Page 1 Service Manual 75, 90 HP...
Page 3 BRP US Inc. Technical Publications 250 Sea Horse Drive Waukegan, Illinois 60085 United States † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. †...
Page 4: Table Of Contents
ABLE ONTENTS SECTION ........PAGE INTRODUCTION .
Page 5 INTRODUCTION INTRODUCTION CONTENTS ABBREVIATIONS USED IN THIS MANUAL ..........6 .
Page 6: Safety
SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained Always follow common shop safety practices. If technicians who are already familiar with the use you have not had training related to common shop ®...
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
INTRODUCTION 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. lbs. foot pounds barometric pressure sensor horsepower...
Page 9: Engine Emissions Information
INTRODUCTION ENGINE EMISSIONS INFORMATION ENGINE EMISSIONS The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner INFORMATION that would alter the horsepower or allow emis- sions levels to exceed their predetermined factory Maintenance, replacement, or repair of the specifications.
Page 10: Model Designation
INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: LENGTH: J = Johnson = 15” Std. E = Evinrude L = 20” Long Y = 22.5” Special MODEL RUN X = 25” X-long HORSEPOWER PREFIX or SUFFIX Z = 30” XX-long E 200 DP X SC MODEL YR: DESIGN FEATURES: I = 1...
Page 11: Models Covered In This Manual
This manual covers service information on all 79 ® cubic inch, 3-Cylinder Evinrude E-TEC models. Model Number Shaft Color Gearcase E75DPLSCB 20” “S” E75DSLSCS 20” “S” E90DPLSCB 20” “S” E90DSLSCM 20” “S” E90DPXSCB 25” “O” E90WDELSCS 20” “S” 1. Model and serial number 002147 E90WDEXSCS 25”...
Page 12: Service Specifications
INTRODUCTION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS 75 – 90 HP E-TEC Models Full Throttle 4500 to 5500 RPM Operating Range RPM 75 HP (56 kw) @ 5000 RPM Power 90 HP (67.1 kw) @ 5000 RPM Idle RPM in Gear 700 ± 50 EMM Controlled Idle RPM in Neutral 600 ±...
Page 13 INTRODUCTION SERVICE SPECIFICATIONS 75 – 90 HP E-TEC Models Minimum Battery 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Requirements Alternator 25-Amp fully regulated Tachometer Setting 6 pulse (12 pole) Engine Fuse P/N 967545 – 10 A Maximum Temperature 212°F (100°C) Thermostat...
Page 14: Standard Torque Specifications
INTRODUCTION STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE PRODUCT REFERENCE SPECIFICATIONS AND ILLUSTRATIONS BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and Size In. Lbs. Ft. Lbs. N·m models and also to discontinue models. The right No.
Page 15 SPECIAL TOOLS SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS ..............14 UNIVERSAL TOOLS .
Page 16: Special Tools
SPECIAL TOOLS DIAGNOSTIC TOOLS DIAGNOSTIC TOOLS Diagnostic Software P/N 764642 764642 Bootstrap tool P/N 586551 002276 Interface cable P/N 437955 45583 UNIVERSAL TOOLS Universal Puller Set P/N 378103 32885 Lifting eye P/N 321537 23701 Lifting ring assembly P/N 396748 000669 Flywheel holder P/N 771311 42938 Slide hammer P/N 391008...
Page 17 SPECIAL TOOLS UNIVERSAL TOOLS Small puller jaws P/N 432131 23150 Large puller jaws P/N 432129 23148 Bearing puller jaws P/N 432130 23149 Tilt tube nut wrench P/N 342680 46879 Tilt tube service kit P/N 434523 33249 Syringe P/N 346936 50243 Temperature gun P/N 772018 45240 Fresh water flusher P/N 500542...
Page 18: Electrical / Ignition Tools
SPECIAL TOOLS ELECTRICAL / IGNITION TOOLS ELECTRICAL / IGNITION TOOLS Digital multimeter DRC7265 Peak reading voltmeter 49799 Test probe kit P/N 342677 45241 Ohms resolution 0.01 P/N 507972 Purchase through local supplier Stator Test Adapter P/N 5005799 002273 Crimping pliers P/N 322696 30387 Tachometer/timing light P/N 507980 49789...
Page 19: Fuel /Oil System Tools
SPECIAL TOOLS FUEL /OIL SYSTEM TOOLS FUEL /OIL SYSTEM TOOLS Fuel pressure gauge (60 PSI) 005339 Fuel pressure gauge (15 PSI) 004560 Injector test fitting kit 002465 P/N 5007100 P/N 5006397 P/N 5005844 90° fitting, P/N 353322 90° fitting, P/N 353322 POWERHEAD TOOLS Cylinder bore gauge P/N 771310 45303...
Page 20: Gearcase Tools
SPECIAL TOOLS GEARCASE TOOLS 1. Wrist pin retaining ring driver DR1641 Wrist pin pressing tool 23668 Ring compressor – standard CO3768 P/N 318599 P/N 326356 ·P/N 336314 2. Wrist pin cone P/N 318600 GEARCASE TOOLS Gearcase pressure tester 49794 Universal Driveshaft Shimming Tool 002601 Universal Pinion Bearing Remover 002805...
Page 21 SPECIAL TOOLS GEARCASE TOOLS Gearcase Alignment Gauge Kit 004315 Lower Driveshaft Puller P/N 342681 47257 Bearing Installer P/N 326562 32962 P/N 5006349 Gauging Head, “S” Type 005072 Driveshaft seal protector 23692 Prop shaft bearing installer 32880 Gearcases, P/N 352879 P/N 318674 P/N 339750 Backing plate P/N 325867 23621...
Page 22: Trim And Tilt Tools
SPECIAL TOOLS TRIM AND TILT TOOLS TRIM AND TILT TOOLS Tilt cylinder end cap remover 005340 Spanner wrench P/N 912084 32213 P/N 352932, for single-piston tilt systems...
Page 23: Shop Aids
SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 D.P.L. Spray P/N 777183 Oil - XD30™ P/N 777219 “6 in 1” Multi-Purpose Lubricant P/N 777192 Oil - XD50™ P/N 777225 HPF XR™ Gear Lube P/N 778755 Oil - XD100™ P/N 777118 Anti-Corrosion Spray P/N 777193 HPF PRO Gearcase Lube P/N 778755 Engine Tuner P/N 777185...
Page 24 SPECIAL TOOLS SHOP AIDS Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Electrical Grease P/N 503243 P/N 777186 P/N 775612 Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 2 + 4™ Fuel conditioner P/N 775613 Triple-Guard® Grease P/N 508298 Starter Bendix Lube P/N 337016 Gel-Seal and Gasket Remover P/N 771050 Needle Bearing Grease, P/N 378642...
Page 25 SPECIAL TOOLS SHOP AIDS RTV Silicone Sealant P/N 263753 Gasket Sealing Compound P/N 317201 Thermal Joint Compound P/N 322170 Fuel System Cleaner P/N 777184 Pipe Sealant with Teflon P/N 910048 Instant Bonding Adhesive P/N 509955 Gel·Seal II P/N 327361 Locquic Primer P/N 772032 1.
Page 26: Notes
SPECIAL TOOLS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 27 INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............26 .
Page 28: Boat Rigging
INSTALLATION AND PREDELIVERY BOAT RIGGING BOAT RIGGING • Dual-outboard controls require separate key switches with a single emergency stop switch. Remote Controls Control Selection WARNING The remote control used must have start- in-gear prevention. This feature can pre- vent injuries resulting from unexpected boat movement when the outboard starts.
Page 29: Battery Installation
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Installation Control Installation Plan the installation of remote controls carefully, Each outboard requires its own starting battery. following all instructions provided with the remote Select a battery that meets or exceeds the mini- control. mum requirements.
Page 30: Battery Switches And Multiple Batteries
INSTALLATION AND PREDELIVERY BOAT RIGGING Connections Battery Cable Requirements Evinrude outboards are shipped with stranded IMPORTANT: Connect the battery positive (+) copper battery cables for typical installations in cable to the battery positive (+) post FIRST. Con- which the starting battery is positioned close to the nect the battery negative (–) cable to the battery transom.
Page 31 INSTALLATION AND PREDELIVERY BOAT RIGGING Typical battery functions Battery Switch Location • Always locate battery switch as close to the bat- IMPORTANT: Never connect an external battery teries as possible. • isolator to the stator of an Evinrude E-TEC. Locate switch so that it cannot be accidently bumped or switched.
Page 32: Battery And Switch Wiring Diagrams
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery and Switch Wiring Diagrams One outboard: Battery disconnect One outboard: One primary starting battery; one secondary battery BOTH PRIMARY SECONDARY PRIMARY 000135rev1 000136rev2 Two outboards: Two starting batteries for each outboard BOTH BOTH PRIMARY SECONDARY SECONDARY PRIMARY...
Page 33 INSTALLATION AND PREDELIVERY BOAT RIGGING Two outboards: One primary starting battery for each outboard BOTH BOTH PRIMARY PRIMARY Positive (+) Battery cables Negative (–) Battery cables 000086rev2...
Page 34: Fuel System Requirements
INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements Fuel System Primer Outboards require a priming system capable of Overview refilling the fuel system after periods of non-use. Boat fuel systems must meet minimum specifica- Primer bulbs that meet the outboard's minimum tions to insure the proper delivery of fuel to the inside diameter fuel line requirements are used on outboard.
Page 35: Fuel Filters
INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.
Page 36: Cable And Hose Installation
INSTALLATION AND PREDELIVERY BOAT RIGGING Cable and Hose Installation Cable and Wire Harness Routing Before installation, identify all required wiring, WARNING cables, and hoses: • Improper installation and routing of out- Throttle and shift cables • board controls could wear, bind, and dam- Instrument harnesses •...
Page 37: Battery Cables
INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Cables Evinrude outboards are equipped with premium quality battery cables that should be long enough for most installations. When routing battery cables, be sure to: • Route cables through the protective sleeve. • Use the most direct path to route the battery cables to the battery or battery switch.
Page 38 INSTALLATION AND PREDELIVERY BOAT RIGGING Oetiker Clamp Servicing † Use Oetiker clamps for making hose connec- tions. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging com- ponents, and provide solid, permanent connec- tions. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
Page 39 INSTALLATION AND PREDELIVERY BOAT RIGGING Clamp Installation Clamp Removal Method 1: Position Oetiker pincers across clamp A constant stress should be applied to close the ear clamps. This method ensures a positive stress ear and cut clamp. on the hose and does not result in excessive com- pression or expansion of the band material.
Page 40: Outboard Installation
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION OUTBOARD Control Cable Identification IMPORTANT: INSTALLATION Control cable function must be identified before rigging outboard. Hull Preparation Identify each control cable: • Put the control handle into NEUTRAL position. Maximum Capacity The throttle cable casing guide will retract com- pletely and the shift cable casing guide will go to WARNING the midpoint of its travel.
