermostat toward Gently lower crankshaft into place. the top. Apply Triple-Guard grease to threads and • Turn all crankcase seal ring gaps to face up. install the cylinder head screws. DO NOT use any •...
  • Page 236 POWERHEAD POWERHEAD ASSEMBLY Lubricate rod cap screw threads and under screw Install Rod Cap Alignment Fixture, P/N 396749, head mating surface with a light coat of Triple- before tightening rod cap screws. Align the flat Guard grease. Apply outboard lubricant to screw marked “SET”...
  • Page 237 POWERHEAD POWERHEAD ASSEMBLY Apply a light coat of outboard lubricant to the cor- Loosen both rod cap screws one-quarter turn. ners of the connecting rod and rod cap. Place Use Torquing Socket, P/N 346187, to tighten rod frame on connecting rod using the following pro- cap screws in three stages: cedure: •...

  • Page 238: Crankcase Assembly

    POWERHEAD POWERHEAD ASSEMBLY Crankcase Assembly IMPORTANT: The use of Locquic Primer is NOT recommended. If primer is used, crankcase Thoroughly clean and degrease the mating halves must be assembled and tightened within flanges of the crankcase and cylinder block with a ten minutes after the Gel-Seal II has been applied.

  • Page 239: Shift Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Apply Permatex No. 2 to crankcase flange screws Shift Linkage Installation where threaded hole is open to crankcase.Install Install Neutral/Shift Interrupt switch. Apply Nut screws and tighten to a torque of 84 to 108 in. lbs. Lock to screw threads and tighten to a torque of 7 (9.5 to 12 N·m).

  • Page 240: Throttle Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Throttle Linkage Installation Final Powerhead Assembly Apply Nut Lock to threads of throttle lever screw. Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 151. Insert spring into cavity of throttle lever. Install oil recirculating hoses and check valves.

  • Page 241: Powerhead Installation

    POWERHEAD POWERHEAD INSTALLATION POWERHEAD Apply Gasket Sealing Compound to the threads of all powerhead screws. INSTALLATION Loosely install all fasteners before tightening. Apply Permatex No. 2 to both sides of a new base Tighten the 3/8 in. diameter powerhead screws to gasket around the exhaust port only.
  • Page 242 POWERHEAD POWERHEAD INSTALLATION Install water hoses and exhaust back pressure hose. 1. Rear powerhead nut 004252 Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque Port side 008443 of 60 to 84 in. lbs. (7 to 9.5 N·m). 1.

  • Page 243: Pre-Service Adjustments

    • Adjust timing pointer. • Index all spark plugs. Refer to Spark Plug Indexing on p. 40. • Use Evinrude Diagnostics software to start pow- erhead break-in oiling. Refer to Powerhead Break-In on p. 67. 1. Trim/tilt connectors 004251 •...

  • Page 244: Powerhead Views

    POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings – 3.3 L models 007153...
  • Page 245 POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.3 L models 007154...

  • Page 246: Hose Routings - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Port Hose Routings – 3.4 L models 008503...
  • Page 247 POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.4 L models 008502...

  • Page 248: Port - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Port – 3.3 L models 008448...

  • Page 249: Starboard - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Starboard – 3.3 L models 008449...

  • Page 250: Port - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Port – 3.4 L models 008441...

  • Page 251: Starboard - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Starboard – 3.4 L models 008442...

  • Page 252: Front - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Front – 3.3 L models 008450...

  • Page 253: Front - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Front – 3.4 L models 008439...

  • Page 254: Rear - 3.3 L Models

    POWERHEAD POWERHEAD VIEWS Rear – 3.3 L models 007142...

  • Page 255: Rear - 3.4 L Models

    POWERHEAD POWERHEAD VIEWS Rear – 3.4 L models 008440...

  • Page 256: Top

    POWERHEAD POWERHEAD VIEWS 008438...

  • Page 257: Starboard - Icon Models

    POWERHEAD POWERHEAD VIEWS Starboard – ICON models 008504...
  • Page 258 POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 259 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............258 .

  • Page 260: Service Chart

    MIDSECTION SERVICE CHART SERVICE CHART Stern Bracket 40-50 In. lbs. (4.5-5.5 N·m) 64-72 Ft. lbs. (87-98 N·m) 8-12 In. lbs. 10-16 In. lbs. (0.9-1.4 N·m) (1.1-1.8 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.5 N·m) 28-30 Ft.

  • Page 261: Exhaust Housing - 3.3 L Models

    MIDSECTION SERVICE CHART Exhaust Housing – 3.3 L models 22-24 Ft. lbs. (30-33 N·m) See Assembly Instructions 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (14-16 N·m) 144-168 In. lbs. 60-84 In. lbs. (16-19 N·m) (7-9.5 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In.

  • Page 262: Exhaust Housing - 3.4 L Models

    MIDSECTION SERVICE CHART Exhaust Housing – 3.4 L models 22-24 Ft. lbs. (30-33 N·m) 144-168 In. lbs. (16.5-19 N·m) 144-168 In. lbs. (16.5-19 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In. lbs. (7-9.5 N·m) 40-42 Ft. lbs. 144-168 In. lbs. (54-57 N·m) (16.5-19 N·m) 60-84 In.

