BRP EVINRUDE E-TEC E40DRLAA Series Service Manual
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BRP EVINRUDE E-TEC E40DRLAA Series Service Manual

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BRP US Inc.
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.com or www.johnson.com
† 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.
† BEP is a registered trademark of Actuant Corporation.
† Champion is a registered trademark of Federal-Mogul Corporation.
† Deutsch is a registered trademark of The Deutsch Company.
† Dexron is a registered trademark of The General Motors Corporation.
† Fluke is a registered trademark of The Fluke Corporation
† GE is a registered trademark of The General Electric Company.
† GM is a registered trademark of The General Motors Corporation.
† Locquic and Loctite are registered trademarks of The Henkel Group.
† Lubriplate is a registered trademark of Fiske Brothers Refining Company.
† NMEA is a registered trademark of the National Marine Electronics Association.
† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
† Packard is a registered trademark of Delphi Automotive Systems.
† Permatex is a registered trademark of Permatex.
† STP is a registered trademark of STP Products Company.
† Snap-on is a registered trademark of Snap-on Technologies, Inc.
The following trademarks are the property of BRP US Inc. or its affiliates:
®
Evinrude
®
Johnson
®
®
Evinrude
E-TEC
FasTrak™
S.A.F.E.™
SystemCheck™
I-Command™
®
Evinrude
ICON™
®
®
Evinrude
/ Johnson
XD30™ Outboard Oil
®
®
Evinrude
/ Johnson
XD50™ Outboard Oil
®
®
Evinrude
/ Johnson
XD100™ Outboard Oil
Gel-Seal II™
Printed in the United States.
© 2012 BRP US Inc. All rights reserved.
TM, ® and the BRP logo registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
Twist Grip™
Nut Lock™
Screw Lock™
Ultra Lock™
Moly Lube™
®
Triple-Guard
Grease
DPL™ Lubricant
®
2+4
Fuel Conditioner
Carbon Guard™
HPF XR™ Gearcase Lubricant
HPF PRO™ Gearcase Lubricant

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Summary of Contents for BRP EVINRUDE E-TEC E40DRLAA Series

  • Page 1 HPF PRO™ Gearcase Lubricant Evinrude / Johnson XD100™ Outboard Oil Gel-Seal II™ Printed in the United States. © 2012 BRP US Inc. All rights reserved. TM, ® and the BRP logo registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

  • Page 2: Table Of Contents

    ERVICE ANUAL ONTENTS SECTION ........PAGE 1 REFERENCE INFORMATION .

  • Page 3: Table Of Contents

    REFERENCE INFORMATION REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE ..............4 ABBREVIATIONS USED IN THIS MANUAL .

  • Page 4: Reference Information

    REFERENCE INFORMATION SAFETY NOTICE SAFETY NOTICE Before working on any part of the outboard, read the SAFETY section at the end of this manual. This publication is written for qualified, factory- DO NOT perform any work until you have read trained technicians who are already familiar with and understood these instructions completely.

  • Page 5: Outboard Speed Control System And Safety

    REFERENCE INFORMATION SAFETY NOTICE 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 6: Abbreviations Used In This Manual

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

  • Page 7: Emission-Related Installation Instructions

    REFERENCE INFORMATION EMISSION-RELATED INSTALLATION INSTRUCTIONS EMISSION-RELATED Owner’s Responsibility The owner/operator is required to have outboard INSTALLATION maintenance performed to maintain emission lev- els within prescribed certification standards. INSTRUCTIONS The owner/operator is not to, and should not allow Failing to follow these instructions when anyone to, modify the outboard in any manner installing a certified engine in a vessel violates that would alter the horsepower or allow emis-...

  • Page 8: Model Designation

    REFERENCE INFORMATION MODEL DESIGNATION MODEL DESIGNATION DESIGN FEATURES: B Blue Paint MODEL IDENTIFICATION C Counter Rotation The first two characters identify D Evinrude E-TEC Model Version: Electric Start w/Remote Steering AA A First major variant G Graphite Paint AB A Second major variant H High Output AF A...

  • Page 9: Models Covered In This Manual

    REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on the following Evinrude E-TEC models: • 52.7 cubic inch (.86 L), 2-Cylinder starting with serial number 5332574. • 79 cubic inch (1.29 L), 3-Cylinder starting with serial number 5347742. Model Shaft Gearcase...

  • Page 10: Service Specifications Aa Models

    REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS SERVICE SPECIFICATIONS AA MODELS 40 – 60 HP E-TEC Models 40 HP – 5000 to 6000 RPM Full Throttle 50 HP – 5500 to 6000 RPM Operating Range RPM 60 HP – 5500 to 6000 RPM 40 HP (29.4 kw) @ 5500 RPM Power 50 HP (36.8 kw) @ 5750 RPM...
  • Page 11 REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS SERVICE SPECIFICATIONS AA MODELS 40 – 60 HP E-TEC Models Minimum Battery 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Requirements 25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery Alternator applications.

  • Page 12: Service Specifications Ab Models

    REFERENCE INFORMATION SERVICE SPECIFICATIONS AB MODELS SERVICE SPECIFICATIONS AB MODELS 40 – 60 HP E-TEC Models 40 HP – 5000 to 6000 RPM Full Throttle 50 HP – 5500 to 6000 RPM Operating Range RPM 60 HP – 5500 to 6000 RPM 40 HP (29.4 kw) @ 5500 RPM Power 50 HP (36.8 kw) @ 5500 RPM...
  • Page 13 REFERENCE INFORMATION SERVICE SPECIFICATIONS AB MODELS SERVICE SPECIFICATIONS AB MODELS 40 – 60 HP E-TEC Models Minimum Battery 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Requirements 25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery Alternator applications.

  • Page 14: Service Specifications Aa Models

    REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS SERVICE SPECIFICATIONS AA MODELS 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 ±...
  • Page 15 REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS SERVICE SPECIFICATIONS AA MODELS 75 – 90 HP E-TEC Models Minimum Battery 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Requirements 25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery Alternator applications.

  • Page 16: Standard Torque Specifications

    REFERENCE INFORMATION 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 17: Wire Size Table

    REFERENCE INFORMATION WIRE SIZE TABLE WIRE SIZE TABLE This table provides closest equivalent size cross references between American and metric wire sizes. American Wire Gauge Metric Wire Size American Wire Gauge (AWG) is a standardized Metric wire size is also standardized. Metric wire wire gauge system used in North America to iden- size is determined by the number of strands of tify the diameter of round, electrically conducting...
  • Page 18 REFERENCE INFORMATION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 19 ROUTINE SERVICE ROUTINE SERVICE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 20 LIFTING THE OUTBOARD .

  • Page 20: Inspection And Maintenance Schedule

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

  • Page 21: Lifting The Outboard

    ROUTINE SERVICE LIFTING THE OUTBOARD LIFTING THE OUTBOARD RIGGING OUTBOARD CONNECTIONS IMPORTANT: For complete outboard rigging WARNING and remote control installation information, refer To avoid personal injury, make sure the lift- to the Predelivery and Installation Guide ing capacity of the hoist is at least twice included with the service manual set.
  • Page 22 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable Retainer Clip Installation Cable, Hose, and Wire Routing When installing retainer clips on control arm link- CAUTION age pins, clips should be locked and must not be bent or deformed. To prevent accidental starting while servic- ing, disconnect the battery cables at the For proper installation, review the following steps: battery.

  • Page 23: Control Cable Installation

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS If there are not enough threads on the shift cable NOTICE After installation, make sure there for the adjustment, or if the gearcase does not is enough clearance for all cables to avoid shift fully into FORWARD or REVERSE, refer to binding or chafing through all engine steering SHIFT ROD ADJUSTMENT on p.

  • Page 24: Systemcheck Harness Connections

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS IMPORTANT: the seal only. DO NOT fill connectors with Electri- Move control handle to FOR- cal Grease. WARD and pull back slowly to NEUTRAL. Make sure the engine throttle lever is against the stop. If not, remove slack by adjusting cable trunnion.

  • Page 25: I-Command Network Connections

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS I-Command Network Connections Connect the I-Command Engine Interface Cable to the EMM CANbus connector. If the outboard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to supply informa- tion to the network: Remove lower motor covers.
  • Page 26 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS YLINDER ODELS ODELS EMM CANbus connector cap is clipped to EMM Adjust harness routing as needed and secure with cooling water hose. Remove clip from cap and tie straps. install on I-Command harness connector. Use an I-Command Ignition and Trim Harness to connect the outboard to the key switch and trim/tilt control.

  • Page 27: Water Pressure Gauge

    ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Route I-Command Ignition Harness through wire Water Pressure Gauge channel in flywheel cover. Install electrical cover. To display engine water pressure, install a water Make sure both harnesses are in front of the tab pressure hose fitting in the cylinder block as and tighten with tie strap.

  • Page 28: Battery And Battery Connections

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

  • Page 29: Oetiker Clamp Servicing

    ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide corrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
  • Page 30 ROUTINE SERVICE OETIKER CLAMP SERVICING Clamp Installation Clamp Removal A constant stress should be applied to close the Method 1: Position Oetiker pincers across clamp 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 31: Adjustments

    ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS Throttle Friction Adjustment Tiller models are equipped with a throttle friction Steering Friction Adjustment adjustment knob located on the steering handle. Tighten the knob to reduce the effort required to Tiller models are equipped with a steering friction hold a throttle setting.

  • Page 32: Tilt Limit Switch Adjustment (75 - 90 Hp)

    ROUTINE SERVICE ADJUSTMENTS Tilt Limit Switch Adjustment Place the outboard in normal operating position. (75 – 90 HP) Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment WARNING tab DOWN to increase the maximum tilt position. If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in...