Page 41 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Brackets and Jack Plates WARNING When mounting an outboard on boats equipped with transom brackets or jack plates, refer to the DO NOT install an outboard on a curved or manufacturer's recommendations. irregular surface. Doing so can wear, bind, •...
Page 42: Transom Measuring And Drilling
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Measuring and Drilling IMPORTANT: Some steering systems require additional spacing. Refer to steering sys- Hull Centerline tem manufacturer for recommendations. Use the chines of the boat as reference points to The top edge of the transom should be more than locate the centerline of the boat transom.
Page 43 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION For dual-outboard installations, transom height Position drill fixture on top of transom or bracket should be measured at the outboard centerlines. and align indicator points with centerline. Use a straightedge as a reference to extend the bottom of the boat.
Page 44 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagrams IMPORTANT: This is not a template. 6 7/16" 6 7/16" (163.5mm) (163.5mm) 2" (50.8mm) (50.8mm) 90° 10 11 12 8" 8" (203.2mm) (203.2mm) 90° 4 15/16" 4 15/16" (125.4mm) (125.4mm) 000133m Quantity 1.
Page 45: Lifting The Outboard
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Lifting the Outboard Steering Systems Lifting Fixtures Mechanical Cables All Evinrude outboards equipped with tilt tubes are WARNING designed to be compatible with mechanical steer- ing systems that meet ABYC Standard P-17. Sin- To avoid personal injury, make sure the lift- gle-cable mechanical steering systems can be ing capacity of the hoist is at least twice used on single or dual-outboard installations if an...
Page 46 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Manual Hydraulic Steering arm. For single motor, single cable applications, the drag link should be installed in the rear hole. Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard.
Page 47: Outboard Mounting
INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Outboard Mounting Assemble transom mounting plates on mounting bolts. IMPORTANT: Some rigging components, such Install the mounting bolts through the transom as steering cables, must be fitted to the outboard from the inside of the boat. before the outboard is mounted to the transom.
Page 48: Outboard Rigging
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING OUTBOARD RIGGING Place the grommet into position in the lower engine cover. CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. Cable, Hose, and Wire Routing Refer to Control Cable Identification on p.
Page 49 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING • With remote control lever in NEUTRAL, pull firmly Use long nose pliers to insert straight section of on firmly on throttle cable casing to remove slack. clip into linkage pin hole. With engine throttle cam against stop, place the cable trunnion into the upper anchor pocket and adjust the trunnion nut so the casing fits onto the throttle lever pin.
Page 50: Electrical Harness Connections
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Electrical Harness Connections Install electrical cover and secure with screws. Place the wiring harness through notch in lower motor cover and route to the recess in the fly- wheel cover. Secure the cable with a tie strap as shown: 002102 IMPORTANT:...
Page 51: Canbus Connections
INSTALLATION AND PREDELIVERY OUTBOARD RIGGING CANbus Connections EMM CANbus connector cap is clipped to EMM cooling water hose. Remove clip from cap and If the outboard will be used with I-Command, or install on CANbus harness connector. other NMEA 2000 compliant CANbus instruments, the following connections will supply information to the network.
Page 52 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING switch is on. Quick Connect-style network does sure both harnesses are in front of tab and CAN- NOT use this connection. bus ignition harness is in wire channel. 1. Trim/Tilt connector 006734 1. CANbus EMM harness 006739 2.
Page 53: Fuel And Oil Priming
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING FUEL AND OIL PRIMING When using alcohol-extended fuels, be aware of the following: Fuel Requirements • The boat’s fuel system may have different requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. WARNING •...
Page 54: Fuel System Priming
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Fuel System Priming Observe all fuel lines, both in the boat and on the outboard. Repair any fuel leaks. Vent Line Clamp WARNING In compliance with Code of Federal Regulations, 49 CFR §173.220, all outboards using a fuel Failure to check for fuel leaks could allow a vapor separator must be shipped with a vent line leak to go undetected, resulting in fire or...
Page 55: Oil Injection Rate
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Oil Injection Rate Powerhead oil programming labels are provided to identify EMM oil programming. Install the cor- The Engine Management Module (EMM) controls rect label to alert user to specific oil requirements. the oil injection rate based on engine RPM. This rate can be adjusted for the type of oil being used, and also for powerhead break-in.
Page 56: Break-In Oiling
INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Break-In Oiling Observe oil flow through the oil distribution hoses. IMPORTANT: DO NOT add oil in the fuel tank on Evinrude E-TEC models. The Engine Management Module (EMM) auto- matically supplies extra oil to the engine during the first two hours of operation above 2000 RPM.
Page 57: Before Start-Up
INSTALLATION AND PREDELIVERY BEFORE START-UP BEFORE START-UP Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run- Gearcase Lubricant ning outboard: • Tilt the motor up and engage the tilt support. With outboard vertical, check the gearcase lubri- •...
Page 58: Running Checks
INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS Emergency Stop / Key Switch Check emergency stop function. With outboard WARNING running at IDLE, pull safety lanyard from emer- gency stop switch. Outboard must stop immedi- DO NOT run outboard without a water sup- ately.
Page 59: Water Pump Overboard Indicator
INSTALLATION AND PREDELIVERY RUNNING CHECKS Water Pump Overboard Indicator Idle Speed A steady stream of water should flow from the Make sure the outboard idles within the specified overboard indicator. idle RPM range. If the outboard is run on a flush- ing device, the idle speed and quality may not be representative of actual in water use.
Page 60: Propellers
INSTALLATION AND PREDELIVERY PROPELLERS PROPELLERS IMPORTANT: If the propeller blades have too much pitch, the engine will operate below its nor- Propeller Selection mal range at full throttle. Power will be lost, and powerhead damage could occur. If the propeller CAUTION blades have too little pitch, the engine will operate above its normal range and damage from over-...
Page 61: Propeller Hardware Installation
INSTALLATION AND PREDELIVERY PROPELLERS Propeller Hardware Installation WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.
Page 62: Final Adjustments
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS FINAL 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,...
Page 63: Trim Sending Unit Adjustment
INSTALLATION AND PREDELIVERY FINAL 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 64: Trim Tab Adjustment
INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Trim Tab Adjustment 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. The trim tab is adjustable to compensate for this steering torque.
Page 65: Dual-Outboard Alignment
INSTALLATION AND PREDELIVERY FINAL 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 66: Notes
INSTALLATION AND PREDELIVERY NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 67 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 66 ANTI-CORROSION PROTECTION .
Page 68: Inspection And Maintenance Schedule
MAINTENANCE 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 69: Anti-Corrosion Protection
MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity PROTECTION Connect ohmmeter leads between engine ground 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 70: Cooling System
MAINTENANCE COOLING SYSTEM COOLING SYSTEM Thread garden hose into flushing port. Check the condition of cooling system compo- nents regularly: • water intake screens; • water pump; • all internal water passages; • thermostats; • all external water hoses and fittings; •...
Page 71: Water Intake Screens
MAINTENANCE LUBRICATION LUBRICATION Water Intake Screens Inspect condition of water intake screens. Clean Steering System or replace as needed. WARNING Confirm function of overboard water pressure indi- cator. Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, mak- ing operator control difficult.
Page 72: Swivel Bracket And Trailering Bracket
MAINTENANCE LUBRICATION Swivel Bracket and Trailering Throttle and Shift Linkage Bracket Disconnect the battery cables at the battery. Lubricate the swivel bracket with Triple-Guard Remove clips and washers from throttle and shift grease. lever pins. Carefully, remove casing guides from pins.
Page 73: Propeller Shaft
MAINTENANCE LUBRICATION Propeller Shaft removing the lower, drain/fill plug. A tie strap can be used to check lubricant level. Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage. WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.
Page 74 MAINTENANCE LUBRICATION Inspect the lubricant for water contamination. Slowly fill the gearcase with gearcase lube Water can make the lubricant milky in appear- through the drain/fill hole until it appears at the oil ance. However, normal aeration can also cause level hole.
Page 75: Trim And Tilt
MAINTENANCE LUBRICATION Trim and Tilt Check reservoir fluid level every three years or every 300 operating hours. System capacity is approximately 21 fl. oz. (620 ml). • Tilt the outboard and engage the tilt support. Single Ram Trim System 004278 1.
Page 76: Battery And Battery Connections
MAINTENANCE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY FUEL AND OIL SYSTEMS CONNECTIONS Routine replacement of filters reduces the possi- bility of foreign material restricting the incoming Check battery connections frequently. Periodically fuel or oil supplies. remove battery to clean and service connections. Replacement filter elements are available through WARNING Evinrude/Johnson Genuine Parts.
Page 77: Air Silencer