  • Page 263: Muffler

    MIDSECTION SERVICE CHART Muffler 007117...

  • Page 264: Tilt Tube

    MIDSECTION TILT TUBE TILT TUBE Remove the nut from the starboard side. The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist.

  • Page 265: Installation

    MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of thread are WARNING engaged. Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.

  • Page 266: Exhaust Housing Service

    MIDSECTION EXHAUST HOUSING SERVICE EXHAUST HOUSING Remove the exhaust housing. SERVICE Exhaust Housing Removal Before removing the exhaust housing: • Remove the gearcase. Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p. 287. • Remove the powerhead. Refer to POWER- HEAD REMOVAL on p.

  • Page 267: Exhaust Housing Installation

    MIDSECTION EXHAUST HOUSING SERVICE If removed, coat the lower mounts with soapy Exhaust Housing Installation water and press into the exhaust housing with the Bring the exhaust housing into position with the “OUTSIDE” mark facing outward. stern bracket. Install four new lower mount screws with lock- patch.

  • Page 268: Exhaust Housing Disassembly - 3.3 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Attach the ground lead and lockwasher to the Exhaust Housing Disassembly – starboard side of the steering arm. 3.3 L models Remove two front adapter to outer exhaust hous- ing screws. Remove three nuts at rear of the adapter.

  • Page 269: Exhaust Housing Disassembly - 3.4 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Mark the water tube for correct reassembly loca- Exhaust Housing Disassembly – tion. Remove six inner exhaust housing screws. 3.4 L models Remove the inner exhaust housing. Remove two front adapter to outer exhaust hous- ing screws. 13638 Remove the water tube and grommet from the inner exhaust housing.

  • Page 270: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING SERVICE Loosen and remove the upper mount plate screws Cleaning and Inspection and remove the mount plate. WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). Clean all parts with parts cleaning solvent and dry with compressed air.

  • Page 271: Exhaust Housing Assembly - 3.3 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Inspect the water tube for obstructions or kinks, Coat the outside diameter of a new water tube which may restrict water flow. grommet with Adhesive 847. Install grommet in the inner exhaust housing. Install the water tube. Exhaust Housing Assembly –...
  • Page 272 MIDSECTION EXHAUST HOUSING SERVICE Install a new inner exhaust housing seal. Apply Lubricate the upper mount with soapy water and Adhesive 847 to the seal groove. push into place in the adapter housing. The mount radius must face aft with the “TOP” mark facing Apply Locquic Primer and Nut Lock to the upper mount plate screws and install the plate and screws loosely.

  • Page 273: Exhaust Housing Assembly - 3.4 L Models

    MIDSECTION EXHAUST HOUSING SERVICE Tighten the small adapter to exhaust housing Install grommet and water tube in the inner screws and nuts to a torque of 60 to 84 in. lbs. (7 exhaust housing. to 9.5 N·m). 1. Water tube grommet 006982 13691 Clean and degrease the adapter housing and...
  • Page 274 MIDSECTION EXHAUST HOUSING SERVICE Loosely install the small retaining screws, nuts, Install four mount plate screws and washers and and washers. tighten to a torque of 22 to 24 ft. lbs. (30 to 33 N·m). 32580 006986 Lubricate the upper mount with soapy water and push into place in the adapter housing.

  • Page 275: Stern Bracket

    MIDSECTION STERN BRACKET STERN BRACKET Remove the steering shaft and thrust washer. It may be necessary to tap the steering shaft out using a wood dowel and mallet. Stern Bracket Disassembly Before servicing the stern bracket: • Remove gearcase. Refer to Gearcase GEAR- CASE REMOVAL AND INSTALLATION on p.
  • Page 276 MIDSECTION STERN BRACKET Remove the anode. Remove the tilt limit switch and retainer from the swivel bracket. 1. Anode 30762 1. Tilt limit switch 30758 2. Retainer Remove the swivel bracket. Inspect and, if neces- sary, replace the tilt tube bushings. Disconnect the trail lock spring and remove it from the swivel bracket.

  • Page 277: Stern Bracket Assembly

    MIDSECTION STERN BRACKET Remove the two trim rod rollers from the swivel Stern Bracket Assembly bracket. IMPORTANT: Before proceeding, make sure all components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evi- dence of deterioration.
  • Page 278 MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in. (25 to 27 N·m).
  • Page 279 MIDSECTION STERN BRACKET • Install the steering shaft keeper. Apply Locquic Coat the bushings and seal lips with Triple- Primer and Nut Lock to the splines of the steering Guard grease. shaft and lower mount bracket. 30765 / 30764 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.

  • Page 280: Exhaust Relief Muffler Assembly

    MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY EXHAUST RELIEF The overboard indicator and flush port in the exhaust relief grommet connect to the adaptor MUFFLER ASSEMBLY housing assembly with a hose. This hose is not connected to the muffler assembly. The exhaust relief muffler is located at the rear of the adaptor housing and concealed by the lower motor covers.
  • Page 281 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............280 GEARCASE TYPES .