  • Page 33: Trim Sending Unit Adjustment (40 - 60 Hp)

    ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment WARNING (40 – 60 HP) To avoid personal injury, do not adjust the The sending unit eccentric cam must be adjusted sending unit eccentric cam while the so that the gauge needle is aligned with the lowest engine is being tilted.

  • Page 34: Trim Sending Unit Adjustment (75 - 90 Hp)

    ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not show center position, tilt the outboard up and (75 – 90 HP) adjust the sending unit by pivoting it up or down. Tilt the outboard and engage the tilt support. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

  • Page 35: Trim Tab Adjustment

    ROUTINE SERVICE 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 36: Dual-Outboard Alignment

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

  • Page 37: Operational Checks

    ROUTINE SERVICE OPERATIONAL CHECKS OPERATIONAL CHECKS • Squeeze fuel primer bulb until hard or activate electric primer. Observe all fuel hoses and con- nections. Repair any leaks. DANGER • Start outboard. Inspect all hoses and connec- tions. Repair any leaks or misrouted hoses DO NOT run the engine indoors or without immediately.

  • Page 38: Cooling System

    ROUTINE SERVICE COOLING SYSTEM Tachometer Pulse Setting COOLING SYSTEM (SystemCheck) Regularly inspect cooling system components for Confirm accuracy of tachometer reading. corrosion, damage, leaks, or restrictions: • Adjust dial on back of tachometer to required • water intake screens setting (the outboard should not be running). •...

  • Page 39: Engine Flushing

    ROUTINE SERVICE COOLING SYSTEM Engine Flushing Turn water supply on. Flush the outboard with fresh water following each Run outboard at IDLE only until full operating tem- use in brackish, salt, or polluted water to minimize perature is reached. the accumulation of scale and silt deposits in cool- Leave the outboard in VERTICAL (DOWN) posi- ing system passages.

  • Page 40: Running The Outboard Using A Hose And Flushing Adapter

    ROUTINE SERVICE COOLING SYSTEM Running the Outboard Using a Install flushing adapter onto gearcase water inlet screens. Hose and Flushing Adapter WARNING To prevent injury from contact with rotat- ing propeller, remove the propeller before running engine with a flushing adapter. A flushing adapter may be used to provide cooling water when running the outboard to: •...

  • Page 41: Lubrication

    ROUTINE SERVICE LUBRICATION LUBRICATION Tiller Handle Lubricate the tiller handle grease fittings with Tri- Steering System ple-Guard grease. WARNING Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, mak- ing operator control difficult. Grease the stainless steel output end of the steer- ing cable with Triple-Guard grease.

  • Page 42: Swivel Bracket And Trailering Bracket

    ROUTINE SERVICE LUBRICATION Swivel Bracket and Trailering Tilt Tube Bracket Lubricate the tilt tube grease fittings with Triple- Guard grease. Lubricate the swivel bracket with Triple-Guard grease. Apply grease until the grease begins to flow from the upper or lower swivel bracket areas. Coat the pivot points of the trailering bracket with Triple-Guard grease.

  • Page 43: Propeller Shaft

    ROUTINE SERVICE LUBRICATION Shift the remote control to the NEUTRAL/IDLE Gearcase Lubricant position. Draining Install control cables. WARNING Check proper throttle and shift function. Gearcase lubricant may be under pressure Propeller Shaft and/or hot. If plug is removed from a recently operated outboard, take precau- Debris from the water can become lodged around tions to avoid injury.
  • Page 44 ROUTINE SERVICE LUBRICATION Inspection Remove the lubricant level plug and the lubricant drain/fill plug. Inspect the lubricant and the magnets on the plugs for metal chips. The presence of metal fuzz Use Gearcase Filler, P/N 501882, to slowly fill the can indicate normal wear of the gears, bearings, gearcase with HPF PRO lubricant through the or shafts within the gearcase.

  • Page 45: Trim And Tilt

    ROUTINE SERVICE LUBRICATION Trim and Tilt • Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring CAUTION level to the bottom of the fill plug threads. Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

  • Page 46: Spark Plugs

    ROUTINE SERVICE 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 47: Fuel And Oil Systems

    ROUTINE SERVICE FUEL AND OIL SYSTEMS FUEL AND OIL SYSTEMS Air Silencer The air silencer maximizes air flow while minimiz- Routine replacement of filters reduces the possi- ing noise. bility of foreign material restricting the incoming fuel or oil supplies. Replacement filter elements are available through Evinrude/Johnson Genuine Parts.

  • Page 48: Anti-Corrosion Protection

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

  • Page 49: Storage

    ROUTINE SERVICE 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.

  • Page 50: Additional Recommendations

    ROUTINE SERVICE PRE-SEASON SERVICE Additional Recommendations PRE-SEASON SERVICE • Fill 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 51: Submerged Engines

    ROUTINE SERVICE SUBMERGED ENGINES SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL SYSTEM PRIMING on p. 140 and Oil Supply Priming on p. 169. Make sure all oil injection Once an outboard has been submerged in fresh hoses are clean and filled with oil.
  • Page 52 ROUTINE SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 53 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 54 LATCH HOOK INSTALLATION .

  • Page 54: Upper Cover Service

    ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE LOWER COVER SERVICE Latch Hook Installation Lower Cover Removal Insert threaded bracket into pocket. Remove lower engine cover screws. 1. Bracket 006468 1. Lower cover screws 002168 Apply Ultra-Lock to screw threads. Place hook into position with opening toward the front.

  • Page 55: Lower Cover Installation

    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 56: Latch Handle Installation

    ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006470 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
  • Page 57 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............58 EMM FUNCTIONS .

  • Page 58: 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 59: Emm Inputs And Outputs Diagram

    ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS J1-A J1-B OUTPUTS x 100 3550 M E N U 008026 1. Engine Management Module (EMM) 7. Low Oil Switch 13. Fuel Injector 2. Battery (12 volt) 8.

  • Page 60: 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 61: 5 V Circuit Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS 5 V Circuit Sensor Monitors the EMM’s 5 V sensor circuit. Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude If sensor voltage is less than 4.75 volts, the EMM: Diagnostics software to troubleshoot the sensors.

  • Page 62: Low Oil Switch

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS If cylinder head temperature exceeds 212° F If cylinder head does not reach operating temper- (100° C) above 3500 RPM, or 230° F (110° C) ature (104°F / 40°C below 2300 RPM) in 10 min- below 3500 RPM, the EMM: utes, the EMM: Activates SHUTDOWN...

  • Page 63: Throttle Position Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Throttle Position Sensor Crankshaft Position Sensor The throttle position sensor receives a voltage sig- Ribs spaced on the flywheel mark crankshaft posi- nal from the EMM. As the throttle lever is rotated, tion. As the ribs pass the magnetic field of the the EMM receives a return voltage signal through CPS, an AC voltage signal is generated.

  • Page 64: Internal Emm Functions

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM Exhaust Water Valve Activation (60 - 65 HP) FUNCTIONS During acceleration, the EMM opens a valve that injects water into the exhaust housing. This water ROM Verification changes the tuning of the exhaust, allowing the The EMM performs a self-test of programming engine to develop more midrange horsepower as every time it is turned ON.

  • Page 65: Engine Monitor System

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

  • Page 66: 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 67: Diagnostic Software Functions

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS DIAGNOSTIC TART ODELS Diagnostic communications on non-running rope SOFTWARE FUNCTIONS start models requires a power supply to the EMM. The EMM stores valuable information about the Use Diagnostic Power Supply Tool, P/N 587005, outboard and its running history.

  • Page 68: Static Information

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS If Diagnostic Power Supply Tool, P/N 587005, is The serial number and cylinder location displayed not available, a Battery Cable, P/N 584348, can on the Injector Coefficients screen must match the be connected to the engine mounted solenoid. actual cylinder placement for each injector.

  • Page 69: Occurred Service Codes (Faults)

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Occurred Service Codes (Faults) Historical Faults Service codes are saved if an abnormal condition The Historical Faults screen keeps a history of all occurs while the outboard is running. previously saved codes, including code number, the number of times the event occurred, and oper- The Occurred Faults screen of the diagnostics ating hours of the last occurrence.

  • Page 70: Dynamic Tests

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Overheat Prime Oil This test is used to check the “ENG TEMP” or This test is used to cycle the oil injection pump for “HOT” circuit of the Engine Monitoring system. priming the oiling system. Perform this test with outboard running to activate oil injection pump.

  • Page 71: Tiller/Remote Programming

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Powerhead Break-In Ignition Timing Use the diagnostics software to start break-in oil- Use the Ignition Timing screen to check and ing after a powerhead rebuild. The break-in oiling adjust EMM timing. EMM timing must be synchro- program runs for two hours of outboard operation, nized to crankshaft position.

  • Page 72: Tps Calibration

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS TPS Calibration Fuel Injector Servicing TPS Calibration synchronizes throttle plate open- All E-TEC fuel injectors use software program- ing with throttle position sensor voltage. ming to compensate for variations in fuel flow. Each injector and its location on the outboard is Refer to TPS Calibration on p.

  • Page 73: Reports

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

  • Page 74: Emm Transfer

    ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING IMPORTANT: EMM SERVICING Software replacement requires the use of Bootstrap Tool, P/N 586551. Install tool between engine and boat harness key/stop switch IMPORTANT: If a new EMM is being installed, connectors as instructed by update program. refer to EMM Transfer on p.

