Table Of Contents - Evinrude E-TEC E40DRLSCB Service Manual

Table of Contents

Table Of Contents4
Introduction5
Safety Information6
Units Of Measurement8
Abbreviations Used In This Manual8
List Of Abbreviations8
Engine Emissions Information9
Manufacturer's Responsibility9
Dealer's Responsibility9
Owner's Responsibility9
Epa Emission Regulations9
Model Designation10
Models Covered In This Manual11
Identifying Model And Serial Numbers11
Service Specifications12
Standard Torque Specifications14
Product Reference And Illustrations14
Special Tools15
Diagnostic Tools View16
Universal Tools View16
Electrical/Ignition Tools View18
Powerhead Tools19
Fuel /Oil System Tools19
Gearcase Tools20
Trim And Tilt Tools22
Manual Starter Tools22
Shop Aids View23
Notes26
Installation And Predelivery27
Boat Rigging28
Remote Controls28
Control Selection28
Control Installation29
Battery Installation29
Minimum 12 Volt Battery Recommendations29
Location And Preparation29
Connections30
Battery Cable Requirements30
Battery Switches And Multiple Batteries30
Marine Style Battery Post Diagram30
Typical Battery Functions31
Battery Switch Requirements31
Battery Switch Location31
Battery Switch Operation31
Battery And Switch Wiring Diagrams32
One Outboard: Battery Disconnect Diagram32
One Outboard: One Primary Starting Battery; One Secondary Battery Diagram32
Wo Outboards: Two Starting Batteries For Each Outboard Diagram32
Two Outboards: One Primary Starting Battery For Each Outboard Diagram33
Fuel System Requirements34
Fuel Hose34
Fuel System Primer34
Fuel Filters35
Portable Fuel Tanks35
Outboard Fuel System Recommendations35
Cable And Hose Installation36
Cable And Wire Harness Routing36
Typical Small Splash Well Diagram36
Typical Large Splash Well Diagram36
Protective Sleeve/Conduit37
Battery Cables37
Oetiker Clamp Servicing38
Oetiker Stainless Steel Stepless Clamps Table38
Clamp Identification Numbers View38
Clamp Installation39
Clamp Removal39
Outboard Installation40
Hull Preparation40
Control Cable Identification40
Mounting Surface40
Transom Clearances41
Water Flow41
Transom Brackets And Jack Plates41
Mounting Hardware41
Transom Measuring And Drilling42
Hull Centerline42
Dual-Outboard Centerlines42
Transom Height42
Transom Drilling Locations43
Drilling And Hardware Diagrams44
Lifting The Outboard46
Steering Systems46
Lifting Fixtures46
Mechanical Cables46
Manual Hydraulic Steering47
Drag Links47
Outboard Mounting48
Mounting Height48
Mounting Bolt Installation48
Outboard Rigging50
Cable, Hose, And Wire Routing50
Control Cable Adjustments50
Cable Retainer Clip Installation51
Locked Retainer Clip View51
Electrical Harness Connections52
Water Pressure Gauge52
Seal View52
Water Pressure Hose Fitting View52
Canbus Connections53
Fuel And Oil Priming55
Fuel Requirements55
Minimum Octane55
Additives55
Fuel System Priming56
Vent Line Clamp56
Oil Requirements56
Engine Lubricant Below 32°F (0°C)56
Oil Injection Rate57
Xd100 Outboard Oil Decal View57
Break-In Oiling58
Oil Supply Priming58
Before Start-Up59
Gearcase Lubricant59
Oil Level59
Trim And Tilt Fluid59
Running Checks60
Engine Monitoring System60
Fuel System Checks60
Start-In-Gear Prevention60
Emergency Stop / Key Switch60
Remote Control Operation60
Tachometer Pulse Setting60
Water Pump Overboard Indicator61
Operating Temperature61
Idle Speed61
Break-In61
Propeller Selection62
Propeller Hardware Installation63