  • Page 282: Service Chart

    GEARCASE SERVICE CHART SERVICE CHART V6 P “L2”–T ERFORMANCE ODELS EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (3-4 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft. lbs. 26-28 Ft. lbs. (24-27 N·m) 60-84 in.
  • Page 283 GEARCASE SERVICE CHART V6 S “M2”– TANDARD OTATION TYPE EARCASE 60-84 In. lbs. (7-9.5 N·m) 24-36 In. lbs. (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft.

  • Page 284: Gearcase

    GEARCASE SERVICE CHART V6 C “M2”–T OUNTER OTATION EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 60-84 in. lbs. 18-20 Ft.

  • Page 285: Gearcase Types

    GEARCASE GEARCASE TYPES GEARCASE TYPES Housing Outboard Model Description of Features Gear Ratio Type high speed profile, external water screens, pressed in 90°V6 20 in. “L2” 14:26 (.538) propeller bearing housing, performance gearset (V6). 90°V6 20 in. front water inlets and straight leading edge, pressed in 90°V6 25 in.

  • Page 286: Propeller Service

    GEARCASE PROPELLER SERVICE PROPELLER SERVICE Propeller Selection Inspection CAUTION Carefully examine propeller and outboard for the Selection of the wrong propeller could following: reduce engine service life, affect boat per- • Damaged blades and signs of propeller cavita- formance, or cause serious damage to the tion (burned paint, etc.) powerhead.

  • Page 287: Propeller Hardware Installation

    Occasionally, one propeller will not cover a wide ferent thrust bushings, spacers, and cotter pin range of boat applications — water skiing to keepers are used. See the Evinrude/Johnson high speed performance boating. In such cases, Genuine Parts and Accessories Catalog for cor- it might be necessary to have a propeller for rect propeller hardware.

  • Page 288: Gearcase Leak Test

    GEARCASE GEARCASE LEAK TEST If cotter pin holes in the nut (without keeper) and GEARCASE LEAK TEST shaft do not align, tighten further. Do not loosen. Drain lubricant before testing. Install keeper (if applicable). Install new cotter pin. Use Gearcase Pressure Tester, P/N 507977. Aluminum or stainless steel Install lubricant drain/fill plug and seal, thread Small diameter hub...

  • Page 289: Gearcase Removal And Installation

    GEARCASE GEARCASE REMOVAL AND INSTALLATION GEARCASE REMOVAL Remove the 3/8-16 x 3.5 in. screw and washer, and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads.
  • Page 290 GEARCASE GEARCASE REMOVAL AND INSTALLATION Gearcase Installation Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. WARNING • Water tube enters the water pump. • Lower inner exhaust housing installs correctly. During service, the outboard may drop •...
  • Page 291 GEARCASE GEARCASE REMOVAL AND INSTALLATION IMPORTANT: ft. lbs. (47 to 54 N·m). For adjustment, refer to New gearcase screws are treated Trim Tab Adjustment on p. 30. with a thread-locking material. Apply Triple-Guard grease to threads to ensure that the correct clamping force is achieved when tightening—If a previously installed screw is re-used, use a wire brush to remove any old thread-locking material or...

  • Page 292: Water Pump Service

    GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE Assembly Apply a drop of Adhesive 847 in the seal ring Disassembly groove at each of the four ribs. Rotate the driveshaft counterclockwise to unlock IMPORTANT: Do not allow any sealer to get into the impeller key.
  • Page 293 GEARCASE WATER PUMP SERVICE On outboard models with 1/2 in. diameter water Guard grease to the o-rings and install water tube tube, install the water tube grommet with the in exhaust housing. inside taper facing up. 1. O-rings 007152 1. Water tube grommet 32000 Apply Triple-Guard grease to screw threads and On outboard models with 5/8 in.
  • Page 294 GEARCASE WATER PUMP SERVICE Apply a thin bead of Adhesive 847 in the seal Slide the water pump down the driveshaft. Align groove, and install the special shaped O-ring seal. impeller slot with the impeller key. Rotate the driveshaft to engage the key with the impeller, and slide water pump down over key.

  • Page 295: Shift Rod Adjustment

    GEARCASE SHIFT ROD ADJUSTMENT SHIFT ROD On 25 in. and 30 in. models, place the appropriate water tube spacer and grommet on the impeller ADJUSTMENT housing cover. Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

  • Page 296: Gearcase - Standard Rotation

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY • GEARCASE – STANDARD ROTATION GEARCASE Hydrostatic Seal Grooves — Must be in good condition to help prevent propeller ventilation. DISASSEMBLY Pre-Disassembly Inspection WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).

  • Page 297: Propeller Shaft Bearing Housing Removal

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the propeller shaft bearing housing from the gearcase using: Removal • Propeller Shaft Bearing Housing Puller Kit, P/N 354060. IMPORTANT: Identify gearcase type before dis- assembly. For counter rotation gearcases, refer to DO NOT use tools designed to push on the pro- GEARCASE DISASSEMBLY on p.

  • Page 298: Pinion Gear And Driveshaft Removal

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Pull propeller shaft and bearing housing far Pinion Gear and Driveshaft enough to loosen the PRESSED bearing housing Removal from the gearcase housing. Adjust the shift rod to move the clutch dog as far forward as possible.