  • Page 75: Installation

    ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING Installation Installation is the reverse of removal. Pay close attention when performing the following tasks. Make sure isolator mounts are placed in slots in of EMM case. Slide EMM into position. 1. Isolator mounts 006478 Apply Nut Lock to threads of EMM retaining screws.
  • Page 76 ENGINE MANAGEMENT MODULE (EMM) NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 77 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............78 VISUAL INSPECTIONS .

  • Page 78: Diagnostic Procedures

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Operational Inspections Run the outboard to confirm actual symptoms PROCEDURES 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 79: 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. 80. operate: • Use an inductive timing light to check ignition •...

  • Page 80: 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 81: 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 82: 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 83: 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 84: 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 85: 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 86: 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. 88 •...

  • Page 87: Ignition Control Circuit Tests

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

  • Page 88: Fuel Delivery Tests

    SYSTEM ANALYSIS FUEL DELIVERY TESTS FUEL DELIVERY TESTS Voltage should be 55 V when the outboard is cranking or running. • The EMM controls the fuel pump ground (brown WARNING wire). Use an ohmmeter to check continuity between pin 2 of fuel pump connector and Protect against hazardous fuel spray.

  • Page 89: 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 90: Exhaust Water Valve (60Hp)

    SYSTEM ANALYSIS EXHAUST WATER VALVE (60HP) EXHAUST WATER VALVE Disconnect the water valve outlet hose. (60HP) During rapid acceleration, the EMM opens a valve that injects water into the exhaust. This water changes exhaust tuning, boosting midrange horsepower as the boat comes on plane. If the valve is plugged or not working, the operator may not notice a problem during slow accelera- tion.
  • Page 91 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............92 IGNITION SYSTEM CIRCUIT DIAGRAM, 40 –...

  • Page 92: Service Chart

    ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 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. (19 to 21 N·m) 84 to 106 in lbs.
  • Page 93 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 94: Ignition System Circuit Diagram, 40 - 60 Hp

    ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 60 HP IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 60 HP 1 2 3 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Neutral switch Crankshaft position sensor Main harness ground Stator Capacitor...

  • Page 95: Ignition System Circuit Diagram, 75 - 90 Hp

    ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP 1 2 3 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Neutral switch Crankshaft position sensor Main harness ground Stator Capacitor...

  • Page 96: 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 97 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, 75–90 HP Purple Stator winding, 1S Yellow Injector, cylinder 2, 40–65 HP Green Stator winding, 2S Brown Injector, cylinder 3, 75–90 HP...

  • Page 98: 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 99: 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 100: Engine Temperature Sensor Test

    ELECTRICAL AND IGNITION SENSOR TESTS Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test 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 101: 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 102: Charging System Tests

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TART ODELS Use a Peak Reading Voltmeter, P/N 507972, to TESTS check stator output voltage. Set meter to the 50 VAC scale. 12 V Charging Circuit WARNING To test the operation of the regulator in the EMM, you must be able to run the outboard continuously To prevent accidental starting of outboard, at approximately 5000 RPM, such as in a test tank...
  • Page 103 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Following the manufacturer’s directions, connect Start and run the outboard at approximately 5000 the variable load tester (carbon pile) across the RPM. Use the variable load tester to draw the bat- battery terminals. Stevens model LB-85 and tery down at a rate equivalent to the stator’s full Snap-On model MT540D are examples of testers output.

  • Page 104: Electric Start Circuit

    ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A – J1-B 008049 1. Marine battery 9. PURPLE wire (switched B+) 2. RED wire (POS) 10. Engine Management Module (EMM) 3. BLACK wire (NEG) 11. YELLOW/RED wire, start 4.
  • Page 105 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 106: Electric Start Tests

    ELECTRICAL AND IGNITION ELECTRIC START TESTS Key Switch, START Position ELECTRIC START TESTS 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 107 ELECTRICAL AND IGNITION ELECTRIC START TESTS Starter Voltage Drop Test • Observe voltage reading. STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to To prevent accidental starting of outboard, starter motor terminal. disconnect crankshaft position sensor •...

  • Page 108: Remote Control Switch Tests

    ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or continuity light to test the SWITCH TESTS continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
  • Page 109 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 110: Tilt/Trim Relay Test

    ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST The meter must indicate battery voltage (12 V) with B+ connected to either terminal. The tilt and trim (TNT) module contains the cir- cuitry and relays required for power trim and tilt operation.

  • Page 111: 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 warn the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...
  • Page 112 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 113: Tachometer Circuit Tests

    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 114: Flywheel And Stator Servicing

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING FLYWHEEL AND STATOR Disconnect wiring harness and remove wiring from cover. 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 115: Stator Service

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywheel Holder, P/N 771311, or equivalent, Stator Service and a 1 5/16 in. socket to remove flywheel nut. Disconnect stator harness connector. Discard flywheel nut. Remove three allen head screws to remove stator. 002088 1.

  • Page 116: Ignition Coil Servicing

    ELECTRICAL AND IGNITION IGNITION COIL SERVICING Thoroughly clean the crankshaft and flywheel IGNITION COIL tapers with Cleaning Solvent and let dry. SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis- connect ignition coil electrical connector. Remove two ignition coil retaining screws. Do not lose the rubber washers between coil and bracket.

  • Page 117: 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 WARNING To prevent accidental starting while servic- ing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.

  • Page 118: Timing Verification

    ELECTRICAL AND IGNITION TIMING ADJUSTMENTS location to align with the cast-in TDC boss on the Check ignition timing after any of the following flywheel. Tighten retaining screw. procedures: • Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement • CPS replacement •...

  • Page 119: Electric Starter Servicing

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Starter Installation Apply Triple-Guard grease to the threads of the SERVICING two starter screws, the double-ended stud, and also to the washers. Starter Removal Position the starter and install the screws and IMPORTANT: Do not clean the starter drive washers.

  • Page 120: 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 (plug) 42329 2. Terminal latch (receptacle) To disconnect the connector, press the latch and pull the connectors apart.

  • Page 121: Amp Connectors

    ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors IMPORTANT: Always use the appropriate meter test probes and adapters when testing compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. UPERSEAL Disconnect Lift latch. Pull connectors apart. 1.
  • Page 122 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 an 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 123: Packard Connectors

    ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back side of the terminal engages a terminal with seal into connector housing until shoulder in the connector housing to hold the ter- seated.
  • Page 124 ELECTRICAL AND IGNITION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 125 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............126 FUEL SYSTEM HOSE ROUTING .

  • Page 126: Service Chart

    FUEL SYSTEM SERVICE CHART SERVICE CHART YLINDER ODELS 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.
  • Page 127 FUEL SYSTEM SERVICE CHART YLINDER ODELS 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 IMPORTANT: DO NOT lubricate TPS TPS to throttle shaft surface to throttle shaft surface 10-14 in. lbs (1.1-1.6 n·m) 10-14 in.
  • Page 128 FUEL SYSTEM SERVICE CHART YLINDER ODELS 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 129 FUEL SYSTEM SERVICE CHART YLINDER ODELS 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 130: Fuel System Hose Routing

    FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING YLINDER ODELS Fuel Supply Fuel Return 002148 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...
  • Page 131 FUEL SYSTEM YLINDER ODELS 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) Fuel return manifold...

  • Page 132: Fuel System Circuit Diagrams

    FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAMS FUEL SYSTEM CIRCUIT DIAGRAMS YLINDER ODELS J1-A J1-B 006479 Stator Capacitor GREEN WHITE/RED (55 V) BROWN Fuel injector BLACK ground wires Fuel circulation pump BLUE...
  • Page 133 FUEL SYSTEM YLINDER ODELS 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 134: Fuel System Requirements

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

  • Page 135: Fuel Requirements

    FUEL SYSTEM FUEL SYSTEM REQUIREMENTS Fuel Requirements When using alcohol-extended fuels, be aware of the following: • The boat’s fuel system may have different WARNING requirements regarding the use of alcohol fuels. Gasoline is extremely flammable and Refer to the boat’s owner guide. highly explosive under certain conditions.

  • Page 136: Components

    FUEL SYSTEM COMPONENTS COMPONENTS Vacuum from the fuel lift pump pulls fuel from the fuel tank. Once fuel reaches the pump, internal pump pressure forces the fuel from the pump The fuel system includes the following compo- through the fuel filter and into the vapor separator. nents: •...
  • Page 137 FUEL SYSTEM COMPONENTS The vapor separator is serviced as an assembly and includes the fuel circulation pump. 1. Vent hose connection to intake 002180 The vapor separator vent is opened and closed by Vapor Separator Assembly 006555 1. Circulation pump a float valve.

  • Page 138: Fuel Circulation Pump

    FUEL SYSTEM COMPONENTS Fuel Circulation Pump Fuel Manifolds The fuel circulation pump is an electric high pres- The fuel supply and return manifolds route fuel sure fuel pump. through the high pressure side of the fuel system. Fuel Supply Fuel Supply Manifold The pump is mounted to the vapor separator and The fuel supply manifold supplies pressurized fuel draws fuel from the fuel chamber.
  • Page 139 FUEL SYSTEM COMPONENTS The EMM is programmed to compensate for vari- Injector Fuel Supply ations in fuel flow. Each injector and its location on Fuel is supplied to the injectors by the fuel circula- the outboard is identified by the EMM. DO NOT tion pump and the fuel supply manifold.

  • Page 140: Fuel System Priming

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

  • Page 141: Fuel System Tests

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

  • Page 142: Pressure Regulator Test

    FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 148 to This test requires Injector Test Fitting kit, remove vapor separator. P/N 5005844. Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.