MAINTENANCE FUEL AND OIL SYSTEMS Air Silencer Hoses and Connections The air silencer on Evinrude outboards maximizes Check condition of all hoses and connections in air flow while minimizing noise. both the fuel and oil systems: • Visually inspect all components. •...
Page 78: Spark Plugs
MAINTENANCE SPARK PLUGS SPARK PLUGS plug with the OPEN side of the ground electrode facing the fuel injector. Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs. Use only recommended spark plugs with the cor- rect gap setting.
Page 79: Storage
MAINTENANCE STORAGE STORAGE Software Control Method Winterization can also be run using Evinrude Diagnostics software. With the outboard running, IMPORTANT: DO NOT start outboard without a start the process at the Settings/Adjustments water supply to the outboard’s cooling system. screen and follow the instructions. Cooling system and/or powerhead damage could occur.
Page 80: Additional Recommendations
MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE Additional Recommendations • Top off oil reservoir. If the outboard was removed from the boat for • inspect the fuel filter. If there is debris in the fuel storage, make sure it is reinstalled with factory filter, it must be replaced.
Page 81: Submerged Engines
MAINTENANCE SUBMERGED ENGINES SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL AND OIL PRIMING on p. 51. Make sure all oil injection hoses are clean and filled with oil. Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) Make sure high pressure fuel system does not hours of recovery.
Page 82: Notes
MAINTENANCE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 83 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 82 .
Page 84 ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE LOWER COVER SERVICE Latch Hook Installation Insert threaded bracket into pocket. Lower Cover Removal Remove lower engine cover screws. 1. Bracket 006468 Apply Ultra-Lock to screw threads. Place hook into position with opening toward the front. Tighten 1.
Page 85 ENGINE COVER SERVICE LOWER COVER SERVICE Lower Cover Installation Start the top front screw next and draw cover halves together. Installation of lower motor covers will be easier if the following steps are performed in order: • Install air silencer on throttle body. •...
Page 86: Engine Cover Service
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 006470 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
Page 87 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............86 .
Page 88: Description
ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION DESCRIPTION The Engine Management Module (EMM) is a water-cooled engine controller. It controls many outboard systems including alternator output for the 12 V and 55 V circuits. Operating voltage is supplied to the EMM by the stator. This section discusses the functions of the EMM and its various internal and external sensors.
Page 89: 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 002043T 1. Engine Management Module (EMM) 7. Air Temperature Sensor (AT) 13. Fuel Injector 2. Battery (12 volt) 8. Oil Pressure Switch (component of 11) 14.
Page 90: Internal Sensors
ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS INTERNAL SENSORS If sensor reads less than -71°F (-57.4°C) or greater than 313°F (156°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.
Page 91: Barometric Pressure Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS Barometric Pressure Sensor Supplies the EMM with barometric pressure read- Sensor inputs and internal EMM controllers are ing to compensate for changes in altitude and air used to control outboard operation. Use Evinrude density.
Page 92: Engine Temperature Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Engine Temperature Sensor Low Oil Switch Monitors cylinder head temperature. The sensor The low oil switch monitors the oil level in the oil is a negative temperature coefficient thermistor tank. (NTC). If the oil level falls below one-quarter capacity, the If cylinder head temperature exceeds 212°...
Page 93: Crankshaft Position Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Crankshaft Position Sensor If code 11 is present as both a Hard Fault and a Stored Fault, refer to Control Cable Adjust- The CPS is a magnetic device. It is mounted on ments on p. 46. the throttle body, next to the flywheel.
Page 94: Internal Emm Functions
ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM Neutral RPM Limiter FUNCTIONS This feature prevents engine damage due to excessive RPM if accelerated in NEUTRAL. Neu- tral engine speed is limited to 1800 RPM. ROM Verification Engine Monitor and Warning The EMM performs a self-test of programming Systems every time it is turned ON.
Page 95: Engine Monitoring System
ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITORING SYSTEM ENGINE MONITORING 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). The engine monitoring system warns the operator •...
Page 96: Warning System
ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING SHUTDOWN MODE SYSTEM Outboard “shutdown” will occur if specific faults are detected by the EMM: The S.A.F.E. (Speed Adjusting Failsafe Electron- Code 29 Excessive EMM temperature ics) warning system alerts the operator and pro- Code 31 Excessive engine temperature tects against engine damage from the following Code 33 Excessive NO OIL condition...
Page 97: Diagnostic Software Functions
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS DIAGNOSTIC Static Information SOFTWARE FUNCTIONS Static information is viewed when the outboard is NOT running. This includes manufacturing infor- mation. The EMM stores valuable information about the outboard and its running history. This information The outboard model and serial numbers displayed can be used for troubleshooting, for checking on the Identity screen must match the identifica-...
Page 98: 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 99: Dynamic Tests
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Tests Ignition Test Use the diagnostics software to test each ignition Dynamic tests are performed with the outboard circuit. Refer to Static Ignition Test on p. 111. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.
Page 100: Oil Control Settings
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Oil Control Settings Powerhead Break-In Use the diagnostics software to start break-in oil- Set Oil Type ing after a powerhead rebuild. The break-in oiling The TC-W3 oil type setting is the standard setting program runs for two hours of outboard operation, for all outboards.
Page 101: 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 102: Fuel Injector Servicing
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Fuel Injector Servicing Reports All E-TEC fuel injectors use software program- Engine reports provide service records and can ming to compensate for variations in fuel flow. be used to document the running history of an out- Each injector and its location on the outboard is board.
Page 103: Software Replacement
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Software Replacement IMPORTANT: Software replacement requires a “Bootstrap” Tool, P/N 586551. Engine Management Software programs are loaded into the EMM at the factory. Periodically, a new program may be available to enhance the operation of an outboard.
Page 104: Emm Servicing
ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING Installation Installation is the reverse of removal. Pay close IMPORTANT: attention when performing the following tasks. If a new EMM is being installed, refer to EMM Transfer on p. 101. Make sure isolator mounts are placed in slots in of EMM case.
Page 105 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............104 .
Page 106: Diagnostic Procedures
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Operational Inspections PROCEDURES Run the outboard to confirm actual symptoms before performing any unnecessary procedures. Inspection should include the following: Visual Inspections • Make sure the outboard can be cranked easily, Inspect wiring and electrical connections. Disas- with no mechanical binding.
Page 107: Troubleshooting
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Troubleshooting • Use the diagnostics software Dynamic Tests to isolate a faulty cylinder. See DYNAMIC TESTS Outboard will not crank, starter does not on p. 106. operate: • Use an inductive timing light to check ignition •...
Page 108: Dynamic Tests
SYSTEM ANALYSIS DYNAMIC TESTS DYNAMIC TESTS Fuel Control Adjustment Use this test is to help identify a cylinder that may 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...
Page 109: Emm Led Indicators
SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS Starting Starting mode occurs from the time the flywheel The EMM LED indicators provide a quick refer- begins to turn until the outboard is running for 2 ence to the status of several outboard systems. seconds.
Page 110: Running
SYSTEM ANALYSIS EMM LED INDICATORS Running LED 3 – Sensor circuits (5 V), “SENSOR FAULT.” For LIGHT ON, check for possible fault codes: When the outboard is running, all of the LEDs • Code 12 – TPS circuit fault should be off. If a light is on, check for: •...
Page 111: Ignition Output Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS IGNITION OUTPUT Crankshaft Position Sensor • Provides EMM with input. TESTS • Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated. DANGER Alternator Output/System Voltage • System voltage from EMM (white/red) provides The electrical system presents a serious 55 VDC to the high pressure fuel pump, the oil shock hazard.
Page 112: Crankshaft Position Sensor (Cps) Test
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Crankshaft Position Sensor (CPS) System Voltage Test Test The ignition system is powered by the 55 V sys- tem. When the CPS is working properly, EMM LED 2 turns on while the outboard is being started. Use the Evinrude Diagnostics software Monitor screen to check system voltage.
Page 113: Static Ignition Test
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Static Ignition Test IMPORTANT: This test is operating the ignition coil with 12 V battery power on the system voltage Perform the static ignition test using Evinrude (55 V) circuit. An inductive probe with low sensitiv- Diagnostics software and an inductive timing light.
Page 114: 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. 114 •...
Page 115: Ignition Control Circuit Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Control Circuit Tests If circuits test good, replace EMM. Ignition Coil Tests Use a digital multimeter to test the following: • System voltage supply to ignition coil. There are no simple ignition coil tests available. •...