  • Page 299: Gearcase – Standard Rotation

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove the driveshaft from the gearcase. The Locked Driveshaft Removal bearing housing, shims, thrust bearing, and thrust The driveshaft to pinion taper is a locking taper. If washer will come out with the driveshaft. necessary, use Driveshaft Puller, P/N 390706, and Backing Plate, P/N 325867, to break the lock.

  • Page 300: Driveshaft Service

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Driveshaft Service Install the roll pin to the specified dimension. To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin. Replace the damaged component. 0.125 in. (3.2 mm) 1. Roll pin DR4610 Shift Housing, Gear, and Propeller Shaft Removal...

  • Page 301: Gearcase Housing Inspection

    GEARCASE – STANDARD ROTATION GEARCASE HOUSING INSPECTION GEARCASE HOUSING Remove propeller shaft assembly from gearcase. INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection. Inspect pinion bearing and forward thrust surface of gearcase housing. Use Gearcase Alignment Gauge Kit, P/N 5006349 to check the condition of gearcase housing prior to reassembly.

  • Page 302: Shifter, Bearing And Seal Servicing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING SHIFTER, BEARING AND NOTICE Alignment Gauge Puller, P/N 354718, to install and remove press fit pro- SEAL SERVICING peller shaft bearing housing in L2 and M2 Type gearcase housings. Pinion Bearing Removal Failure to follow this procedure will result in Remove pinion bearing retaining screw.

  • Page 303: Shift Housing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Pinion Bearing Installation Position new O-ring on the pinion bearing retain- ing screw. Apply Gasket Sealing Compound to O- Assemble the following components of Pinion ring. Apply Nut Lock to screw threads. Install the Bearing Remover and Installer, P/N 5005927, as screw and tighten to a torque of 60 to 84 in.
  • Page 304 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Push the pin out of the clutch dog. Remove all shifter detent as needed to help ease removal of parts. parts. 1. Pin 006888 1. Shift lever pin 006890 2. Shift shaft 3.
  • Page 305 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Shift Housing Assembly Thoroughly grease 25 needle bearings with Nee- dle Bearing grease and place in the bearing case. IMPORTANT: Clean and inspect all parts before beginning assembly procedures. Replace any damaged parts.
  • Page 306 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro- shift cradle. Pull shifter detent back up to NEU- peller shaft. Install the clutch dog on the shaft with TRAL position to hold the cradle and shaft in “PROP END”...

  • Page 307: Driveshaft Bearing Housing

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear- Service ing housing’s bottom groove. The bottom groove is an oil passage. Gearcase damage The driveshaft bearing is not serviceable. Replace could result.

  • Page 308: Propeller Shaft Bearing Housing Service

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Propeller Shaft Bearing Housing Inspect the bearing housing anode. Replace anode if it is reduced to two-thirds of original size. Service Tighten screws to a torque of 108 to 132 in. lbs. (12 to 15 N·m).
  • Page 309 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Bearing Installation OUNTER OTATION HOUSING Bearing Installation Tool: Oil, then install new bearings in bearing housing. • P/N 432401 – front bearing Place the lettered end of the bearing case on the •...

  • Page 310: Driveshaft Shimming

    GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING Rear Seal Installation DRIVESHAFT SHIMMING Apply Gasket Sealing Compound to metal casings of the seals before installing. NOTICE If a new pinion gear is needed, replace gear set before shimming. Use Seal Installation Tool to install new seals back to back in bearing housing.
  • Page 311 GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING Select collar, P/N 341440, and the correct shim Check squareness of the bearing housing mount- gauge bar: ing surface by holding the shim gauge bar against • the pinion while rotating just the bearing hous- “M2”: Shim gauge bar, P/N 349957 ing.

  • Page 312: Gearcase Assembly

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Housing Installation Lubricate a new shift rod cover O-ring with Triple- Water Intake Screens Guard grease. Install the O-ring into the shift rod cover. Install water intake screens. Tighten screws to a torque of 60 to 84 in.

  • Page 313: Pinion Gear And Driveshaftinstallation

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY “L2” T Apply Gasket Sealing Compound to the threads of EARCASES the shift rod cover screws. Tighten the screws to a Apply Gasket Sealing Compound to both sides of torque of 60 to 84 in. lbs. (7 to 9.5 N·m). a new shift rod cover gasket.
  • Page 314 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Using Driveshaft Seal Protector, P/N 318674, Lightly coat the threads of a new pinion nut with slide the driveshaft bearing housing onto the outboard lubricant. Use Pinion Nut Starting Tool, driveshaft and into position in the gearcase. P/N 342216, to install nut on the driveshaft.

  • Page 315: Propeller Shaft Bearing Housing And Gear Installation - "L2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Pad handle of holder to prevent damage to gear- Slide the gear assembly onto the propeller shaft case. until it engages the pinion gear. 1. Thrust bearing and thrust washer 006843 Lightly apply Triple Guard Grease to a new bear- 1.

  • Page 316: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY gearcase. Align and level gearcase assembly in Propeller Shaft Bearing Housing fixture as shown. Secure fixture to floor press. and Gear Installation – “M2” Type IMPORTANT: The propeller shaft bearing hous- ing on the “M2” type gearcases is PRESSED into the gearcase housing.
  • Page 317 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Place bearing housing in gearcase. gearcase. Align and level gearcase assembly in fixture as shown. Secure fixture to floor press. 006846 Align retaining holes in bearing housing with screw holes in gearcase. Thread Alignment Pins, P/N 354140, into gearcase.