  • Page 143: Fuel Injector Resistance Test

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

  • Page 144: Lift Pump Vacuum Test

    FUEL SYSTEM FUEL SYSTEM TESTS Results: NOTICE Do not use fuel primer bulb, manual Normal pressure: fuel primer, or electric fuel pump primer to • Perform the Lift Pump Vacuum Test on p. 144. restart outboard. A positive pressure in the Make sure no air leaks or restrictions exist in fuel supply could damage some vacuum the fuel supply hose or boat fuel system.

  • Page 145: 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 146: Fuel Component Servicing

    FUEL SYSTEM FUEL COMPONENT SERVICING FUEL COMPONENT Wrap a shop towel completely around the pres- sure test valve while connecting fitting from Fuel SERVICING Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly. WARNING Gasoline is extremely flammable and highly explosive under certain conditions.

  • Page 147: 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 contents.

  • Page 148: Vapor Separator Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Installation Remove vapor separator/fuel pump from the mounting stud and slide vapor separator housing Place fuel pump in position on crankcase. Apply from the grooves of the isolator mounts. Nut Lock to mounting screws. Tighten screws to a torque of 24 to 36 in.

  • Page 149: Fuel Manifold Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Manifold Service Installation Check condition of sealing O-rings on fuel mani- Removal fold fittings. Lubricate O-rings with outboard lubri- Disconnect the battery cables at the battery. cant and insert fuel manifold fittings into injector. Both fittings must be fully seated into the injector Relieve fuel system pressure.

  • Page 150: Fuel Injector Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injector Service Remove injector screws. Mark fuel injectors to show cylinder locations. NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers for each cylinder.
  • Page 151 FUEL SYSTEM FUEL COMPONENT SERVICING Align the angled edges of both sides of the tool Turn the puller nut until the fuel injector is base with the edge of the fuel injector housing as removed from the fuel injector housing. shown.
  • Page 152 FUEL SYSTEM FUEL COMPONENT SERVICING Install injector into mount housing. Press on injec- Select the Replace Injector button. tor face until injector seats in mount housing. 002318 1. “Replace Injector” button 008568A Installation Use the drop down menu to navigate to the saved coefficient file location.
  • Page 153 FUEL SYSTEM FUEL COMPONENT SERVICING Make sure the serial number displayed on the through mounting flange of injector and into cylin- screen matches the serial number printed on the der head. serial number label of the replacement injector. 002316 Tighten screws in stages, starting with the lower 1.

  • Page 154: 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 vapor separator vent hose, main bear- NOT use strong carburetor cleaner or the hot ing vent hose, air temperature sensor, crankshaft soaking tank method for cleaning.
  • Page 155 FUEL SYSTEM FUEL COMPONENT SERVICING Inspection Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve Inspect the leaf plate assemblies for damage or on reed plate and install screws. Tighten screws contamination: to a torque of 25 to 35 in.
  • Page 156 FUEL SYSTEM FUEL COMPONENT SERVICING Tighten the center screws first and expand out- ward. Tighten in stages to a final torque of 60 to 120 in. lbs. (7 to 13.5 N·m). 002501 Install vapor separator vent hose and main bear- ing vent hose.
  • Page 157 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............158 OIL SUPPLY DIAGRAMS .

  • Page 158: Service Chart

    OILING SYSTEM SERVICE CHART SERVICE CHART 40 – 65 HP 30 to 42 in lbs. (3.5 - 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 tp 42 in lbs. (3.5 - 5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock...
  • Page 159 OILING SYSTEM 75 – 90 HP 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant...

  • Page 160: Oil Supply Diagrams

    OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 40 – 65 HP 008060 Oil tank Oil distribution manifold Oil pick-up/filter Crankcase oil inlet (port) Oil injection pump Cylinder oil inlet (starboard)
  • Page 161 OILING SYSTEM 75 – 90 HP 008061 Oil tank Oil distribution manifold Oil pick-up/filter Crankcase oil inlet (port) Oil injection pump Cylinder oil inlet (starboard)

  • Page 162: Oil Recirculation Diagrams

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 40 – 65 HP Starboard view Port view 002483a 75 – 90 HP Port view Starboard view 002223...

  • Page 163: Oiling System Circuit Diagram

    OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM J1-A J1-B 008050 Stator Main harness ground (BLACK) Alternator grounds (BLACK) Alternator output, WHITE / RED wires (55 V) Capacitor (55 V) EMM injector control (BLUE) 55 V to injection pump (WHITE / RED) Oil injection pump Low oil switch Low oil switch to EMM (TAN/BLACK)

  • Page 164: Oil System Requirements

    OILING SYSTEM OIL SYSTEM REQUIREMENTS OIL SYSTEM COMPONENTS REQUIREMENTS The oiling system includes the following compo- nents: Recommended Lubricants • Oil tank • Oil injection pump and manifold assembly Evinrude/Johnson XD100, XD50, or XD30 out- • Oil level switch board oils are recommended for use in Evinrude •...

  • Page 165: Oil Injection Pump

    OILING SYSTEM COMPONENTS The oil manifold distributes the oil supplied by the YLINDER ODELS pump. Oil Tank Components: • Tank, 2 quart. (1.87 liter) capacity • Oil pickup and filter assembly • Oil injection pump and manifold assembly • LOW OIL switch •...

  • Page 166: Low Oil Warning

    OILING SYSTEM COMPONENTS LOW OIL Warning Cylinder and Crankcase A switch in the oil tank assembly monitors the oil The oil distribution manifold provides crankcase level in the oil tank. lubrication through oil distribution hoses and pressed-in fittings on the crankcase and cylinder If the oil level falls below one-quarter capacity, the block.

  • Page 167: Oil Recirculation System

    OILING SYSTEM COMPONENTS Crankcase / Main Bearing Recirculation YLINDER ODELS The movement of oil through the main bearings is controlled by internal passages, external fittings and hoses, and check valves. Lower to upper main bearing oil flow: • Lower main bearing cavity to internal crankcase passage to external fitting, external hoses with in-line check valve to external fitting at upper main bearing, and into upper main bearing...

  • Page 168: Oil Control Settings

    OILING SYSTEM OIL CONTROL SETTINGS OIL CONTROL SETTINGS NOTICE Running an Evinrude E-TEC out- board on other grades of oil while set to the Oil Injection Rate XD100 oil ratio will result in increased engine wear and shortened outboard life. EMM programming controls the rate of oil injection based on engine RPM.

  • Page 169: Break-In Oiling

    OILING SYSTEM OIL CONTROL SETTINGS Install decals in a highly visible location, such as Oil Supply Priming one of the following: • Dashboard/deck of boat, next to key switch WARNING • Deck of boat, next to the remote oil fill Always use caution while working around •...

  • Page 170: Oiling System Tests

    OILING SYSTEM OILING SYSTEM TESTS Observe oil flow through all oil distribution hoses. OILING SYSTEM TESTS Air must be purged during the priming procedure. IMPORTANT: Always perform visual inspections to identify oiling system leaks. Make sure the oil tank is filled and oil supply is not contaminated. Oil Injection Pump Voltage Tests IMPORTANT: Do NOT perform static tests using...

  • Page 171: Oil Injection Pump Resistance Test

    OILING SYSTEM OILING SYSTEM TESTS Use the Oil Injector test of Evinrude Diagnostic Set digital multimeter to a scale that reads 55 V software Static Test screen to activate the oil (DC). pump. Start the engine. Observe voltage at pin A. •...

  • Page 172: Oil Injection Pump Function Test

    OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Function Test Oil Injection Fittings Flow Test Remove oil distribution hose from fitting at oil dis- Make sure the oil injection fittings of the cylinder tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.

  • Page 173: Oil Component Servicing

    OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Installation Cut Replacement Oil Hose, P/N 778708, to the SERVICING correct length. Insert hose support in manifold end of hose. WARNING IMPORTANT: DO NOT insert distribution hoses into manifold without a hose support. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.
  • Page 174 OILING SYSTEM OIL COMPONENT SERVICING YLINDER ODELS 1. Low oil switch connector 008076 1. Screw 008073 IMPORTANT: Note oil distribution hose rout- ings before proceeding with disassembly. Remove oil distribution hoses from the manifold. Installation Position oil tank assembly on powerhead. Clean mounting screws and apply Nut Lock to threads.

  • Page 175: Oil Injection Pump

    OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Apply a drop of outboard lubricant to a new oil Removal pump o-ring. Install o-ring on oil pump flange. Remove oil distribution hoses from oil manifold. Refer to Oil Distribution Hoses on p. 173. Remove oil from oil tank.
  • Page 176 OILING SYSTEM OIL COMPONENT SERVICING YLINDER ODELS Install oil pump and manifold straight into oil tank. IMPORTANT: Be sure oil pick up assembly is positioned in front of oil tank baffle to prevent interference with the LOW OIL switch. 1. Oil pick up assembly 008183 2.
  • Page 177 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........178 COMPONENTS .

  • Page 178: Hose Routing And Water Flow Diagrams

    COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS YLINDER ODELS 60, 65 HP Water intake screens Water pump Exhaust housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply, EMM to vapor separator Overboard indicator, outgoing water from vapor separator...
  • Page 179 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS YLINDER ODELS Outgoing water (warm/hot) 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 Overboard indicator, outgoing water from vapor separator.

  • Page 180: Components

    COOLING SYSTEM COMPONENTS COMPONENTS IMPORTANT: The water pump housing on 2- cylinder models includes a small hole to the rear Water Pump and Intakes of the water outlet. This hole provides cooling water for the tip of the exhaust passage. Be sure External water intakes mounted in the gearcase to use the correct parts when replacing the water housing collect water and must supply the inlet...