Page 116: Fuel Delivery Tests
SYSTEM ANALYSIS FUEL DELIVERY TESTS FUEL DELIVERY TESTS • The EMM controls the fuel pump ground (brown wire). Use an ohmmeter to check continuity between pin 2 of fuel pump connector and WARNING ground. Use the fuel pump static test to activate the control function of the EMM.
Page 117: Running Fuel System Tests
SYSTEM ANALYSIS FUEL DELIVERY TESTS Results: Results: No injectors actuate: No light activation on any injector wires (outboard • cranks and starter turns flywheel): Use the Monitor screen of the diagnostics soft- • Check stator input to EMM, CPS operation, and ware to make sure voltage is present on the system voltage circuit.
Page 118: Notes
SYSTEM ANALYSIS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 119 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............118 DASH CONNECTIONS, INSTRUMENT HARNESS .
Page 120: Service Chart
ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 75 – 90 HP M ODELS 5 to 8 in lbs. (.6 to .9 N·m) 120 to 140 in lbs. (13.5 to 16 N·m) 100 to 115 ft. lbs. (136 to 156 N·m) 168 to 192 in lbs.
Page 121 ELECTRICAL AND IGNITION SERVICE CHART 24 to 36 in lbs. (2.7 to 4 N·m) 15 to 30 ft. lbs. (20 to 41 N·m) 60 to 84 in lbs. (7 to 9.5 N ·m) 30 to 42 in lbs. (3.4 to 4.8 N·m) 24 to 36 in lbs.
Page 122: Dash Connections, Instrument Harness
ELECTRICAL AND IGNITION DASH CONNECTIONS, INSTRUMENT HARNESS DASH CONNECTIONS, INSTRUMENT HARNESS 3-pin connector – Connect to trim switch located in the handle of the remote control or to trim switch mounted on the boat dash. 6-pin connector – Connect to a pre-wired remote control or to a dash-mounted key switch.
Page 123: 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 124 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 001877 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 2 Purple Stator winding, 1S Yellow Injector, cylinder 3 Green Stator winding, 2S Brown vacant Stator winding, 3S Orange...
Page 125: Ground Circuits
ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS FUSE All ground circuits are essential to reliable out- The engine harness 12 V (B+) circuit is protected board performance. Make sure all ground connec- by one automotive style 10 amp minifuse. tions are clean and tight. Refer to wiring diagrams The fuse is located on the port side of the power- for specific wiring details.
Page 126: Sensor Tests
ELECTRICAL AND IGNITION SENSOR TESTS SENSOR TESTS (1.85 mm). The acceptable clearance is 0.036 to 0.110 in. (1 to 2.8 mm). All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the EMM.
Page 127: Engine Temperature Sensor Test
ELECTRICAL AND IGNITION SENSOR TESTS Air Temperature Sensor (AT) Test Connect red meter lead to terminal “A” and black meter lead to terminal “C.” Rotate the sensor lever Remove the electrical connector from the air tem- through its range of travel. Resistance reading perature sensor.
Page 128: 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 (4 poles each) read no continuity.
Page 129: Charging System Tests
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM Following the manufacturer’s directions, connect the variable load tester (carbon pile) across the TESTS battery terminals. Stevens model LB-85 and Snap-On model MT540D are examples of testers 12 V Charging Circuit available. To test the operation of the regulator in the EMM, WARNING you must be able to run the outboard continuously...
Page 130: V Alternator Circuit
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Start the outboard and run it at approximately 5000 RPM. Use the variable load tester to draw the battery down at a rate equivalent to the sta- tor’s full output. • The ammeter should indicate nearly full output, Approximately 25 A @ 5000 RPM.
Page 131: Electric Start Circuit
ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 006403 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 132 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 300 RPM minal “B”.
Page 133: 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 134: No Load Current Draw Test
ELECTRICAL AND IGNITION ELECTRIC START TESTS After re-installing the solenoid, coat all wires and Use an inductive ammeter or connect a 0 to 100 terminals with Black Neoprene Dip. amp ammeter in series with a heavy jumper between the battery positive (+) terminal and the starter positive (+) terminal.
Page 135: Remote Control Switch Tests
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test SWITCH TESTS Use an ohmmeter or continuity light to test the continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
Page 136: Neutral Start Switch Test
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 137: 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 138: 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 139: Check Engine Circuit Test
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS WATER TEMP/ HOT Circuit Test the two connectors, replace SystemCheck 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 140: Low Oil Circuit Test
ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT LOW OIL Circuit Test 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 141: Flywheel And Stator Servicing
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING FLYWHEEL AND Disconnect wiring harness and remove wiring from cover. STATOR SERVICING IMPORTANT: Weak flywheel magnets cause low alternator output and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as a peak-reading voltmeter, which might cause unnecessary parts replacement.
Page 142 ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywheel Holder, P/N 771311, or equivalent, Put the puller on flywheel with body flat side up. and a 1 5/16 in. socket to remove flywheel nut. Attach the puller body with the three shoulder Discard flywheel nut.
Page 143: Stator Service
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Stator Service Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry. ™ Disconnect stator harness connector. Remove three allen head screws to remove sta- tor. 002093 Align the flywheel keyway and install flywheel. Coat the threads of a new flywheel nut with Triple- Guard grease.
Page 144: Timing Adjustments
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TIMING ADJUSTMENTS the tool. Mark the flywheel directly across from the pointer. Label this mark “A.” Timing Pointer The timing pointer must be adjusted to indicate top dead center (TDC) of the number 1 piston. This reference to the position of the number 1 pis- ton is used to synchronize the electronic timing controlled by the EMM with the mechanical posi-...
Page 145: Timing Verification
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TPS Calibration Repeat the entire adjustment process to make sure pointer is aligned correctly. Use Evinrude Diagnostics software to tell the Install spark plugs. Refer to Spark Plug Indexing EMM what throttle position sensor voltage is when the throttle plates begin to open.
Page 146: Electric Starter Servicing
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Starter Disassembly SERVICING Remove the retaining ring, spacers, spring and starter pinion from pinion shaft. Starter Removal IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead.
Page 147: Starter Cleaning And Inspection
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove brush holder cap from armature and Clean the commutator with 300-grade emery frame assembly. Do not lose the brush springs. cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove any trace of oil or metal dust from commutator.
Page 148: Starter Assembly
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING If the pinion does not properly engage the fly- Compress the brushes and springs with a modi- wheel, the pinion and screw shaft assembly could fied putty knife. be worn, distorted, or dirty. Locate the cause of binding and correct it before completing the assembly.
Page 149: Starter Installation
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Apply Locquic Primer and Screw Lock to the Install spacer and retaining clip. Spacer must be threaded portion, and install the two thru-bolts. raised to cover clip completely. Tighten bolts to a torque of 100 to 110 in. lbs. (11 to 12.5 N·m).
Page 150: 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) 42329 2. Terminal latch (plug) To disconnect the connector, press the latch and pull the connectors apart.
Page 151 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 152 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 153 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation † Connectors Packard Align terminal with connector housing and push IMPORTANT: terminal with seal into connector housing until Always appropriate seated. meter test probes and adapters when testing com- ponents fitted with these terminals. Disconnect Lift latch(s).
Page 154 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Removal Terminal Installation A tab on the back side of the terminal engages a Install wire gasket on wires and feed wires shoulder in the connector housing to hold the ter- through the correct terminal position of the con- minal in place.
Page 155 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............154 FUEL SYSTEM HOSE ROUTING .
Page 156: Service Chart
FUEL SYSTEM SERVICE CHART SERVICE CHART NJECTORS APOR EPARATOR Tighten in 3 stages 5 ft. lbs. (7 N·m) 10 ft. lbs. (14 N·m) 24-36 in. lbs. (2.7-4 N·m) 24-26 Ft. lbs. (33-35 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in.
Page 157 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) IMPORTANT: DO NOT lubricate TPS to throttle shaft surface 10-14 in. lbs (1.1-1.6 n·m) 10-14 in. lbs (1.1-1.6 n·m) 10-18 in. lbs 60-120 in.
Page 158: Fuel System Hose Routing
FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Return 002148a Fuel supply from boat fuel system Fuel lift pump (2 to 8 psi) Pulse hose from cylinder/crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump (20 to 30 psi) Fuel supply manifold Fuel injector(s)
Page 159: Fuel System Circuit Diagram
FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM J1-A J1-B 006756 Stator Capacitor PURPLE WHITE/RED (55 V) GREEN (2) Fuel injector BLACK ground wires BROWN Fuel circulation pump BLUE...
Page 160: Components
FUEL SYSTEM COMPONENTS COMPONENTS pump pressure forces the fuel from the pump through the fuel filter and into the vapor separator. The fuel system includes the following compo- Fuel Filter nents: • Fuel Lift Pump The fuel filter protects the vapor separator and the •...