  • Page 318: Final Assembly And Adjustment

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Apply Ultra Lock to threads and install two retain- ing screws. Tighten screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m). 1. Retainer screws 006835 Final Assembly and Adjustment To complete gearcase assembly, refer to: •...

  • Page 319: Gearcase - Counter Rotation

    GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY GEARCASE – COUNTER ROTATION GEARCASE Install the threaded adaptor from the puller kit on to the propeller shaft until seated. DISASSEMBLY IMPORTANT: Counter rotation (CR) gearcases use unique components and require different ser- vice procedures. Use care when working on counter rotation gearcases.

  • Page 320: Pinion Gear Removal And Driveshaft Servicing

    GEARCASE – COUNTER ROTATION GEARCASE HOUSING INSPECTION Remove propeller shaft, forward gear and bearing Use an appropriate tool to apply downward pres- housing assembly from gearcase. sure on the detent while pulling on the propeller shaft assembly. Remove propeller shaft assembly from the gearcase.

  • Page 321: Shifter, Bearing And Seal Servicing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING SHIFTER, BEARING AND Remove the gear, thrust bearing, and thrust washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. IMPORTANT: The shift housing and bearing are serviced as an assembly.

  • Page 322: Gearcase – Counter Rotation

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a shop cloth to catch ball able tool. Once the detent is past the ball, remove and spring. Pull the shifter detent straight out of the tool and position detent to engage NEUTRAL. the housing.
  • Page 323 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Install arms of shift lever into detent slots. Align Coat thrust bearing and thrust washer with Needle the pivot holes and insert the retaining pin. Push Bearing grease. Place the bearing on the back of shifter detent down.

  • Page 324: Pinion Bearing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Slide the propeller shaft onto the shift shaft, align the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring. Place three coils over each end of the pin, MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE.
  • Page 325 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Push propeller shaft out of the bearing housing. Assembly Position the forward gear bearing housing assem- bly on a flat, level surface. (Mirror or glass can be used.) Use depth gauge to measure distance from flange of housing to flat surface as shown.
  • Page 326 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Coat bearing surfaces of propeller shaft with gear- Use Spanner Wrench, P/N 432400, to tighten the case lubricant. Slide the propeller housing onto gear assembly to a torque of 100 ft. lbs. (136 the propeller shaft.

  • Page 327: Driveshaft Shimming

    GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar: • “M2”: Shim gauge bar, P/N 349957 NOTICE Slide the collar onto the driveshaft with large end If a new pinion gear is needed, in contact with the bearing housing.
  • Page 328 GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Check squareness of the bearing housing mount- Remove the driveshaft from the tool and add the ing surface by holding the shim gauge bar against required shims between the bearing housing and the pinion while rotating just the bearing hous- the thrust washer.

  • Page 329: Gearcase Assembly

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Cover Refer to Shift Rod Housing Installation on Water Intake Screens p. 310 Install water intake screens. Tighten screws to a Pinion Gear and Driveshaft torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Installation Refer to Pinion Gear and Driveshaft Installation on p.

  • Page 330: Final Assembly And Adjustment

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Align retaining holes in bearing housing with Housing must be completely seated in gearcase screw holes in gearcase. Thread Alignment Pins, to install retainer screws. Bearing housing is P/N 354140, into gearcase. approximately level with gearcase. 1.
  • Page 331 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............330 SYSTEM DESCRIPTION .

  • Page 332: Service Chart

    TRIM AND TILT SERVICE CHART SERVICE CHART 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 58-87 Ft. lbs. 84-108 In. lbs. (79-118 N·m) (9.5-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-70 Ft. lbs. (81-95 N·m) DO NOT OVER TIGHTEN 45-55 In.

  • Page 333: System Description

    TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket and Tilt Support The power trim/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in the tilted position. This bracket The system consists of: protects the hydraulic system from damage.

  • Page 334: Modes Of Operation

    TRIM AND TILT MODES OF OPERATION MODES OF OPERATION The trim/tilt hydraulic assembly achieves trim and tilt movement through the following modes of operation. Trim-OUT / Tilt-UP Mode When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.

  • Page 335: Tilt-Down / Trim-In Mode

    TRIM AND TILT MODES OF OPERATION Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, the trim/tilt motor rotates counterclockwise (as viewed from pump end) and turns the pump gears. Fluid pressure passes through the DOWN shuttle valve to the UP shuttle valve, which mechanically opens the UP check valve.

  • Page 336: Impact Relief

    TRIM AND TILT MODES OF OPERATION Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is com- pressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact.

  • Page 337: Shallow Water Drive Tilt Relief

    TRIM AND TILT MODES OF OPERATION Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.

  • Page 338: Manual Release - Up

    TRIM AND TILT MODES OF OPERATION Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve. Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring. 1.

  • Page 339: Manual Release - Down

    TRIM AND TILT MODES OF OPERATION Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylin- ders (in the trim range), and past the manual release valve.