  • Page 181: Adapter/Inner Exhaust Housing

    COOLING SYSTEM COMPONENTS Adapter/Inner Exhaust Housing Pressure Relief Valve A pressure relief valve is used to control water YLINDER ODELS • flow and operating temperature at higher speeds Adapts the cylinder/crankcase assembly (pow- (above approximately 1800 RPM). The pressure erhead) to the exhaust housing and the water relief valve opens as water pressure increases.

  • Page 182: Block Venting

    COOLING SYSTEM COMPONENTS Block Venting Water Pressure Connection A fitting and hose connected to the top of the A fitting and hose for an accessory water pressure exhaust cover allows the constant movement of gauge can be connected at the top of the cylinder water and/or air from the block.

  • Page 183: 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 184: Engine Temperature Check

    COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use Evinrude Diagnostics software to read tem- CHECK 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 185: 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 186: Temperature Sender Servicing

    COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 008346 008347 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.

  • Page 187: Inspection

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Installation on p. 211. VALVE SERVICING 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. 1. Cylinder head seal 002445 Inspection Inspect all parts for cracks, heat damage, or signs...

  • Page 188: Inspection

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING Inspection Inspect all parts for cracks, heat damage, or signs of corrosion. Replace damaged parts. Clean debris from housing and parts. Pressure Relief Valve Assembly Components 002442 Assembly Assembly is the reverse of disassembly. Pay close attention when performing the following additional tasks.
  • Page 189 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............190 COMPRESSION TESTING .

  • Page 190: Service Chart

    POWERHEAD SERVICE CHART SERVICE CHART YLINDER ODELS 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) M, X Q, X 26-30 Ft. lbs. (35-41 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In.
  • Page 191 POWERHEAD SERVICE CHART YLINDER ODELS H, X 30-32 Ft. lbs. (41-43 N·m) 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 See Service Manual Procedure 002284 Extreme Pressure Grease...
  • Page 192 POWERHEAD SERVICE CHART YLINDER ODELS 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) M, X Q, X 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-30 Ft. lbs. (35-41 N·m) Triple-Guard Grease Gasket Sealing Compound...
  • Page 193 POWERHEAD SERVICE CHART YLINDER ODELS H, X 30-32 Ft. lbs. (41-43 N·m) 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 See Service Manual Procedure Extreme Pressure Grease 15-20 Ft.

  • Page 194: Compression Testing

    POWERHEAD COMPRESSION TESTING COMPRESSION TESTING POWERHEAD REMOVAL Start and run outboard until it achieves operating 2-Cylinder Models temperature, then shut OFF. WARNING Disconnect crankshaft position sensor (CPS) con- nector. Remove all spark plugs. Protect against hazardous fuel spray. Before starting any fuel system service, Advance throttle linkage to WOT.
  • Page 195 POWERHEAD POWERHEAD REMOVAL Remove pin and washer from shift rod lever to ODELS release the lower shift rod. Install Lifting Fixture, P/N 396748, on flywheel and seat the three screws completely. NOTICE Be sure to use only the 1 1/8 in. (short) screws, P/N 398067, included with the tool to avoid damage to electronic compo- nents under the flywheel.

  • Page 196: 3-Cylinder Models

    POWERHEAD POWERHEAD REMOVAL 3-Cylinder Models 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 on p. 146. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.

  • Page 197: Powerhead Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Remove the small powerhead screw at rear. DISASSEMBLY Systems Removal To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p.

  • Page 198: Throttle Linkage Removal

    POWERHEAD POWERHEAD DISASSEMBLY Throttle Linkage Removal Shift Linkage Removal Remove throttle cam and throttle lever. Remove shoulder screw from shift arm and retain- ing screw from shift rod lever. Remove the cotter pin and washer holding the shift shaft (2-cylinder models). 2-Cylinder Models 002245 1.

  • Page 199: Crankcase Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY Crankcase Disassembly IMPORTANT: Do not use a tapered punch or any other tool that could jam in or damage the Remove screws and carefully pry off exhaust side taper bore when removing the pin. water cover. Remove crankcase flange screws. 002234 002137 Loosen in stages and remove the main bearing...

  • Page 200: Cylinder Head Removal

    POWERHEAD POWERHEAD DISASSEMBLY Cylinder Head Removal Use Torquing Socket, P/N 331638, to loosen in stages the rod cap retaining screws. DO NOT Remove thermostat cover and thermostat assem- remove the screws. bly. Refer to THERMOSTAT SERVICING on p. 186. Loosen in stages and remove cylinder head screws.

  • Page 201: Crankshaft Removal

    POWERHEAD POWERHEAD DISASSEMBLY Use an appropriate ring expander to remove all necting rod. If necessary, use Wrist Pin Pressing piston rings from pistons. Discard the rings. Tool, P/N 326356, to remove the wrist pin bearing. WARNING Wear safety glasses to avoid injury. 002047 Be careful not to lose any of the 28 needle bear- ings or the two wrist pin washers.
  • Page 202 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 the O-ring from crankshaft sleeve and inspect it.
  • Page 203 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 204: Cylinder Block Cleaning

    POWERHEAD CYLINDER BLOCK CLEANING CYLINDER BLOCK sealant from the cylinder block, crankcase, cylin- der head, and water cover. CLEANING WARNING IMPORTANT: To avoid personal injury, wear eye protec- Before inspecting or assembling tion and rubber gloves when using Gel powerhead, all internal components must be com- Seal and Gasket Remover.

  • Page 205: Powerhead Inspection

    POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diameter of each crankpin and main INSPECTION bearing journal. The lower main bearing journal would only be measured if the bearing was For dimensions, refer to SERVICE SPECIFICA- removed for another reason. TIONS AB MODELS on p. 12. IMPORTANT: Before any inspection process can begin, all internal components must be com-...
  • Page 206 POWERHEAD POWERHEAD INSPECTION The dimensional difference between the two IMPORTANT: Ring end gap increases approxi- areas is cylinder taper. mately 0.003 in. (0.076 mm) for each 0.001 in. • The cylinder taper must not exceed 0.002 in. (0.025 mm) increase in cylinder bore diameter. (0.05 mm).

  • Page 207: Powerhead Assembly

    POWERHEAD POWERHEAD ASSEMBLY POWERHEAD If the installer sticks on the sleeve after installa- tion, thread Slide Hammer, P/N 391008, into ASSEMBLY installer and pull it off. IMPORTANT: Inspect sleeve after installation. IMPORTANT: Proceed slowly. Make no forced Sleeve must not be used if surface is damaged. assemblies unless a pressing operation is called for.
  • Page 208 POWERHEAD POWERHEAD ASSEMBLY lower housing with extended lip facing down. Lubricate upper main bearing with outboard lubri- Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft. 1. Seal lip 002036 1. Upper main bearing 002033 Pack lip of upper oil seal with Moly Lube. Place seal on crankshaft with lip down and enclosed face up.

  • Page 209: Pistons And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Pistons and Connecting Rods Apply Needle Bearing Grease to the wrist pin bearings. Install the bearings in the small end of the connecting rod. Align bearings with Wrist Pin NOTICE It is very important that the pistons Bearing Tool, P/N 336660.
  • Page 210 POWERHEAD POWERHEAD ASSEMBLY Use Wrist Pin Cone, P/N 318600, and Driver, IMPORTANT: Be sure gap of ring fits squarely P/N 318599, to install new wrist pin retaining rings around dowel pin. in each wrist pin hole. Gap of retaining ring faces up, away from notch in piston.

  • Page 211: Cylinder Head Installation

    POWERHEAD POWERHEAD ASSEMBLY Cylinder Head Installation Apply a 1/16 in. (2 mm) bead of RTV Adhesive around each water passage on the block and cyl- Install a new thermostat seal in cylinder head with inder head as shown. side marked “TO CYL HEAD” facing toward ther- mostat.

  • Page 212: Crankshaft And Connecting Rod Installation

    POWERHEAD POWERHEAD ASSEMBLY Crankshaft and Connecting Following sequence stamped on cylinder head, tighten all screws in stages to a torque of 168 to Rod Installation 192 in. lbs. (19 to 21.7 N·m). Apply Gasket Sealing Compound to lower oil seal groove in cylinder block.
  • Page 213 POWERHEAD POWERHEAD ASSEMBLY Lubricate each crankpin and bearing assembly IMPORTANT: Be sure alignment dot on rod cap with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dots face fly- up to crankshaft and install bearing halves. wheel.
  • Page 214 POWERHEAD POWERHEAD ASSEMBLY • Secure restraining jaw “C” and forcing jaw “D” to Tighten the forcing screw to a torque of 14 to 16 frame. in. lbs. (1.6 to 1.8 N·m). Restraining Jaw “C” 21591 1. Contact area of jaw 002071 2.

  • Page 215: Crankcase Assembly

    POWERHEAD POWERHEAD ASSEMBLY Test at least three corners of the rod and cap joint IMPORTANT: Gel-Seal II has a shelf life of at with a pick. Joint must be smooth with no step. least one year when stored at room temperature. Test the Gel-Seal II or replace it if the age of the tube cannot be determined.

  • Page 216: Shift Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Start in the center and work outward in a spiral Note: 3-Cylinder models include a double-ended pattern. stud and use a lock washer under the J-clamp. 002254 2-Cylinder models 002242r 1. J-clamp Apply Nut Lock to crankcase flange screws. Install screws and tighten to a torque of 60 to 84 in.

  • Page 217: Throttle Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Lubricate shift linkage bosses at the base of the Throttle Linkage Installation crankcase with Triple-Guard grease. Insert bush- Apply Nut Lock to threads of throttle lever screw. ings into bosses. Insert spring into cavity of throttle return lever. Apply Triple-Guard grease to the shaft and detent of the shift lever assembly.