Page 161: 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 162: Fuel Manifolds
FUEL SYSTEM COMPONENTS Fuel Manifolds Then, the EMM is programmed to compensate for variations in fuel flow. Each injector and its loca- The fuel supply and return manifolds route fuel tion on the outboard is identified by the EMM. DO through the high pressure side of the fuel system.
Page 163: 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 164: Pressure Regulator Test
FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 168 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 165: 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 to measure the fuel pump coil resistance.
Page 166: Lift Pump Vacuum Test
FUEL SYSTEM FUEL SYSTEM TESTS Results: IMPORTANT: Do not use fuel primer bulb, man- ual fuel primer, or electric fuel pump primer to Normal pressure: • restart outboard. A positive pressure in the fuel Perform the Lift Pump Vacuum Test on supply could damage some vacuum gauges.
Page 167: Lift Pump Diaphragm Test
FUEL SYSTEM FUEL SYSTEM TESTS Lift Pump Diaphragm Test Anti-Siphon Valve Test Perform this test only if a damaged pump is sus- Remove anti-siphon valve from fuel tank. Install pected. This test does not confirm the perfor- adapter fittings and a 36 in. (91.4 cm) length of mance of internal fuel pump check valves.
Page 168: Fuel Component Servicing
FUEL SYSTEM FUEL COMPONENT SERVICING FUEL COMPONENT Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly. SERVICING WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.
Page 169: Fuel Filter Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Filter Service Fuel Lift Pump Service The fuel lift pump is serviceable as a complete Removal assembly or can be repaired with a fuel pump Disconnect the battery cables at the battery. repair kit. Refer to parts catalog for service parts. Remove filter carefully to prevent spilling con- Removal tents.
Page 170: Vapor Separator Service
FUEL SYSTEM FUEL COMPONENT SERVICING Installation Connect the fuel hoses to the fuel filter. Secure with Oetiker clamps. Installation is the reverse of removal. Pay close attention when performing the following additional Squeeze primer bulb to prime fuel system. Hold tasks.
Page 171: Fuel Injector Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injector Service Remove fuel manifold retainer screws and remove retainers from fuel injectors. Mark fuel injectors to show cylinder locations. IMPORTANT: Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diag- nostics Software to make sure that EMM program- ming matches injector positioning.
Page 172 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 006561 1. Adaptor 002196 Remove fuel injector and insulator. Crush Ring Replacement IMPORTANT: Injector crush rings must be replaced if injector is installed in a different head or cylinder location.
Page 173 FUEL SYSTEM FUEL COMPONENT SERVICING Installation through mounting flange of injector and into cylin- der head. IMPORTANT: All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead fail- ure. Installation of replacement injectors requires the use of diagnostics software and fuel flow data supplied with all replacement injectors on 3.5 in.
Page 174: 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 prior to reassembly. DO Disconnect throttle link arm. NOT use strong carburetor cleaner or the hot soaking tank method for cleaning. Remove throttle body screws and throttle body assembly.
Page 175 FUEL SYSTEM FUEL COMPONENT SERVICING Inspection Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed Inspect the leaf plate assemblies for damage or valve on reed plate and install screws. Tighten contamination: screws to a torque of 25 to 35 in. lbs. (2.8 to 4.0 •...
Page 176 FUEL SYSTEM FUEL COMPONENT SERVICING Place gasket on throttle body. Install throttle body Install upper main bearing vent hose and secure on reed plate and install screws. with tie strap. Tighten the center screws first and expand out- Connect throttle linkage and electrical connectors. ward.
Page 177 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............176 OIL SUPPLY DIAGRAMS .
Page 178: Service Chart
OILING SYSTEM SERVICE CHART SERVICE CHART 60 - 84 in lbs. (7 - 9.5 N·m) 30 - 42 in lbs. (3.5 - 5 N·m) 30 - 42 in lbs. (3.5 - 5 N·m) 30 - 42 in lbs. (3.5 - 5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847...
Page 179: Oil Supply Diagrams
OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 006645 Oil tank Oil distribution manifold Oil pick-up/filter Crankcase oil inlet (port) Oil injection pump Cylinder oil inlet (starboard)
Page 180: Oil Recirculation Diagram
OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM Starboard view Port view 002223...
Page 181: Oiling System Circuit Diagram
OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM J1-A J1-B 006480 Stator Stator output (55 V) Alternator grounds (BLACK) Oil Injector ground (BLACK) Alternator output, WHITE / RED wires (55 V) Capacitor (55 V) Main harness ground (BLACK) 55 V to injection pump (WHITE / RED) EMM injector control (BLUE) Oil injection pump...
Page 182: Components
OILING SYSTEM COMPONENTS COMPONENTS The oil manifold distributes the oil supplied by the pump. The oiling system includes the following compo- nents: • Oil tank • Oil injection pump and manifold assembly • Electrical circuit • LOW OIL and NO OIL warning systems •...
Page 183: Low Oil Warning
OILING SYSTEM COMPONENTS LOW OIL Warning Cylinder and Crankcase The oil distribution manifold provides crankcase A sending unit in the oil tank pick-up assembly lubrication through oil distribution hoses and monitors the oil level in the oil tank. pressed-in fittings on the crankcase and cylinder block.
Page 184: Oil Recirculation System
OILING SYSTEM OIL CONTROL SETTINGS OIL CONTROL SETTINGS Oil Recirculation System External hoses fittings, internal cylin- Oil Priming der/crankcase passages, and intake manifold pas- sages are used to recirculate any accumulation of The oiling system of the outboard must be primed: •...
Page 185: Oiling System Tests
OILING SYSTEM OILING SYSTEM TESTS OILING SYSTEM TESTS Oil Injection Pump Voltage Test Check voltage at pin 1 (white/red wire) of oil tank IMPORTANT: electrical connector. Always perform visual inspections to identify oiling system leaks. Make sure the oil Acceptable voltage readings: tank is filled and oil supply is not contaminated.
Page 186: Oil Injection Pump Circuit Resistance Test
OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Circuit Oil Injection Pump Function Test Resistance Test Remove oil distribution hose from fitting at oil dis- tribution manifold. Do not lose the brass hose sup- IMPORTANT: The complete oil injection pump port.
Page 187: Oil Injection Fittings Flow Test
OILING SYSTEM OILING SYSTEM TESTS Oil Injection Fittings Flow Test LOW OIL Sending Unit Test Make sure the oil injection fittings of the cylinder Remove the oil from the oil tank. and crankcase assembly allow fluid to move. Turn the key switch ON. The dash mounted Remove oil distribution hose from oil distribution Engine Monitor system should show a LOW OIL manifold.
Page 188: Oil Component Servicing
OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Once hose is removed from the manifold, make sure hose support is in 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 to each cylinder MUST be the same length.
Page 189: Oil Tank Assembly
OILING SYSTEM OIL COMPONENT SERVICING Oil Tank Assembly Removal Disconnect the battery cables at the battery. Remove engine covers and air silencer. Disconnect the electrical connector to the oil injec- tion pump and manifold assembly. 1. Screws 006778 2. Nut Installation Position oil tank assembly on powerhead.
Page 190: Notes
OILING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 191 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAM ......... 190 COMPONENTS .
Page 192: Hose Routing And Water Flow Diagram
COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAM HOSE ROUTING AND WATER FLOW DIAGRAM Outgoing water (warm/hot) Outgoing water (warm/hot) Incoming water (cool) Incoming water (cool) Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply, EMM to vapor separator...
Page 193: 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 adaptor housing.
Page 194: Pressure Relief Valve
COOLING SYSTEM COMPONENTS Pressure Relief Valve Block Venting A pressure relief valve is used to control water A fitting and hose connected to the top of the flow and operating temperature at higher speeds exhaust cover allows the constant movement of (above approximately 2000 RPM).
Page 195: Operation
COOLING SYSTEM OPERATION OPERATION At higher speeds, water pressure opens the pressure relief valve at approximately 1800 RPM. Water flows through the valve to the cylinder head All models use a two-stage cooling system and bypasses the thermostat. All water flows design.
Page 196: Engine Temperature Check
COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method CHECK Use Evinrude Diagnostics software to read tem- perature displays. 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 197: Idle Operating Temperature Troubleshooting (Below Range)
COOLING SYSTEM ENGINE TEMPERATURE CHECK IMPORTANT: Check thermostat for cracks, heat damage, or If you get low or inaccurate read- signs of corrosion. Check for proper operation. ings with a digital pyrometer, coat the probe loca- Thermostat opens at 143°F (62°C). tion with Thermal Joint Compound, P/N 322170.
Page 198: Thermostat Servicing
COOLING SYSTEM THERMOSTAT SERVICING THERMOSTAT HEAD” facing thermostat. Refer to Cylinder Head Installation on p. 217. SERVICING Disassembly Remove the thermostat cover and O-ring from cyl- inder head. 1. Cylinder head seal 002445 Inspection Inspect all parts for cracks, heat damage, or signs of corrosion.
Page 199: Pressure Relief Valve Servicing
COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Inspection VALVE SERVICING Inspect all parts for cracks, heat damage, or signs 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 thermostat. Disassembly Remove screws and cover from pressure valve assembly.
Page 200: Notes
COOLING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 201 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............200 POWERHEAD REMOVAL .
Page 202: Service Chart
POWERHEAD SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16 N·m) 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) IMPORTANT See Spark Plug Indexing Procedure Apply to crankcase mating flange Apply to water passages 60-84 In.