  • Page 340: Routine Inspections

    TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General If the power trim/tilt system has malfunctioned and the cause has not been determined, the Symp- Check for external signs of fluid leakage. Correct toms Chart on p. 339 should help locate the causes as necessary.

  • Page 341: Symptoms Chart

    TRIM AND TILT TROUBLESHOOTING If the outboard does not tilt as high as it should, STEP 3 and the tilt motor TURNS OFF at maximum tilt Go to TILT/TRIM RELAY TEST on p. 105 to (does not sound like it is stalled at the maximum determine if problem is power supply.
  • Page 342 TRIM AND TILT TROUBLESHOOTING • bypass the reservoir cap. These steps will relieve The “B” adapter, P/N 336659, checks operation the pressure in the unit. of the DOWN circuit. 1. Manual release valve 41739 1. A Adapter 27340 2. Reservoir cap 2.
  • Page 343 TRIM AND TILT TROUBLESHOOTING all rods must be completely extended to check Remove the manual release valve. Install pres- fluid level. sure gauge and adapter “B” to check problems in the DOWN circuit. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure.

  • Page 344: Electrical Circuit Tests

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS ELECTRICAL CIRCUIT Connect a 0 to 100 A DC ammeter in series between the battery side of the starter solenoid TESTS and the red lead to the trim/tilt relay module. Relay Testing When the trim-UP button is pressed, the UP relay is energized and connects the blue trim motor wire to the battery positive (+) terminal.

  • Page 345: Trim And Tilt Motor No Load Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS C. Normal current draw, slow operating The motor shaft must rotate clockwise, as viewed speed – Check for: from the pump end, when positive (+) is applied to • the blue lead, and negative (–) is connected to Manual release valve damaged green lead.

  • Page 346: Trim Gauge Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim Gauge Test Trim Sender Test STEP 1 IMPORTANT: To avoid immediate meter dam- age, never apply a multimeter to an electrical cir- Turn key switch ON. Using a voltmeter, check for cuit where voltage is present. voltage between the trim gauge “I”...

  • Page 347: Trim And Tilt Replacement

    TRIM AND TILT TRIM AND TILT REPLACEMENT TRIM AND TILT Separate the trim/tilt unit wires in the braided tube to permit removal through the hole in the stern REPLACEMENT bracket. Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector.

  • Page 348: Installation

    TRIM AND TILT TRIM AND TILT REPLACEMENT Use a punch to remove the upper pin. Installation Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. Install external snap rings on lower pin with sharp edge of ring facing out.

  • Page 349: Trim And Tilt Service

    TRIM AND TILT TRIM AND TILT SERVICE TRIM AND TILT SERVICE Place trim/tilt wires in braided tube and install through hole in the stern bracket. Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down momentarily and loosen the reservoir cap one full turn.
  • Page 350 TRIM AND TILT TRIM AND TILT SERVICE Screw the manual release valve in. Remove the Remove the three Pozidriv screws securing the retaining ring using retaining ring pliers. Remove reservoir to cylinder body. Remove reservoir. the manual release valve. 41753 Remove the reservoir O-ring from the cylinder 41739 body.
  • Page 351 TRIM AND TILT TRIM AND TILT SERVICE Remove the four screws securing motor to pump solvent and inspect it for tears, clogging, or other manifold assembly. damage. 41760 1. Coupler 41763 2. Filter screen Remove the wire shield from the pump manifold. Remove the three Allen head screws securing the Remove the motor and inspect the motor O-ring pump manifold assembly to cylinder body.

  • Page 352: Tilt Piston Removal

    TRIM AND TILT TRIM AND TILT SERVICE Remove the manifold. Remove five O-rings from Slowly pull the piston out with a rag wrapped cylinder body. Check machined surfaces for nicks around the rod and the top of the cylinder. Drain and scratches.

  • Page 353: Tilt Piston Identification

    TRIM AND TILT TRIM AND TILT SERVICE Remove the washer. Slide the tilt piston off the Two of the piston relief holes are small, the other rod. Be careful not to lose the springs, plungers, two holes are larger. Two of the springs have five or small check valves in the piston assembly.

  • Page 354: Tilt Rod Assembly

    TRIM AND TILT TRIM AND TILT SERVICE Use a screwdriver to carefully pry the scraper out Use a wire brush to clean all thread-locking mate- of the end cap. Discard the scraper. Remove and rial from the threads on the tilt rod. discard the large outer O-ring.

  • Page 355: Trim Rod Removal

    TRIM AND TILT TRIM AND TILT SERVICE Clean any thread-locking material from the Trim Rod Removal threads on the inside of the nut. Spray threads of Unscrew trim cylinder end caps using Trim Cylin- with Locquic Primer and let dry. Apply a small der End Cap Remover/Installer, P/N 436710, or amount of Nut Lock to the threads.

  • Page 356: Trim Rod Assembly

    TRIM AND TILT TRIM AND TILT SERVICE Drain the remaining fluid from the cylinders. Remove the rod from the vise. Use a small screw- Inspect both bores of the trim cylinders for exces- driver to carefully pry the scraper out of the end sive scoring.