Final Adjustments64
Trim Sending Unit Adjustment64
Trim Tab Adjustment65
Outboards With High Transom Heights65
Dual Standard Rotation Outboards65
Dual Outboards, One Counter And One Standard Rotation65
Dual-Outboard Alignment66
Measure Alignment66
Alignment Adjustment66
Confirm Alignment66
Maintenance67
Inspection And Maintenance Schedule68
Anti-Corrosion Protection69
Testing Procedure – Continuity69
Metallic Component Protection69
Exterior Finishes69
Sacrificial Anodes69
Cooling System Maintenance70
Flushing — Outboard Running70
Flushing — Outboard Not Running70
Lubrication71
Steering System Lubrication71
Water Intake Screens71
Additional Maintenance71
Swivel Bracket And Trailering Bracket72
Tilt Tube72
Throttle And Shift Linkage72
Propeller Shaft Lubrication73
Gearcase Lubricant Draining73
Gearcase Lubricant Inspection73
Gearcase Lubricant Filling74
Trim And Tilt Lubrication75
Battery And Battery Connections76
Fuel And Oil Systems76
Fuel Filter76
Oil Filters And Oil Reservoir76
Air Silencer77
Hoses And Connections77
Spark Plugs Removal78
Spark Plugs Indexing78
Storage79
Fuel System Treatment79
Internal Engine Treatment79
Throttle Control Method79
Pre-Season Service80
Additional Recommendations80
Outboard Mounting Bolts80
Battery(S)80
Power Trim And Tilt80
Operational Checks80
Submerged Engines81
Prolonged Submersion (Fresh Or Salt Water)81
Engine Dropped Overboard (In Salt Water)81
Engine Cover Service83
Upper Cover Service84
Lower Cover Service84
Latch Hook Installation84
Lower Cover Removal84
Lower Cover Installation85
Latch Handle Installation86
Trim Switch Installation86
Engine Maintenance Module (Emm)87
Engine Maintenance Module (Emm) Description88
Emm Functions88
Emm Connections88
Led Indicators88
Emm Inputs And Outputs Diagram89
Internal Sensors90
Emm Temperature Sensor90
55 V Circuit Sensor90
12 V Circuit Sensor90
Engine Management Module (Emm)90
External Sensors91
Barometric Pressure Sensor91
Air Temperature Sensor91
Engine Temperature Sensor92
Low Oil Switch92
Throttle Position Sensor92
Crankshaft Position Sensor93
Neutral Switch93
Internal Emm Functions94
Rom Verification94
Idle Controller94
Neutral Rpm Limiter94
The Engine Monitoring System95
System Self-Test95
Service Mode95
Engine Running95
Safe Warning System96
Shutdown Mode96
Diagnostic Software Functions97
Communication97
Static Information97
Dynamic Information98
Stored Service Codes (Faults)98
Hard Faults, Persistent Faults98
Static Tests98
Dynamic Test Screen View99
Ignition Test99
Oil Injector Test99
Fuel Pump Test99
Oil Control Settings100
Tiller/Remote Programming100
Set Oil Type100
Powerhead Break-In100
Ignition Timing101
Tps Calibration101
Idle Speed Control101
Fuel Injector Servicing102
Reports102
Software Replacement103
Emm Transfer103
Emm Servicing104
System Analysis105
Diagnostic Procedures106
Visual Inspections106
Operational Inspections106
Troubleshooting107
Outboard Will Not Crank, Starter Does Not Operate107
Outboard Cranks, Will Not Start107
Outboard Runs, Low On Power, Misfires107
Dynamic Tests108
Cylinder Drop Tests108
Fuel Control Adjustment108
Inductive Amp Meter Test108
Emm Led Indicators109
Key On109
Starting109
Running110
Ignition Output Tests111
Ignition System Requirements111
Wiring Inspection111
Stator Output Voltage Test111
Crankshaft Position Sensor (Cps) Test112
System Voltage Test112
Static Ignition Test113
Running Ignition Tests114