  • Page 218: Final Powerhead Assembly

    POWERHEAD POWERHEAD ASSEMBLY and tighten screw to a torque of 120 to 144 in. lbs. Final Powerhead Assembly (13.5 to 16 N·m). Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 154. Install oil recirculating hoses and check valves. Refer to OIL RECIRCULATION DIAGRAMS on p.

  • Page 219: Upper Mount Servicing (3-Cylinder)

    POWERHEAD UPPER MOUNT SERVICING (3-CYLINDER) UPPER MOUNT Inspect mounts and replace if necessary. IMPORTANT: The motor mount, washer, and SERVICING (3-Cylinder) screw are serviced as an assembly. Do not disas- semble. Removal Remove mount retainer screw. 39820 Installation 002069 Place mount assemblies in position, with flats fac- ing away from each other.

  • Page 220: Powerhead Installation

    POWERHEAD POWERHEAD INSTALLATION POWERHEAD Loosely install all powerhead screws before tight- ening: INSTALLATION Powerhead Mounting – 2-Cylinder Models Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only. Install gasket on exhaust housing. To ensure proper sealing, mating surfaces must be clean and dry.
  • Page 221 POWERHEAD POWERHEAD INSTALLATION Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing. retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1.

  • Page 222: Powerhead Mounting - 3-Cylinder Models

    POWERHEAD POWERHEAD INSTALLATION TION on p. 371. Use Lifting Fixture, P/N 396748, and hoist to slowly lower powerhead onto exhaust housing. Guide into position over alignment pin at rear of exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and drive- shaft splines.
  • Page 223 POWERHEAD POWERHEAD INSTALLATION • Apply Gasket Sealing Compound to exhaust relief Tighten the upper mount screws to a torque of muffler gasket and retaining screws. Install muffler 110 to 130 ft. lbs. (149 to 176 N·m). Make sure and tighten screws to a torque of 60 to 84 in. lbs. that screw heads are tight against steering arm.

  • Page 224: Shift Linkage Adjustment

    POWERHEAD POWERHEAD INSTALLATION • Connect the power trim connectors. Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N·m). 002152 Install the lower engine covers. Refer to LOWER 1. Adjustment screws 002125 COVER SERVICE on p. 54. 2.

  • Page 225: Powerhead Views

    POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS 2-Cylinder Port – Hose Routings 006490 2-Cylinder Starboard – Hose Routings 006491...
  • Page 226 POWERHEAD POWERHEAD VIEWS 2-Cylinder Port Dressed Powerhead 008428 2-Cylinder Starboard Dressed Powerhead 008159...
  • Page 227 POWERHEAD POWERHEAD VIEWS 2-Cylinder Port Rope Start Models 008370 2-Cylinder Starboard Rope Start Models 008185...
  • Page 228 POWERHEAD POWERHEAD VIEWS 2-Cylinder Front 008160...
  • Page 229 POWERHEAD POWERHEAD VIEWS 2-Cylinder Rear 008161...
  • Page 230 POWERHEAD POWERHEAD VIEWS 2-Cylinder Top 008162...
  • Page 231 POWERHEAD POWERHEAD VIEWS 2-Cylinder Top, Rope Start Models 008186...

  • Page 232: 3-Cylinder Port Models

    POWERHEAD POWERHEAD VIEWS 3-Cylinder Port – Hose Routings 006760 3-Cylinder Starboard – Hose Routings 006761...
  • Page 233 POWERHEAD POWERHEAD VIEWS 3-Cylinder Port Dressed Powerhead 008163 3-Cylinder Starboard Dressed Powerhead 008164...
  • Page 234 POWERHEAD POWERHEAD VIEWS 3-Cylinder Front 008166...
  • Page 235 POWERHEAD POWERHEAD VIEWS 3-Cylinder Rear 008167...
  • Page 236 POWERHEAD POWERHEAD VIEWS 3-Cylinder Top 008165...
  • Page 237 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHARTS ..............238 TILT TUBE, 75 –...

  • Page 238: Service Charts

    MIDSECTION SERVICE CHARTS SERVICE CHARTS , 40 – 60 HP XHAUST OUSING 24-26 Ft. lbs. 18-20 Ft. lbs. (32.5-35 N·m) (24.5-27 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) 16-18 ft. lbs (22-24.5 N·m) Triple-Guard Grease Gasket Sealing Compound...
  • Page 239 MIDSECTION SERVICE CHARTS , 75 – 90 HP 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...
  • Page 240 MIDSECTION SERVICE CHARTS , 40 – 60 HP P TERN RACKET OWER 45-50 Ft. lbs. (61-68 N·m) 10-16 In. lbs. (1-2 N·m) 144-168 In. lbs. (16-19 N·m) 45-50 Ft. lbs. (61-68 N·m) IMPORTANT Triple-Guard grease on all pivot points Triple-Guard Grease 002220 Gasket Sealing Compound...
  • Page 241 MIDSECTION SERVICE CHARTS , 75 – 90 HP P TERN RACKET OWER 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.
  • Page 242 MIDSECTION SERVICE CHARTS , 40 HP M TERN RACKET ANUAL 40-45 Ft. lbs. (54-61 N·m) 144-168 In. lbs. See Text (16-19 N·m) 144-168 In. lbs. (16-19 N·m) 40-45 Ft. lbs. (54-61 N·m) See Text 144-168 In. lbs. (16-19 N·m) IMPORTANT Triple-Guard Grease Triple-Guard grease...
  • Page 243 MIDSECTION SERVICE CHARTS ILLER ANDLE 18-20 Ft. lbs. (24.5-27 N·m) 24-36 In. lbs. (2.7-4 N·m) 36-48 In. lbs. (4-5.4 N·m) 18-20 Ft. lbs. (24.5-27 N·m) 36-40 Ft. lbs. 20-30 In. lbs. 18-20 Ft. lbs. (49-54 N·m) (2.3-3.4 N·m) (24.5-27 N·m) 18-20 Ft.

  • Page 244: Tilt Tube, 75 - 90 Hp

    MIDSECTION TILT TUBE, 75 – 90 HP TILT TUBE, 75 – 90 HP 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 245: Installation

    MIDSECTION TILT TUBE, 75 – 90 HP 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 246: Exhaust Housing, 40 - 60 Hp

    MIDSECTION EXHAUST HOUSING, 40 – 60 HP EXHAUST HOUSING, 40 – 60 HP The exhaust housing contains no serviceable internal parts. The exhaust water valve and the exhaust relief muffler can both be serviced without removing the exhaust housing. Exhaust Housing Removal Before removing the exhaust housing: •...

  • Page 247: Exhaust Water Valve (60 Hp)

    MIDSECTION EXHAUST HOUSING, 40 – 60 HP Exhaust Water Valve (60 HP) Apply Nut Lock to screws, install and tighten 60 to 84 in. lbs. (7 to 9.5 N.m). Disconnect water valve electrical connector. Remove screws and bracket holding valve to exhaust housing.

  • Page 248: Exhaust Housing Installation

    MIDSECTION EXHAUST HOUSING, 40 – 60 HP Exhaust Housing Installation Place lower thrust washer on the steering shaft and place the lower front mount into position. Bring the exhaust housing into position with the stern bracket. 1. Thrust washer 17526 2.

  • Page 249: Exhaust Housing, 75 - 90 Hp

    MIDSECTION EXHAUST HOUSING, 75 – 90 HP EXHAUST HOUSING, Remove the exhaust housing. 75 – 90 HP Exhaust Housing Removal Before removing the exhaust housing: • Remove the gearcase. Refer to GEARCASE REMOVAL AND INSTALLATION on p. 292. • Remove the powerhead. Refer to POWER- HEAD REMOVAL on p.

  • Page 250: Exhaust Housing Installation

    MIDSECTION EXHAUST HOUSING, 75 – 90 HP If removed, coat the lower mounts with soapy Exhaust Housing Installation water and press into the exhaust housing with the Bring the exhaust housing into position with the “OUTSIDE” mark facing outward. stern bracket. Install four new lower mount screws with lock- patch.

  • Page 251: Exhaust Housing Disassembly

    MIDSECTION EXHAUST HOUSING, 75 – 90 HP Exhaust Housing Disassembly Remove the front and rear screws retaining the adapter/inner exhaust housing to the exhaust housing. 1. Lower inner exhaust housing screws 001974 Remove the water tube from the inner exhaust housing.

  • Page 252: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING, 75 – 90 HP Cleaning and Inspection Inspect the water tube for obstructions or kinks, which may restrict water flow. WARNING Exhaust Housing Assembly Wear safety glasses to avoid personal Place a new gasket between the exhaust mega- injury, and set compressed air to less than phone and adapter housing.
  • Page 253 MIDSECTION EXHAUST HOUSING, 75 – 90 HP Install the water tube through the top of the inner Apply Adhesive 847 to the bottom flange of the exhaust housing and align as shown: inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.

  • Page 254: Stern Bracket, 40 - 60 Hp Power Tilt

    MIDSECTION STERN BRACKET, 40 – 60 HP POWER TILT the hole in the outer housing and the alignment STERN BRACKET, pin into the adapter housing. 40 – 60 HP Power Tilt Stern Bracket Disassembly Remove the bumpers from the upper mount retaining screws.

  • Page 255: Stern Bracket Assembly

    MIDSECTION STERN BRACKET, 40 – 60 HP POWER TILT To separate the swivel bracket from the stern Stern Bracket Assembly bracket, remove one tilt tube nut. Assemble the tie bar to the stern brackets. Place the ground lead and starwasher between the port stern bracket and tie bar.