Page 203 POWERHEAD SERVICE CHART 30-32 Ft. lbs. (41-43 N·m) Must have alignment tool Triple-Guard Grease Gasket Sealing Compound Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Outboard Lubricant Permatex No. 2 Gel Seal II Extreme Pressure Grease 15-20 Ft. lbs. (20-27 N·m) 110-130 Ft.
Page 204: Powerhead Removal
POWERHEAD POWERHEAD REMOVAL POWERHEAD REMOVAL Remove six retaining screws and exhaust relief muffler. WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure. To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
Page 205 POWERHEAD POWERHEAD REMOVAL Remove the small powerhead screw at rear. Use a suitable tool to carefully separate the pow- erhead from exhaust housing. 002161 1. Rear small powerhead screw 002160 IMPORTANT: Do not damage the powerhead Remove remaining four small powerhead screws, or exhaust housing mating surfaces.
Page 206: Powerhead Disassembly
POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Throttle Linkage Removal DISASSEMBLY Remove throttle cam and throttle lever. General 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 207: Crankcase Disassembly
POWERHEAD POWERHEAD DISASSEMBLY IMPORTANT: Remove the ball, guide, and spring of the shift Do not use a tapered punch or detent assembly from the crankcase. any other tool that could jam in or damage the taper bore when removing the pin. 1.
Page 208: Cylinder Head Removal
POWERHEAD POWERHEAD DISASSEMBLY Connecting Rods and Pistons Separate crankcase and cylinder block. It may be 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 209: Crankshaft Removal
POWERHEAD POWERHEAD DISASSEMBLY IMPORTANT: The wrist pin fit is loose on both sides. Push the Reattach each rod cap to its rod wrist pin through to free the piston from the con- as soon as the piston is removed. Each cap is necting rod.
Page 210 POWERHEAD POWERHEAD DISASSEMBLY Remove the upper main bearing. Use a punch to remove the housing seal. Discard seal. 1. Upper oil seal 002034 2. Upper main bearing 1. Punch 002053 Remove the lower bearing seal housing. Inspect housing and replace if necessary. Remove O-ring from crankshaft sleeve and inspect it.
Page 211 POWERHEAD POWERHEAD DISASSEMBLY Inspect the crankshaft sleeve and replace if nec- Use a bearing separator to support the bearing, essary. To remove the sleeve, use Slide Hammer, and press off the crankshaft. P/N 432128, and Large Puller Jaws, P/N 432129. 002052 002041 Remove center main bearings and split sleeves...
Page 212: 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. IMPORTANT: Before inspecting or assembling powerhead, all internal components must be com- pletely clean and free of contaminants.
Page 213: Powerhead Inspection
POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft INSPECTION Measure the diameter of each crankpin and main 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 214: Pistons
POWERHEAD POWERHEAD INSPECTION The dimensional difference between the two Ring end gap should be: • areas is cylinder taper. 0.011 to 0.023 in. (0.28 to 0.58 mm) • The cylinder taper must not exceed 0.002 in. IMPORTANT: Ring end gap increases approxi- (0.05 mm).
Page 215: Bearings
POWERHEAD POWERHEAD ASSEMBLY POWERHEAD Inspect crankshaft rod bearings for excess wear, nicks, or scratches. Replace if necessary. ASSEMBLY 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. IMPORTANT: Use new wrist pin retaining rings, gaskets, seals, and O-rings during assembly.
Page 216 POWERHEAD POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installa- lower housing with extended lip facing down. tion, thread Slide Hammer, P/N 391008, into Lubricate seal lip with Triple-Guard grease. installer and pull it off. IMPORTANT: Inspect sleeve after installation. Sleeve must not be used if surface is damaged.
Page 217: Pistons And Connecting Rods
POWERHEAD POWERHEAD ASSEMBLY Pistons and Connecting Rods Lubricate upper main bearing with outboard lubri- cant and install on crankshaft. IMPORTANT: It is very important that the pis- tons in this engine are installed in the correct loca- tion and direction. New pistons are stamped “EXH.”...
Page 218 POWERHEAD POWERHEAD ASSEMBLY the connecting rod. Align bearings with Wrist Pin Use Wrist Pin Cone, P/N 318600, and Driver, Bearing Tool, P/N 336660. P/N 318599, to install new wrist pin retaining rings in each wrist pin hole. Gap of retaining ring faces up, away from notch in piston.
Page 219: Cylinder Head Installation
POWERHEAD POWERHEAD ASSEMBLY Cylinder Head Installation IMPORTANT: Be sure gap of ring fits squarely around dowel pin. Install a new thermostat seal in cylinder head with side marked “TO CYL HEAD” facing toward ther- mostat. Refer to THERMOSTAT SERVICING on p. 196 before installing cylinder head.
Page 220: Crankshaft And Connecting Rod Installation
POWERHEAD POWERHEAD ASSEMBLY Crankshaft and Connecting Apply a 1/16 in. (2 mm) bead of RTV Adhesive around each water passage on the block and cyl- Rod Installation inder head as shown. Apply adhesive with a brush Rotate cylinder block so crankcase mating flange around thermostat seat area on block.
Page 221 POWERHEAD POWERHEAD ASSEMBLY dowel pin hole will help in the alignment pro- Install rod cap screws finger tight (NO MORE than cess. 6 in. lbs. (1 N·m) maximum). 1. Lower seal housing 002070 002116 2. Upper oil seal 3. Alignment marks IMPORTANT: Be sure alignment dot on rod cap matches dot on rod and that both dots face fly-...
Page 222 POWERHEAD POWERHEAD ASSEMBLY • setting (one line showing). Rotate adjustment Tighten forcing screw until jaws contact con- knob 180° to lock in position. necting rod. • Slide frame down until adjustment stop contacts the rod cap. The groove lines on the jaws must be centered on the rod/crankpin diameter.
Page 223: Crankcase Assembly
POWERHEAD POWERHEAD ASSEMBLY IMPORTANT: case mating flange. The sealer must not come If a new screw is used, it must be within 1/4 in. (6.4 mm) of bearings. installed as above. Then, it must be removed, re- lubricated, and installed again. Loosen forcing screw and remove the frame.
Page 224 POWERHEAD POWERHEAD ASSEMBLY When the crankcase is seated, install and firmly Apply Nut Lock to crankcase flange screws. Install seat the crankcase taper pin. screws and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 002121 002105 Tighten main bearing nuts in stages to a final...
Page 225: Shift Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Shift Linkage Installation Apply Triple-Guard grease to shoulder of shift arm screw and Nut Lock to threads. Install arm, screw, Place the spring, guide, and ball of the shift detent and washer and tighten screw to a torque of 120 assembly into the crankcase.
Page 226: Final Powerhead Assembly
POWERHEAD POWERHEAD ASSEMBLY Final Powerhead Assembly Apply Nut Lock to threads of throttle cam screw. Install cam, screw, and washer on cylinder block Install the reed plate and throttle body assemblies. and tighten screw to a torque of 120 to 144 in. lbs. Refer to Intake Manifold Service on p.
Page 227: Upper Mount Servicing
POWERHEAD UPPER MOUNT SERVICING UPPER MOUNT Inspect mounts and replace if necessary. IMPORTANT: SERVICING The motor mount, washer, and screw are serviced as an assembly. Do not disas- Removal semble. Remove mount retainer screw. 39820 Installation 002069 Place mount assemblies in position, with flats fac- ing away from each other.
Page 228: Powerhead Installation
POWERHEAD POWERHEAD INSTALLATION POWERHEAD Loosely install all powerhead screws and upper mount screws before tightening. INSTALLATION • Tighten the six large powerhead screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m) in the Powerhead Mounting sequence shown.
Page 229 POWERHEAD POWERHEAD INSTALLATION IMPORTANT: Connect the power trim connectors. Retighten powerhead mounting screws after outboard has been run at full operat- ing temperature and allowed to cool. Apply Gasket Sealing Compound to exhaust relief muffler gasket and retaining screws. Install muffler and tighten screws to a torque of 60 to 84 in.
Page 230: Shift Linkage Adjustment
POWERHEAD POWERHEAD INSTALLATION Shift Linkage Adjustment • Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N·m). Adjust shift linkage as follows: • Loosen adjustment screws on shift lever. • Be sure that ball is centered in detent assembly. •...
Page 231: Powerhead Views
POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Short Block Starboard Short Block...
Page 232: Port Dressed Powerhead
POWERHEAD POWERHEAD VIEWS Port Dressed Powerhead Starboard Dressed Powerhead...
Page 233: Front
POWERHEAD POWERHEAD VIEWS Front...
Page 234: Rear
POWERHEAD POWERHEAD VIEWS Rear...
Page 235: Top
POWERHEAD POWERHEAD VIEWS...
Page 236: Notes
POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 237 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............236 TILT TUBE .
Page 238: Service Chart
MIDSECTION SERVICE CHART SERVICE CHART TERN RACKET 8-12 In. lbs. 40-50 In. lbs. (0.9-1.4 N·m) (4.5-5.5 N·m) 110-130 Ft. lbs. (149-176 N·m) 10-16 In. lbs. (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 239 MIDSECTION SERVICE CHART XHAUST OUSING 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) 18-20 Ft. lbs. (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 150-180 In. lbs. (17-20 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...
Page 240: 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 241: 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 242: Exhaust Housing
MIDSECTION EXHAUST HOUSING EXHAUST HOUSING Remove the exhaust housing. Exhaust Housing Removal Before removing the midsection: • The gearcase must be removed. Refer to GEARCASE REMOVAL INSTALLA- TION on p. 261. • The powerhead must be removed. Refer to POWERHEAD REMOVAL on p. 202. Remove and discard four lower mount screws.
Page 243: Exhaust Housing Disassembly
MIDSECTION EXHAUST HOUSING Exhaust Housing Disassembly Remove the three upper screws and three lower screws securing the inner exhaust housing to the Remove the front and rear screws retaining the adapter housing. adapter/inner exhaust housing to the exhaust housing. 1. Upper inner exhaust housing screws 001975 1.
Page 244: Cleaning And Inspection
MIDSECTION EXHAUST HOUSING IMPORTANT: Remove the four screws securing the exhaust A distorted exhaust housing will megaphone to the adapter housing. cause the upper driveshaft splines to wear exces- sively and will damage the crankshaft splines. 1. Adapter to megaphone screws 001976 2.