  • Page 357: Manifold And Reservoir Installation

    TRIM AND TILT TRIM AND TILT SERVICE Lubricate and install a new O-ring and two new Manifold and Reservoir back-up rings on the trim rod piston. Place one Installation back-up ring on each side of the O-ring. Position Lubricate five new manifold body O-rings. Place the open end of the back-up rings 180°...

  • Page 358: Trim Rod Installation

    TRIM AND TILT TRIM AND TILT SERVICE removed later for the Pressure Leakdown Test Attach the reservoir to the cylinder body with three on p. 339. Pozidriv screws. Tighten the screws to a torque of 35 to 52 in. lbs. (4.0 to 5.9 N·m). 41851 41866 Install the reservoir filter screen in the cylinder...

  • Page 359: Tilt Rod Installation

    TRIM AND TILT TRIM AND TILT SERVICE P/N 912084. Tighten caps to a torque of 60 to 70 P/N 912084. Tighten cap to a torque of 58 to 87 ft. ft. lbs. (81 to 95 N·m). lbs. (79 to 118 N·m). 41868 41870 Tilt Rod Installation...
  • Page 360 TRIM AND TILT TRIM AND TILT SERVICE Install the filter screen. Fill the reservoir to the bottom of the fill hole with Power Trim/Tilt & Steering Fluid. Install and tighten the reservoir cap. Turn the manual release valve in until it seats. Cycle the unit up and down several times to purge air.
  • Page 361 TRIM AND TILT TRIM AND TILT SERVICE Check the tilt rod bushings. Replace them if they are worn excessively. 41888 Check the bushings on the bottom of the manifold body. Replace them if they are worn excessively. 41878 Check system operation in both trim and tilt range.
  • Page 362 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 363 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 364 S–2...

  • Page 365: Marine Products And The Safety Of People Who Use Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.

  • Page 366: Outboard Shift Systems And Safety

    SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...

  • Page 367: Outboard Speed Control System And Safety

    SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...

  • Page 368: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: • Must not come apart; • Must not jam;...
  • Page 369 SAFETY How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When • Follow warnings marked “ ” closely. rigging •...

  • Page 370: Outboard Fuel, Electrical System, And Safety

    SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? •...
  • Page 371 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields •...
  • Page 372 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard GASOLINE Check for leaks under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 373: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: • outboard parts • bolts, nuts, and washers • boat’s transom What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
  • Page 374 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.

  • Page 375: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

    SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? • Shock absorption system must always be ready to absorb some blows to the lower parts of the outboard. • Outboard must not trim in too far suddenly. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.

  • Page 376: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
  • Page 377 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.

  • Page 378: Summing Up

    SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! • Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...

  • Page 379: Marine Products And The Safety Of People Who Fix Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: •...
  • Page 380 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
  • Page 381 SAFETY Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 382 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 383: Handling Lead/Acid Batteries

    SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.

  • Page 384: Gasoline - Handle With Care

    SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...

  • Page 385: Hazardous Products

    SAFETY Hazardous Products Know how items in the shop can hurt people... READ • “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an emergency arise • “How to dispose of can” It’s all on the back of the can or bottle label.

  • Page 386: Safety Awareness Test

    6) Have you received training related to common shop safety practices to protect your- self and others around you? 7) When replacement parts are required, will you use Evinrude /Johnson Genuine ®...
  • Page 387 INDEX INDEX Connecting Rod 233 Crankshaft 228, 229 Abbreviations 6 Pinion Gear 300, 301 Accessories Break-In I-Command Water Pressure Transducer EMM Programming 169, 241 Kit, P/N 5008300 24 Gearcase 289, 316, 328 XD100 Outboard Oil Decal, P/N 352369 Oiling 169 Procedure 67 Adapter Housing 185 Service 264...
  • Page 388 INDEX Cover Service 50 Driveshaft Crankcase Installation 311 Assembly 236 Removal 296, 318 Disassembly 220 Service 298 Crankshaft Shimming 308 Assembly 228 Special Removal Procedures 297 Bearings 228 Driveshaft Bearing Housing Disassembly 222 Seal Removal 305 Inspection 226 Dual-Outboard Installation 233 Alignment 31 Crankshaft Position Sensor I-Command settings 23...
  • Page 389 INDEX Transfer 70 Injector Servicing 147 Engine Monitor Intake Manifold 151 Description 62 Minimum Octane 134 Low Oil Warning 177 Pressure Tests 139 No Oil Warning 166 Priming 138 Operation Check 32 Relieving Pressure 143 Engine Temperature Check 185 Requirements 133 Engine Temperature Sensor Troubleshooting 139 Description 58...
  • Page 390 INDEX Idle Controller 61 Models Ignition Included Models 9 Electrical Circuits 90 Model Designation 8 Ignition Coil Servicing 111 Serial Number Location 8 Ignition Coil Tests 84 Motor Mounts Primary Circuit Resistance Test 84 Lower Mount Servicing 264, 265, 271 Required Systems 80 Upper Mount Servicing 266, 268, 270, 272 Running Tests 83...
  • Page 391 INDEX Servicing 177 Installation 313 Tests 173 Rear Seal Installation 308 Rear Seal Removal 306 Propeller Shaft Bearing Housing, Counter Packard Connector Servicing 125 Rotation Pinion Gear Assembly 323 Bearing Installation 301 Installation 327 Bearing Removal 300 Propeller Shaft, Counter Rotation Installation 311 Removal 318 Removal 296...
  • Page 392 INDEX Shift Actuator Removal 200 Submerged Engines 46 Shift Housing Switches Assembly 303, 320 Key Switch 103 Installation 310, 327 Swivel Bracket Removal 298 Installation 277 Shift Housing, Counter Rotation Lubrication 36 Disassembly 319 Removal 274 Removal 318 SystemCheck Shift Interrupt Switch 60 Circuits 105, 106 Shift Linkage Oil System Warnings 166...
  • Page 393 INDEX Identification 351 Removal 350 Gearcase Pressure Tester, P/N 507977 Tilt Rod Assembly 352 Gearcase Vacuum Tester, P/N 507982 286 Installation 357 Guide Rods, P/N 383175 230 Tilt Support 331 Hydraulic Cylinder Rod Holder, P/N Tilt Tube 983213 354, 355 Installation 263 Injector Test Fitting Kit, P/N 5005844 140 Lubrication 36...
  • Page 394 INDEX Terminal Release Tool, P/N 351413 124 Trim Gauge Test 344 Test Propeller 10, 12 Trim Rods Thermal Joint Compound, P/N 322170 189 Assembly 354 Tilt Cylinder End Cap Remover/Installer, P/ Installation 356 N 326485 350, 357 Removal 353 Tilt Cylinder Seal Protector, P/N 326005 Trim Sender Adjustment 29 Tilt Tube Service Kit, P/N 434523 262...
  • Page 395 INDEX Water Intake Screens 33 Inspection 33 Installation 310, 327 Removal 299, 318 Water Pressure Gauge 24 Water Pump Assembly 290 Description 185 Disassembly 290 Inspection 290 Water Supply Tube 185 Winterizing 44 Wiring Harness Connections 22 Wrist Pin Installation 231 Removal 222 I–9...
  • Page 396 INDEX NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other I–10...