Ignition Control Circuit Tests115
Ignition Coil Tests115
Capacitor Test115
Control Signal Test115
Fuel Delivery Tests116
Fuel Pump Static Test116
Fuel Injector Static Test116
Running Fuel System Tests117
Exhaust Water Valve Static Test118
Exhaust Water Valve Dynamic Test118
Electrical And Ignition119
Electrical And Ignition: Service Chart120
Dash Connections, Instrument Harness122
Instrument Harness Diagram (Mws)122
Elecrtical Harness Connections123
Engine Harness To Stator Connector123
Emm J1-A Connector123
Emm J1-B Connector124
Emm J2 Connector124
Ground Circuits125
Fuse125
Emm Ground Tests125
Additional Ground Tests125
Sensor Tests126
Throttle Position Sensor (Tps) Test126
Air Temperature Sensor (At) Test127
Stator Tests128
Stator Resistance Tests128
Stator Voltage Output Test128
Stator Winding Resistance Specification128
Charging System Tests129
12V Charging Circuit Test129
Variable Load Test Diagram129
Battery Charging Graph129
55 V Alternator Circuit Test130
Electric Start Circuit131
Start Circuit Diagram131
Start Circuit Operation132
Solenoid Wiring132
Engine Wire Harness132
Instrument Wire Harness132
Electric Start Tests133
Starter Solenoid Test133
Key Switch, Start Position133
No Load Current Draw Test134
Remote Control Switch Tests135
Key Switch Test135
Neutral Start Circuit Test135
Neutral Start Switch Test136
Emergency Stop Switch Test136
Tilt/Trim Relay Test137
Exhaust Water Valve Test138
Systemcheck Circuit Tests138
Gauge Self-Test Check138
Check Engine Circuit Test139
Low Oil Circuit Test140
No Oil Circuit140
Water Temp/ Hot Circuit Test140
Tachometer Circuit Tests141
Flywheel And Stator Servicing141
Flywheel Removal141
Stator Service143
Flywheel Installation143
Timing Adjustments144
Timing Pointer144
Timing Verification145
Calibration Of Tps145
Electric Starter Servicing146
Starter Removal146
Starter Disassembly146
Starter Cleaning And Inspection147
Starter Assembly148
Connector Servicing150
Starter Installation150
Deutsch Connectors150
Terminal Removal150
Terminal Installation151
Crimping Terminals151
Amp Connectors151
Packard Connectors153
Fuel System155
Service Chart - Injectors, Vapor Separator, Fuel Pump156
Service Chart - Reed Plate Assembly And Throttle Body157
Fuel System Hose Routing158
Fuel System Circuit Diagram159
Fuel System Components160
Fuel Lift Pump160
Fuel Filter Info160
Vapor Separator160
Fuel Circulation Pump161
Fuel Reservoir161
Fuel Supply161
Electrical Circuit161
Fuel Manifolds162
Fuel Injectors162
Injector Fuel Supply162
Fuel Flow Compensation162
Fuel System Tests163
Fuel System Pressure Test163
Pressure Regulator Test164
Vapor Separator Vent Check164
Fuel Injector Pressure Test164
Fuel Injector Resistance Test165
Circulation Pump Resistance Test165
Lift Pump Pressure Test165
Lift Pump Vacuum Test166
Lift Pump Diaphragm Test167
Anti-Siphon Valve Test167
Fuel Component Servicing168
Relieving Fuel System Pressure168
Fuel Filter Service169
Fuel Lift Pump Service169
Vapor Separator Service170
Fuel Manifold Service170
Fuel Injector Service171
Crush Ring Replacement172
Intake Manifold Service174
Oiling System177
Oiling System Service Chart178
Oil Supply Diagrams179
Oil Recirculation Diagram180
Oiling System Circuit Diagram181
Oiling System Components182
Oil Tank Assembly182
Oil Injection Pump182
Electrical Circuit (55 V)182
Low Oil Warning183
No Oil Warning183
Cylinder And Crankcase183
Oil Control Settings Info184