  • Page 256: Stern Bracket, 75 - 90 Hp Power Tilt

    MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Install the tilt tube. Tighten the tilt tube nuts 40 to STERN BRACKET, 45 ft. lbs. (54 to 61 N·m), then back off 1/8 to 1/4 75 – 90 HP Power Tilt turn.
  • Page 257 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Remove the steering shaft and thrust washer. It Remove the anode. may be necessary to tap the steering shaft out using a wood dowel and mallet. 1. Anode 30762 Remove the swivel bracket. Inspect and, if neces- 30735 sary, replace the tilt tube bushings.
  • Page 258 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Remove the tilt limit switch and retainer from the Remove the two trim rod rollers from the swivel swivel bracket. bracket. 1. Tilt limit switch 30758 1. Trim rod roller 30754 2.

  • Page 259: Stern Bracket Assembly

    MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Stern Bracket Assembly Install the two trim rod rollers on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. IMPORTANT: (25 to 27 N·m). Before proceeding, make sure all components have been thoroughly cleaned.
  • Page 260 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Install the tilt limit switch and retainer on the swivel • Coat the bushings and seal lips with Triple- bracket. Tighten screws to a torque of 40 to 50 in. Guard grease. lbs.

  • Page 261: Stern Bracket, 40 Hp Manual Tilt

    MIDSECTION STERN BRACKET, 40 HP MANUAL TILT STERN BRACKET, Install the steering shaft keeper. Apply Locquic Primer and Nut Lock to the splines of the steering 40 HP Manual Tilt shaft and lower mount bracket. Clamp Screw Service Inspect clamp screw assemblies). Replace swivel plate and retainer if bent or loose.
  • Page 262 MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Slide the pivot shaft and upper thrust washer out Loosen the steering friction screw while pushing of the swivel bracket. outward on the steering friction pin. When the pin is flush with the inside surface of the casting, remove the steering friction thrust ring.
  • Page 263 MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Drive the steering friction bushing up and out of Remove the two stern bracket flange screws and the swivel bracket. separate the stern brackets from the swivel bracket. COA2974 1. Flange screws COA2992 Remove the thrust rod from the stern brackets.

  • Page 264: Stern Bracket Assembly

    MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Remove the starboard stop link retaining screw Stern Bracket Assembly and nut from the swivel bracket. Place the reverse lock springs in the swivel bracket. Insert the reverse lock pins in the swivel bracket and part way through the reverse lock springs.
  • Page 265 MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Install the bushing, the port stop link, and the Place the swivel bracket between the stern brack- tilt/run lever in the swivel bracket. The tilt/run lever ets. should be in the RUN position. Install the tilt tube through the following parts and install the tilt tube nuts loosely: •...
  • Page 266 MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Install and tighten the nut to a torque of 144 to 168 Place the steering friction bushing in the swivel in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews. 1.

  • Page 267: Tilt Assist Cylinder

    MIDSECTION STERN BRACKET, 40 HP MANUAL TILT Install new upper and lower seals in the swivel Tilt Assist Cylinder bracket with lips of seals facing away from the The optional accessory tilt assist cylinder can be bracket. replaced without disassembly of the stern brack- ets.

  • Page 268: Tiller Handle Service - Standard

    MIDSECTION TILLER HANDLE SERVICE – STANDARD Remove set screw from starboard stern bracket TILLER HANDLE lower pivot pin access hole and use an appropri- SERVICE – Standard ate tool to remove lower pivot pin. Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.

  • Page 269: Disassembly

    MIDSECTION TILLER HANDLE SERVICE – STANDARD Remove the electrical cover. Disassembly Loosen throttle friction control so there is no restriction on grip. IMPORTANT: Do not back screw out com- pletely. Nut is under spring tension. 1. Electrical cover 002509 Disconnect the electrical harness coming from the tiller handle.
  • Page 270 MIDSECTION TILLER HANDLE SERVICE – STANDARD Pull the throttle pin out of the cable. Remove the throttle cable retaining clip. Pry the cable trunnion out of the steering handle and remove cable. 24294 1. Retaining clip 24286 2. Cable trunnion Remove stop switch cover screws and cover/stop switch assembly.

  • Page 271: Inspection

    MIDSECTION TILLER HANDLE SERVICE – STANDARD outer handle. After removing, chip away remnants Install the metal outer handle over the plastic inner of inner handle. handle and drive the outer handle into place. 24284 31202 Remove throttle cable seal from the inner handle. Secure tab of the inner handle into recess of the Inspection outer handle with the steel pin.
  • Page 272 MIDSECTION TILLER HANDLE SERVICE – STANDARD Install the throttle control plate on outer handle. Be sure the twist-grip's speed indicator line is positioned with the speed range symbol on the handle. Snap the grip into place. 1. Throttle control plate 24295 1.

  • Page 273: Installation

    MIDSECTION TILLER HANDLE SERVICE – STANDARD Installation Install electrical cover. Apply Triple-Guard grease to the two steering handle bushings. Place the bushings into the steering bracket. Attach the steering handle to the bracket. Tighten screw to a torque of 36 to 40 ft. lbs.

  • Page 274: Tiller Handle Service - Long Handle

    MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE TILLER HANDLE Secure electrical harness with tie strap. SERVICE – Long Handle Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Use Ball Socket Remover tool, P/N 342226, to 1.

  • Page 275: Disassembly

    MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove the electrical cover. Remove the screws attaching tiller bracket to steering arm. Remove tiller bracket and handle. 1. Electrical cover 002084 1. Screw 006361 Disconnect the electrical harness coming from the tiller handle. Disassembly Loosen throttle friction control so there is no restriction on grip.
  • Page 276 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove stop switch cover screws, unplug stop Remove the helix halves, rollers, and guides. switch electrical connector and remove stop switch assembly. 1. Helix halves COA2674 2. Rollers 3. Guides 006713 Pull the throttle pin out of the cable. Disconnect trim switch connector.
  • Page 277 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove the throttle cable retaining clip. Pry the Use a wooden dowel and a soft mallet to remove cable trunnion out of the steering handle and the inner handle. remove cable. 006678 1. Retainer 006674 2.

  • Page 278: Inspection

    MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove shift handle screw and washer. Remove Inspect the shift cable for kinks and wear. Replace shift handle, bushing and washer. if necessary. Inspect the steering handle components for wear, cracks, or damage. Replace parts if necessary. Assembly Apply Nut Lock to threads of shift pin and install shift pin into shift handle.
  • Page 279 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Coat bushing and washer with Triple-Guard Install shift cable retainer on shift cable trunnion. grease. Apply Nut Lock to threads of screw. 1. Shift cable retainer 006721 1. Bushing 006717 2. Washer Use a soft-faced mallet to install the inner handle. 3.
  • Page 280 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE IMPORTANT: Insert wire guide into inner steering handle. Turn self-tapping screw counter- clock-wise until threads of screw engage threads of screw boss. Failure to follow this procedure will damage the screw boss threads. Once threads are engaged, tighten screw so that there is no space between tab, washer and screw.
  • Page 281 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Make sure trim switch wiring is NOT twisted Lubricate end of the pin, guides, rollers, helix before proceeding. halves, and inner handle guide slot with Moly Lube. 1. Inner tiller handle 006675 2. Wire guide 1.

  • Page 282: Installation

    MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Carefully pull trim switch wires through inner tiller Install bottom cover of tiller handle with seven handle as twist grip assembly is installed. screws. 1. Cover screw 006566 1. Trim switch wiring 006677 Install trim switch connector.

  • Page 283: Control Cable Installation

    MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Install locknuts on screws on top of steering arm. Hold screws with wrench and tighten locknuts to a torque of 18 to 20 ft.lbs. (24.5 to 27 N·m). 1. Bracket 006314 Control Cable Installation 1.
  • Page 284 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE • Install washer, cable anchor, and cable anchor Push the clip towards the hole while lifting on screw on throttle body boss. Tighten screw the curved end with the pliers. securely. • Be sure retainer clip fully engages the pin. •...
  • Page 285 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHARTS ..............286 GEARCASE TYPES, 75 –...

  • Page 286: Service Charts

    GEARCASE SERVICE CHARTS SERVICE CHARTS 40 – 60 HP 60-84 In. lbs. (7-9.5 N·m) 96-120 In. lbs. (11-13.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 10-12 Ft. lbs. (13.5-16 N·m) 28-30 Ft. lbs. (38-40 N·m) 60-84 In. lbs. 18-20 Ft. lbs. (7-9.5 N·m) (24.5-27 N·m) 18-20 Ft.
  • Page 287 GEARCASE SERVICE CHARTS “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) 45-50 Ft. lbs. (61-68 N·m) 60-84 In.
  • Page 288 GEARCASE SERVICE CHARTS “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) 45-50 Ft.

  • Page 289: Gearcase Types, 75 - 90 Hp

    GEARCASE GEARCASE TYPES, 75 – 90 HP GEARCASE TYPES, 75 – 90 HP 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”...
  • Page 290 GEARCASE PROPELLER SERVICE When selecting a propeller, consider the following: Propeller Hardware Installation • Use an accurate tachometer to determine the engine’s full-throttle RPM. WARNING • The outboard should be trimmed for top speed. To prevent accidental starting while servic- •...

  • Page 291: Gearcase Leak Test

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

  • Page 292: Gearcase Service, 40 - 60 Hp Models

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE REMOVAL AND INSTALLATION GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE REMOVAL Remove the 5/16-18 x 1.25 in. screw and washer, and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser-...
  • Page 293 GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE REMOVAL AND INSTALLATION Gearcase Installation • Driveshaft engages the crankshaft. • Inner exhaust housing installs correctly. WARNING • Shift rod does not turn and is positioned prop- erly in the shift rod lever below the crankcase. During service, the outboard may drop unexpectedly.