Page 245 MIDSECTION EXHAUST HOUSING Place a new grommet on the water tube and coat and three upper screws and tighten to a torque of the outside edge with Adhesive 847. 60 to 84 in. lbs. (7 to 9.5 N·m). 1. Water tube grommet 001977 1.
Page 246 MIDSECTION EXHAUST HOUSING Clean and degrease the adapter housing and Apply Gasket Sealing Compound to threads of the outer exhaust housing mating surfaces with four retaining screws and tighten to a torque of 60 Cleaning Solvent. Apply Gel-Seal II sealant to the to 84 in.
Page 247: Exhaust Housing Installation
MIDSECTION EXHAUST HOUSING Exhaust Housing Installation Bring the exhaust housing into position with the stern bracket. Install four new lower mount screws with lock- patch. Tighten screws to a torque of 38 to 45 ft. lbs. (51 to 61 N·m). 25”...
Page 248: Stern Bracket
MIDSECTION STERN BRACKET STERN BRACKET Remove the steering shaft and thrust washer. It may be necessary to tap the steering shaft out Stern Bracket Removal using a wood dowel and mallet. Before servicing the stern bracket: • Remove gearcase. Refer to GEARCASE REMOVAL AND INSTALLATION on p.
Page 249 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 250: Stern Bracket Assembly
MIDSECTION STERN BRACKET Stern Bracket Assembly Remove the two trim rod rollers from the swivel 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 251 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 252 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 253: Swivel Bracket Disassembly (Manual Tilt)
MIDSECTION STERN BRACKET Swivel Bracket Disassembly Remove starboard reverse lock link. (Manual Tilt) Loosen set screw and remove reverse lock release collar. 1. Starboard reverse lock link 006696 Remove port reverse lock link. 1. Reverse lock release collar 006697 2. Set screw Remove reverse lock springs from locking lever and reverse lock spring screws.
Page 254 MIDSECTION STERN BRACKET Remove retaining ring and bellcrank shaft spacer Remove port trail lock lever and trail lock shaft as from reverse lock pivot shaft. an assembly. 1. Retaining ring 006693 1. Port trail lock lever and shaft 006704 Remove screw from trail lock lever. Remove trail Remove port and starboard trail lock shaft bush- lock lever and reverse lock pivot shaft from swivel ings from swivel bracket.
Page 255: Swivel Bracket Assembly (Manual Tilt)
MIDSECTION STERN BRACKET Swivel Bracket Assembly Apply blue Nut Lock to screw and assemble port trail lock lever on trail lock shaft with screw, (Manual Tilt) washer and nylon washer. Install in swivel bracket from port side. DO NOT tighten screw at this time. Reverse Lock and Trail Lock Reference 1.
Page 256 MIDSECTION STERN BRACKET Assemble starboard trail lock lever and trail lock Install remaining bellcrank shaft spacer on spring to reverse lock pivot shaft. reverse lock pivot shaft, then install retaining ring. 1. Reverse lock pivot shaft and rod 006691 1. Retaining ring 006693 2.
Page 257 MIDSECTION STERN BRACKET Tighten screw to a torque of 60 to 84 in. lbs. (7 to Install reverse lock release collar and tighten set 9.54 N·m). screw. 1. Port reverse lock link 006695 1. Reverse lock release collar 006697 2. Set screw Place reverse lock lever rod through hole at top of Install locking lever, pins and new cotter pins.
Page 258: Notes
MIDSECTION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 259 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............258 GEARCASE TYPES .
Page 260: Service Chart
GEARCASE SERVICE CHART SERVICE CHART “S”–T EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 60-84 In.
Page 261 GEARCASE SERVICE CHART “O”– – S TYPE EARCASE TANDARD OTATION 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft.
Page 262: Gearcase Types
GEARCASE GEARCASE TYPES GEARCASE TYPES Gearcase General Service Procedure Outboard Model Type Comparison Comparison (L) Models with Unique housing, shafts, “S” 20 in. shaft gears, and bearings Similar (X) Models with Unique housing, shafts, “O” 25 in. shaft gears, and bearings PROPELLER SERVICE GEARCASE LEAK TEST Inspection...
Page 263: Gearcase Removal And Installation
GEARCASE GEARCASE REMOVAL AND INSTALLATION GEARCASE REMOVAL Remove the forward screw with washer and recessed retaining screw. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly.
Page 264: Gearcase Installation
GEARCASE GEARCASE REMOVAL AND INSTALLATION Gearcase Installation Apply Gel-Seal II to gearcase mating surface pads on exhaust housing. Slide the gearcase into WARNING place, making sure: • Driveshaft engages the crankshaft. During service, the outboard may drop • Water tube enters the water pump. unexpectedly.
Page 265: Water Pump
GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE ft. lbs. (47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment on p. 62. Disassembly Rotate the driveshaft counterclockwise to unlock the impeller cam. Remove the four impeller hous- ing screws. 1.
Page 266: Assembly
GEARCASE WATER PUMP SERVICE Assembly Install the water tube grommet with the inside taper facing up. Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs. IMPORTANT: Do not allow any sealer to get into the air bleed groove in the impeller housing.
Page 267 GEARCASE WATER PUMP SERVICE Run a thin bead of Adhesive 847 in the seal impeller, and slide water pump down over cam. groove, and install the special shaped O-ring seal. Be sure impeller cam does not fall out of position. 1.
Page 268: Shift Rod Adjustment
GEARCASE SHIFT ROD ADJUSTMENT SHIFT ROD With the gearcase in NEUTRAL, rotate the shift rod up or down as necessary for correct adjust- ADJUSTMENT ment. Once correct height is achieved, rotate rod one half turn or less to direct offset forward. Check the shift rod height from the shift rod hole to IMPORTANT: The NEUTRAL detent is a two-...
Page 269: Gearcase Disassembly
GEARCASE GEARCASE DISASSEMBLY 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). IMPORTANT: Clean and inspect all parts during disassembly.
Page 270: Propeller Shaft Bearing Housing Removal
GEARCASE GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Assemble components and pull the bearing hous- ing from the gearcase. Remove the thrust washer, Removal thrust bearing, and reverse gear from gearcase. Remove the two screws, washers, and retainers holding the propeller shaft bearing housing. 22775 Pinion Gear and Driveshaft 1.
Page 271 GEARCASE GEARCASE DISASSEMBLY Locked Driveshaft Removal Remove the four driveshaft bearing housing screws. The driveshaft to pinion taper is a locking taper. If necessary, use Driveshaft Puller, P/N 390706, and Backing Plate, P/N 325867, to break the lock. Install the tools as shown by clamping them around the driveshaft.
Page 272: Driveshaft Service
GEARCASE GEARCASE DISASSEMBLY Driveshaft Service “S” Type Gearcases Install the roll pin flush. To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin. Replace the damaged component. 1. Roll pin DR4596 “O” Type Gearcases Install the roll pin to the specified dimension. 29337 To assemble the driveshaft, install new driveshaft retainer into the groove of the upper driveshaft.
Page 273: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE GEARCASE HOUSING INSPECTION GEARCASE HOUSING Shift Housing, Gear and Propeller Shaft Removal INSPECTION Push down on the shift rod. This will move the detent lever downward to clear the inside of the Thoroughly clean gearcase housing to remove all gearcase when the shaft assembly is pulled out.
Page 274: Internal Gearcase Service
GEARCASE SHIFTER, BEARING AND SEAL SERVICE SHIFTER, BEARING AND “O” Type Gearcases Use a 7/8 in. wrench to hold the remover in place. SEAL SERVICE Use a 3/4 in. wrench to turn flange nut clockwise. Draw the bearing up from the housing. Pinion Bearing Removal Remove pinion bearing retaining screw.
Page 275: Shift Housing Disassembly
GEARCASE SHIFTER, BEARING AND SEAL SERVICE “O” Type Gearcases screw and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1. O-ring DRC7416 Shift Housing Disassembly 1. 1/4-20 X 1/2 in. Hex head screw 824182 2.
Page 276 GEARCASE SHIFTER, BEARING AND SEAL SERVICE Push the pin out of the clutch dog. Remove all shifter detent as needed to help ease removal of parts. parts. 1. Shift lever pin DSC02449 2. Shift shaft DSC02489 3. Cradle 1. Pin COA3561 4.
Page 277: Shift Housing Assembly
GEARCASE SHIFTER, BEARING AND SEAL SERVICE Shift Housing Assembly Thoroughly grease 25 needle bearings with Nee- dle Bearing grease and place in the bearing case IMPORTANT: (“O” Type gearcases). Clean inspect parts before beginning assembly procedures. Replace any damaged parts. Lightly coat the detent ball and spring with Needle Bearing grease.
Page 278 GEARCASE SHIFTER, BEARING AND SEAL SERVICE 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 279: Driveshaft Bearing Housing Service
GEARCASE SHIFTER, BEARING AND SEAL SERVICE Driveshaft Bearing Housing groove is an oil passage. Gearcase damage could result. Service The driveshaft bearing is not serviceable. Replace the bearing housing assembly if the bearing is worn or damaged. Also, inspect the driveshaft bearing surface if the bearing is damaged.
Page 280: Propeller Shaft Bearing Housing Service
GEARCASE SHIFTER, BEARING AND SEAL SERVICE 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. Rear Seal Removal (12 to 15 N·m).
Page 281 GEARCASE SHIFTER, BEARING AND SEAL SERVICE Bearing Installation Rear Seal Installation Oil, then install new bearings in bearing housing. Apply Gasket Sealing Compound to metal casings of the seals before installing. Place the lettered end of the bearing case on the bearing installer, then press the bearing into the Use Seal Installation Tool to install new seals back housing until the tool seats.
Page 282: Driveshaft Shimming
GEARCASE DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select correct collar and shim gauge bar: • Collar: P/N 341440 • Shim gauge bar: P/N 328367 IMPORTANT: If new pinion gear is needed, replace gear set before shimming. Slide the collar onto the driveshaft with large end in contact with the bearing housing.
Page 283: Gearcase Assembly
GEARCASE GEARCASE ASSEMBLY GEARCASE ASSEMBLY between the gauge bar and the bearing housing between each pair of screw holes. Replace the Water Intake Screens bearing housing and repeat check if variance is greater than 0.004 in. (0.010 mm). Install water intake screens. Tighten screws to a torque of 60 to 84 in.
Page 284: Shift Rod Housing Installation
GEARCASE GEARCASE ASSEMBLY Shift Rod Housing Installation Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket. Place the gasket on Lubricate a new shift rod cover O-ring with Triple- the gearcase. Guard grease. Install the O-ring into the shift rod cover.