Oil Recirculation System184
Oil Priming184
Oiling Rates, Break-In Oiling184
Oiling System Tests185
Oil Injection Pump Voltage Test185
Oil Injection Pump Circuit Resistance Test186
Oil Injection Pump Function Test186
Oil Injection Fittings Flow Test187
Low Oil Sending Unit Test187
Oil Component Servicing188
Oil Distribution Hoses188
Oil Tank Assembly Removal189
Oil Tank Assembly Installation189
Cooling System191
Cooling System: Hose Routing And Water Flow Diagrams192
Cooling System Components193
Water Pump And Intakes193
Exhaust Housing193
Pressure Relief Valve193
Thermostat194
Block Venting194
Water Pressure Connection194
Cooling System Operation195
Emm And Vapor Separator Cooling195
Cylinder Block / Cylinder Head Cooling195
Engine Temperature Check196
Software Method196
Pyrometer Method196
Idle Operating Temperature Troubleshooting (Below Range)197
Thermostat Inspection197
Thermostat Servicing198
Disassembly198
Inspection198
Assembly198
Pressure Relief Valve Servicing199
Powerhead201
Powerhead Service Chart202
Powerhead Removal204
Powerhead Removal (Rope Start Models)205
Powerhead Disassembly206
Throttle Linkage Removal206
Shift Linkage Removal206
General206
Crankcase Disassembly207
Cylinder Head Removal208
Connecting Rods And Pistons208
Crankshaft Removal209
Cylinder Block Cleaning212
Powerhead Inspection213
Cylinder Head Check213
Crankshaft Check213
Cylinder Bore Check213
Pistons Check214
Piston Rings Check214
Bearings Check214
Powerhead Assembly215
Crankshaft Assembly215
Bearings215
Pistons And Connecting Rods217
Installing Pistons218
Cylinder Head Installation219
Crankshaft And Connecting Rod Installation220
Crankcase Assembly223
Shift Linkage Installation225
Throttle Linkage Installation225
Final Powerhead Assembly226
Powerhead Installation227
Powerhead Mounting227
Shift Linkage Adjustment229
Port Short Block View230
Starboard Short Block View230
Powerhead Views230
Port Dressed Powerhead View231
Starboard Dressed Powerhead View231
Port Rope Start Models View232
Starboard Rope Start Models View232
Front View233
Rear View234
Top View235
Top View, Rope Start Models236
Midsection237
Midsection Service Chart - Stern Bracket, Power Tilt Models238
Midsection Service Chart - Stern Bracket, Manual Tilt Models239
Exhaust Housing Diagram240
Tiller Handle (Long) Diagram241
Tilt Tube Service242
Tilt Tube Removal242
Tilt Tube Installation243
Exhaust Housing Service244
Exhaust Housing Removal244
Exhaust Water Valve Servicing245
Exhaust Relief Muffler245
Exhaust Housing Installation246
Stern Bracket - Power Tilt Models247
Stern Bracket Disassembly (Power Tilt)247
Stern Bracket Assembly (Power Tilt)248
Stern Bracket - Manual Tilt Models249
Clamp Screw249
Stern Bracket Disassembly (Manual Tilt)249
Stern Bracket Assembly (Manual Tilt)252
Tilt Assist Cylinder255
Tiller Handle Service - Standard256
Tiller Handle Removal256
Tiller Handle Disassembly257
Tiller Handle Inspection258
Tiller Handle Assembly258
Tiller Handle Installation260
Throttle Cable Adjustment261
Tiller Handle Service - Long Handle262
Tiller Handle Inspection And Assembly266
To Install The Tiller Handle270
Installation270
Control Cable Installation271
Shift Cable Adjustment271
To Adjust The Throttle Cable272
Midsection And Tiller Adjustments273
Steering Friction Adjustment273
Throttle Friction Adjustment273
Gearcase275
Gearcase Service Chart276
Propeller Service277
Gearcase Leak Test277