  • Page 397: Trouble Check Chart

    TROUBLE CHECK CHART OUTBOARD WILL NOT START TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Battery switch not ON Check battery switch operation Discharged battery Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit.
  • Page 398 TROUBLE CHECK CHART OUTBOARD WILL NOT START OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Check wiring and emergency stop switch. Check Stop circuit grounded the safety lanyard is installed and stop circuit is not grounded. No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return Water in fuel manifold.
  • Page 399 TROUBLE CHECK CHART OUTBOARD HARD TO START OUTBOARD HARD TO START OBSERVATION POSSIBLE CAUSE PROCEDURE Weak battery Check battery, recharge or replace Clean and tighten connections, check voltage Battery cables and connections drop on high amperage circuit Starter or bendix/drive gears Check starter, inspect bendix/drive gears Check water separator/fuel filter, sample fuel from Water in fuel system...
  • Page 400 TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OBSERVATION POSSIBLE CAUSE PROCEDURE Check key switch and ground to key switch, refer Key switch or wire harness to SYSTEM ANALYSIS and ELECTRICAL AND ground IGNITION Outboard starts and Check EMM LED indicators.
  • Page 401 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM service codes and check System- SystemCheck light Outboard is in S.A.F.E. Check warning Refer to specifications, check recommended WOT Incorrect propeller RPM;...
  • Page 402 TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSERVATION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F.E. Access EMM fault codes Incorrect, fouled, or worn spark Replace spark plugs plugs Check water separator/fuel filter, sample fuel from Water in fuel system fuel return manifold test port Contaminated or poor fuel...
  • Page 403 MWS Instrument Wiring Harness DRC6165R...
  • Page 404 I-Command Keyswitch/TNT Wiring Harness A. Trim down B. Trim up C. Trim sender 47 ohm 5 watt resistor 5. Battery + (12V) 1. Stop circuit 2. Start solenoid 3. Ground (B-) 6. Choke 4. Switched B+ (12V) Switched B+ (12V) 10 Amp Fused B+ (12V) Ground (B-)
  • Page 405 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
  • Page 407 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH FUEL VOLTMETER TRIM/TILT WATER PRES. FUEL TANK SENDER WARNING HORN DRC6278R...
  • Page 408 Evinrude E-TEC EMM LED Diagnostic Indicators V Models In-line Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS in the Service Manual. KEY ON : LED’s illuminate to indicate circuit function...
  • Page 409 FUSE 3.3 L V6 / 200-250HP E-TEC 1 2 3 1 2 3 4 5 1 2 3 4 5 1. Oil Injector J1-A 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor J1-B 6.
  • Page 411 FUSE 3.4 L V6 / 250-300HP E-TEC 1 2 3 1 2 3 4 5 1 2 3 4 5 1. Oil Injector J1-A 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor J1-B 6.
  • Page 413 EVINRUDE 115 – 300 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied.
  • Page 414 CHECK ENGINE 2 seconds Cycle master power switch off and back on. Check ICON buss cable connections. See Evinrude ICON Installation Guide. Check actuator harness and connections. Check for RFI from excessive spark plug gap. See Evinrude ICON Installation 149 ICON throttle actuator sensor fault...

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E-tec 225E-tec 250E-tec 300

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