Page 285: Pinion Gear And Driveshaft Installation
GEARCASE GEARCASE ASSEMBLY Pinion Gear and Driveshaft Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the Installation driveshaft and into position in the gearcase. Refer to DRIVESHAFT SHIMMING on p. 280 before proceeding. Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing Service on p.
Page 286: Propeller Shaft Bearing Housing And Gear Installation
GEARCASE GEARCASE ASSEMBLY Use Driveshaft Holding Socket, P/N 311875, Pin- Housing must be completely seated to install Holder, P/N 334455, Wrench retainer tabs. Retainer, P/N 341438, to tighten the pinion nut to a torque of 100 to 110 ft. lbs. (136 to 149 N·m). Pad handle of holder to prevent damage to gear- case.
Page 287 GEARCASE GEARCASE ASSEMBLY “O” Type Gearcases Re-tighten two retainer screws to 18 to 20 ft. lbs. (24 to 27 N·m). Loosen retainer screws 1/4 turn. Confirm that torque on the wedge screw is 15 to Install wedge, screw, and washer. Apply Ultra 20 in.
Page 288: Notes
GEARCASE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 289 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SYSTEM DESCRIPTION ............. 288 .
Page 290: 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 291: Routine Inspections
TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General Use the following guidelines to check a single pis- ton trim/tilt unit that is not working correctly. Check for external signs of fluid leakage. Correct causes as necessary. Cylinder Leakdown: • Manual release valve seals Check the battery and make sure it is in good •...
Page 292: 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 293: Trim And Tilt Motor No Load Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim and Tilt Motor No Load Test Trim Gauge Test IMPORTANT: STEP 1 Securely fasten motor in a suit- able fixture before proceeding with this test. Turn key switch ON. Using a voltmeter, check for voltage between the trim gauge “I”...
Page 294: Trim Sender Test
TRIM AND TILT TRIM AND TILT SERVICE TRIM AND TILT SERVICE Trim Sender Test IMPORTANT: Removal To avoid immediate meter dam- age, never apply a multimeter to an electrical cir- Remove lower engine cover and disconnect the cuit where voltage is present. trim/tilt connectors.
Page 295 TRIM AND TILT TRIM AND TILT SERVICE Separate the trim/tilt unit wires in the braided tube Use a punch to remove the upper pin. to permit removal through the hole in the stern bracket. 25065 Retract the tilt cylinder rod. 25078 Remove the external snap rings from the lower pin.
Page 296: Disassembly
TRIM AND TILT TRIM AND TILT SERVICE Remove the unit from the stern brackets far Screw the manual release valve in. Remove the enough to remove the ground lead from the pump retaining ring using a small pick or screwdriver. motor mounting screw.
Page 297: Assembly
TRIM AND TILT TRIM AND TILT SERVICE Remove the four large motor flange retaining Install a new motor O-ring. screws. Remove the motor and discard O-ring, screws, and washers. 004280 Position the motor on the manifold and install four 004282 new screws and lock washers.
Page 298: Installation
TRIM AND TILT TRIM AND TILT SERVICE Installation Install new retaining ring in groove. Install the ground lead. Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. If loosened, tighten the tilt tube nut to a torque of 45 to 50 ft.
Page 299: Adjustments
TRIM AND TILT ADJUSTMENTS ADJUSTMENTS Place trim/tilt wires in braided tube and install through hole in the stern bracket. Refer to Trim Sending Unit Adjustment on p. 61. Refer to Tilt Limit Switch Adjustment on p. 60. 25079 Release the tilt support and lower the outboard. Tighten the manual release valve to a torque of 45 to 55 in.
Page 300: Notes
TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 301 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 302 S–2...
Page 303: 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 304: 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 305: 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 306: 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 307 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 308: 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 309 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 310 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 311: 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 312 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 313: 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 314: 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 315 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 316: 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 317: 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 318 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 319 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 320 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 321: 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 322: 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 323: 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 324: Safety Awareness Test
SAFETY Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations...
Page 325 INDEX INDEX Bearing n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Connecting Rod 219 Abbreviations 6 Crankshaft 208, 209, 213, 214, 215...
Page 326 INDEX Diagnostic Software Pressure Relief Valve 192, 197 Thermostat 11, 192 Break-In Programming 54, 57, 182 Turbulence 39 CANbus Activation 50 Vapor Separator 159 Communication with Outboard 95 Water Intake Screens 68, 69, 271, 281 Crankshaft Position Sensor 110 Water Pump 191, 263 Cylinder Drop Tests 106 Water Supply Tube 191, 241, 243 Fuel Injector Programming 100, 169...
Page 327 INDEX Emergency Stop Switch Fuel Injectors Installation 26 Crush Ring Replacement 170 Operation Check 56 Electrical Circuits 157 Test 134 EMM Programming 169, 171 Emissions Information 7 Installation 171 Removal 169 12 V Circuit Sensor 88 Tests 162, 163 Fuel System Connections 86, 87, 121 Diagnostics 95 Additives 10, 51...
Page 328 INDEX Throttle and Shift Linkage 70 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Tilt Tube 70 Honing 210 Trailering Bracket 70...
Page 329 INDEX Propeller Oil Recirculation System 182 Oil Tank 180, 187 Inspection 260 Oiling Rate 53, 98, 182 Installation 59 Priming 54, 182 Selection 58 Propeller Shaft Tests 183 Outboard Excessive Smoking T–5 Installation 281 Outboard Hard to Start T–3 Lubrication 71 Outboard Starts and Stalls T–4 Removal 271 Outboard Starts, Low Maximum RPM T–5...
Page 330 INDEX Shift Linkage Swivel Bracket Adjustment 228 Installation 250 Installation 223 Lubrication 70 Lubrication 70 Manual Tilt 251 Removal 204 SystemCheck Shift Rod Adjustment 11, 266 Circuits 136 Shimming, Driveshaft 280 Dash Connections 120 Shutdown 94 Gauges 26, 93 No Oil 181 LOW OIL Warning Signal 181 Spark Plugs NO OIL Warning Signal 181...
Page 331 INDEX Timing Adjustments Slide Hammer Adaptor Kit, P/N 390898 170 Timing Pointer 142 Slide Hammer, P/N 391008 170, 214, 269 Timing Verification 143 Slide Hammer, P/N 432128 209, 239 TPS Calibration 143 Small Puller Jaws, P/N 432131 278 Tools Stator Test Adaptor, P/N 5005799 126 Backing Plate, P/N 325867 269 Syringe, P/N 346936 185 Bearing Installation Tool, P/N 326562 279...
Page 332 INDEX Troubleshooting n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Charging System Tests 127 Water Intake Screens 68, 271, 281 Cylinder Drop Tests 106...
Page 333: 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 334 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. In gear–Tiller models Make sure outboard is in neutral No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return...
Page 335 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 336 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 337 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 338 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 339 Hose Routing and Water Flow Diagram 75 – 90 HP EVINRUDE E-TEC 1. Intake water screens 2. Water pump 3. Water tube 4. Adaptor housing 5. Cylinder block 6. Pressure valve 7. Thermostat 8. Water supply to EMM 9. Water supply, EMM to vapor separator 10.
Page 340 MWS Instrument Wiring Harness DRC6165R...
Page 341 CANbus Keyswitch/TNT Wiring Harness A. Trim down B. Trim up C. Trim sender 47 ohm 1/4 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 342 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
Page 343 MWS Key Switch and Neutral Safety Switch START 000691...
Page 344 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH WATER PRES. FUEL VOLTMETER TRIM/TILT FUEL TANK SENDER WARNING TO OUTBOARD HORN DRC6278R...
Page 345 75 – 90 HP E-TEC 1. Air Temperature Sensor 2. Throttle Position Sensor 3. Neutral Switch 4. Stator 1 2 3 4 5. Crankshaft Position Sensor B A C 6. Trim/Tilt Connector 7. SystemCheck Connector 8. Key Switch Connector 9. High Pressure Fuel Pump FUSE 10.
Page 346 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 Start assist circuit (SAC) OK (V models only) Sensors / 5V Circuits OK FLASHING LED –...
Page 347 EVINRUDE 40 – 90 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Throttle Position Sensor TPS Voltage > 0.78 V with key ON (or cranking). Becomes stored fault when outboard starts. 2 seconds (TPS) out of idle range When both hard and stored faults are present, check for improperly adjusted throttle cable.
Page 348 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY 51 Fuel injector circuit #1 OPEN LED 2: ON (Running) 2 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C). 52 Fuel injector circuit #2 OPEN LED 2: ON (Running) 2 seconds...
Page 349 *5007527*...

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Evinrude & Johnson E90DPLSCB Service Manual

Able of

Special Tools Special Tools 1

Table of Contents

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil Priming

Before Start-Up

Running Checks

Propellers

Final Adjustments

Notes

Maintenance Maintenance

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Lubrication

Battery and Battery Connections

Fuel and Oil Systems

Spark Plugs

Storage

Pre-Season Service

Submerged Engines

Notes

Table of Contents

System Analysis System Analysis

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Notes

Electrical and Ignition Electrical and Ignition

Table of Contents

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Components

Fuel System Tests

Fuel Component Servicing

Oiling System Oiling System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Evinrude & Johnson E90DPLSCB