Gearcase Installation278
Gearcase Removal And Installation278
Water Pump Disassembly280
Water Pump Inspection280
Water Pump Service280
Water Pump Assembly281
Shift Rod Adjustment282
Gearcase Disassembly283
Pre-Disassembly Inspection283
Propeller Shaft Bearing Housing Removal284
Pinion Gear And Driveshaft Removal285
Shift Housing, Gear And Propeller Shaft Removal286
Locked Driveshaft Removal286
Internal Gearcase Service287
Pinion Bearing Removal287
Pinion Bearing Installation287
Water Intake Screen Check287
Shift Housing Disassembly288
Shift Housing Assembly289
Driveshaft Bearing Housing Service291
Propeller Shaft Bearing Housing Service292
Rear Seal Removal292
Bearing Removal292
Bearing Installation293
Rear Seal Installation293
Driveshaft Shimming294
Gearcase Assembly295
Shift Housing, Gear, And Propeller Shaft Installation295
Shift Rod Housing Installation295
Pinion Gear And Driveshaft Installation296
Propeller Shaft Bearing Housing And Gear Installation298
Trim And Tilt301
Trim And Tilt - System Inspection302
System Description302
Trim And Tilt - Routine Inspections303
Stern Brackets Inspection303
Trim And Tilt Motor Current Draw Tests303
Reservoir Fluid303
Manual Release Valve303
Electrical Circuit Tests303
Relay Testing303
Trim And Tilt Motor No Load Test304
Trim Gauge Test305
Trim Sender Test305
Trim And Tilt Servicing306
Trim And Tilt Removal306
Trim And Tilt Disassembly306
Trim And Tilt Assembly308
Trim And Tilt Installation309
Adjustments310
Manual Starter311
Manual Starter Service Chart312
Recoil Starter Removal313
Recoil Starter Disassembly313
Recoil Starter Cleaning And Inspection315
Recoil Starter Assembly315
Recoil Starter Installation319
Safety321
Matine Products And The Safety Of The People Who Use Them323
Outboard Shift Systems And Safety324
Outboard Speed Control System And Safety325
Outboard Steering Control System And Safety326
How Can Loss Of Steering Control Be Minimized327
Transom Mounted Steering Systems – Check To Uncover Possible Trouble327
Outboard Fuel, Electrical System, And Safety328
How Can Fire And Explosion Be Minimized328
Outboard Mounting System And Safety331
How Can Loss Of Mounting Be Minimized331
If Weakened, Parts Could Fail Later On The Water, When Not Expected332
Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety333
Outboard Emergency Stop System And Safety334
How Can Failure Of The Emergency Stop System Be Minimized335
Summing Up336
Marine Products And The Safety Of People Who Fix Them337
Handling Outboards337
When Lifting Outboards337
Running Outboard With Engine Cover Removed338
Outboard Starting At The Wrong Time338
Running Outboard Too Fast (Overspeeding)339
Running Outboards: Exhaust Fumes339
Running Outboards: Propellers340
Eye Protection340
Handling Lead/Acid Batteries341
Charging Lead Acid Batteries341
Gasoline – Handle With Care342
Hazardous Products343
Safety Awareness Test344
Index345
Trouble Check Chart353
Outboard Will Not Start353
Outboard Hard To Start355
Outboard Will Not Shut Off356
Outboard Starts And Stalls356
Outboard Starts, Low Maximum Rpm357
Excessive Smoking357
Outboard Surges, Runs Rough358
Hose Routing And Water Flow Diagram - 40 – 65 E-Tec Inline 2 Cylinder359
Mws Instrument Wiring Harness360
Canbus Keyswitch/Tnt Wiring Harness361
Lanyard Switch / Emergency Stop Circuits362
Mws Key Switch And Neutral Safety Switch363
Mws Dashboard364
Emm Led Diagnostic Indicators366