  • Page 294: Water Pump Service

    GEARCASE SERVICE, 40 – 60 HP MODELS WATER PUMP SERVICE Adjustment on p. 35. WATER PUMP SERVICE Disassembly Remove the four impeller housing screws. 1. Trim tab screw 001996 Place the shift rod in the shift rod lever. Install the retaining pin and washer.
  • Page 295 GEARCASE SERVICE, 40 – 60 HP MODELS WATER PUMP SERVICE Assembly Apply a thin bead of Adhesive 847 in the seal groove, and install the special shaped O-ring seal. Lightly coat the exterior rim of the impeller cup with Gasket Sealing Compound. Install the cup in the impeller housing.

  • Page 296: Shift Rod Adjustment

    GEARCASE SERVICE, 40 – 60 HP MODELS SHIFT ROD ADJUSTMENT slide water pump down over key. Be sure impeller SHIFT ROD key does not fall out of position. ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

  • Page 297: Gearcase Disassembly

    GEARCASE SERVICE, 40 – 60 HP MODELS 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).

  • Page 298: Propeller Shaft Bearing Housing Removal

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the two retaining rings using Retaining Ring Pliers, P/N 331045. Removal CAUTION Use a 5/16 in. thin wall socket to remove the four screws with O-rings holding the propeller shaft Retaining rings are under extreme pres- bearing housing.

  • Page 299: Pinion Gear And Driveshaft Removal

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE DISASSEMBLY Remove the larger thrust washer, thrust bearing, Remove the four driveshaft bearing housing and reverse gear from the gearcase. Remove the screws. smaller thrust washer located in front of the gear. 1.

  • Page 300: Shift Housing, Gear And Propeller Shaft Removal

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE DISASSEMBLY Locked Driveshaft Removal Shift Housing, Gear and The driveshaft to pinion taper is a locking taper. If Propeller Shaft Removal necessary, use Puller, P/N 387206, and Backing Push down on the shift rod. This will move the Plate, P/N 325867, to break the lock.

  • Page 301: Shifter, Bearing And Seal Service

    GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE SHIFTER, BEARING AND Water Intake Screen Inspect the water intake screen for blockage and SEAL SERVICE remove it by depressing the tabs on either side of the screen and pushing upward. Pinion Bearing Removal Inspect the pinion bearing for damage without removing it.
  • Page 302 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Place the bearing on the installer tool with the let- unwrapping it from around the clutch dog. Dis- tered side of the bearing facing the top of the card the spring.
  • Page 303 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Remove the shift lever pin from the housing. Shift Housing Assembly Remove shift shaft, cradle and shift lever. Move shifter detent as needed to help ease removal of IMPORTANT: Clean and inspect all parts before parts.
  • Page 304 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE With shifter detent in NEUTRAL, install arms of Coat thrust bearing and thrust washer with Needle shift lever into detent slots. Align the pivot holes Bearing grease. Place the bearing on the back of and insert the retaining pin.
  • Page 305 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Slide the propeller shaft onto the shift shaft, align Clean the bearing housing in solvent to remove the hole in the shaft with the hole in the clutch sealer from the seal bore and the O-ring groove.
  • Page 306 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Propeller Shaft Bearing Housing port the bridge, and tighten jaws securely behind the bearing. Service Rear Seal Removal Remove seals using Puller Bridge, P/N 432127, and Large Puller Jaws, P/N 432129. Place the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.
  • Page 307 GEARCASE SERVICE, 40 – 60 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Thoroughly clean the four bearing housing retain- Rear Seal Installation ing screws in solvent. Discard the O-rings. Apply Gasket Sealing Compound to metal casings of the seals before installing. Bearing Installation Oil, then install new bearings in bearing housing.

  • Page 308: Driveshaft Shimming

    GEARCASE SERVICE, 40 – 60 HP MODELS DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select correct collar and shim gauge bar: • Collar: P/N 328363 • Shim gauge bar: P/N 328366 NOTICE If a 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 309: Gearcase Assembly

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE ASSEMBLY GEARCASE ASSEMBLY between the gauge bar and the bearing housing between each pair of screw holes. Replace the bearing housing and repeat check if variance is Shift Housing, Gear, and greater than 0.004 in. (0.101 mm). Propeller Shaft Installation Check squareness of the pinion to the driveshaft.

  • Page 310: Pinion Gear And Driveshaft Installation

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE ASSEMBLY Apply Triple-Guard grease to the threaded end of Place the cover seal on the shift rod cover. the shift rod and insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring.
  • Page 311 GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE ASSEMBLY the driveshaft bearing housing. Do not coat inside Lightly coat the threads of a new pinion nut with bearing housing bore surface of the gearcase. outboard lubricant. Use Pinion Nut Starting Tool, P/N 320675, to install nut on the driveshaft.

  • Page 312: Propeller Shaft Bearing Housing And Gear Installation

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE ASSEMBLY Use Driveshaft Holding Socket, P/N 334995, and assembly onto the propeller shaft until it engages an 11/16 in. open-end wrench, to tighten the pin- the pinion gear. ion nut to a torque of 40 to 45 ft. lbs. (54 to 60s N·m).

  • Page 313: Final Assembly And Adjustment

    GEARCASE SERVICE, 40 – 60 HP MODELS GEARCASE ASSEMBLY Make sure the retaining rings are seated in the Install O-ring in groove in the bearing housing. grooves in the gearcase. Lightly apply Gasket Sealing Compound to the O-ring flange and aft support flange of the bearing housing.

  • Page 314: Gearcase Service, 75 - 90 Hp Models

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE REMOVAL Remove the 3/8-16 in. screw and washer, and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug...
  • Page 315 GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION Gearcase Installation Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. WARNING • Water tube enters the water pump. • Lower inner exhaust housing installs correctly. During service, the outboard may drop •...

  • Page 316: Water Pump Service

    GEARCASE SERVICE, 75 – 90 HP MODELS WATER PUMP SERVICE Apply Triple-Guard grease to threads of the trim WATER PUMP SERVICE tab screw. Install and align the trim tab with the index marks noted prior to disassembly. Tighten Disassembly the trim tab screw to a torque of 35 to 40 ft. lbs. Rotate the driveshaft counterclockwise to unlock (47 to 54 N·m).
  • Page 317 GEARCASE SERVICE, 75 – 90 HP MODELS 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 318 GEARCASE SERVICE, 75 – 90 HP MODELS WATER PUMP SERVICE Apply a thin bead of Adhesive 847 in the seal slide water pump down over key. Be sure impeller groove, and install the special shaped O-ring seal. key does not fall out of position. 1.

  • Page 319: Shift Rod Adjustment

    GEARCASE SERVICE, 75 – 90 HP MODELS 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 320: Gearcase Disassembly

    GEARCASE SERVICE, 75 – 90 HP MODELS 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).

  • Page 321: Propeller Shaft Bearing Housing Removal

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Assemble components and pull the bearing hous- ing from the gearcase. Removal Remove the two screws, washers, and retainers holding the propeller shaft bearing housing. 22775 Remove the thrust washer, thrust bearing, and reverse gear from gearcase.
  • Page 322 GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Remove the four driveshaft bearing housing Locked Driveshaft Removal 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 323: Driveshaft Service

    GEARCASE SERVICE, 75 – 90 HP MODELS 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”...

  • Page 324: Shift Housing, Gear And Propeller Shaft Removal

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE HOUSING INSPECTION Shift Housing, Gear and GEARCASE HOUSING 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 325: Shifter, Bearing And Seal Service

    GEARCASE SERVICE, 75 – 90 HP MODELS 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.
  • Page 326 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE “O” Type Gearcases Place a new O-ring on the pinion bearing retaining screw. Apply Gasket Sealing Compound to O- ring. Apply Nut Lock to screw threads. Install the screw and tighten to a torque of 60 to 84 in.
  • Page 327 GEARCASE SERVICE, 75 – 90 HP MODELS 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.
  • Page 328 GEARCASE SERVICE, 75 – 90 HP MODELS 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 and inspect all parts before beginning assembly procedures.
  • Page 329 GEARCASE SERVICE, 75 – 90 HP MODELS 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.
  • Page 330 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear- Service ing housing’s bottom groove. The bottom groove is an oil passage. Gearcase damage The driveshaft bearing is not serviceable. Replace could result.
  • Page 331 GEARCASE SERVICE, 75 – 90 HP MODELS 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. (12 to 15 N·m).
  • Page 332 GEARCASE SERVICE, 75 – 90 HP MODELS 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 333: Driveshaft Shimming

    GEARCASE SERVICE, 75 – 90 HP MODELS DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select correct collar and shim gauge bar: • Collar: P/N 341440 • Shim gauge bar: P/N 328367 NOTICE If a 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 334: Gearcase Assembly

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY between the gauge bar and the bearing housing GEARCASE ASSEMBLY between each pair of screw holes. Replace the bearing housing and repeat check if variance is Water Intake Screens greater than 0.004 in. (0.101 mm). Install water intake screens.

  • Page 335: Shift Rod Housing Installation

    GEARCASE SERVICE, 75 – 90 HP MODELS 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.

  • Page 336: Pinion Gear And Driveshaft Installation

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY Pinion Gear and Driveshaft IMPORTANT: The inside taper of the pinion gear and the driveshaft taper MUST be com- Installation pletely free of grease. Clean the tapers with Refer to DRIVESHAFT SHIMMING on p. 333 Cleaning Solvent.

  • Page 337: Propeller Shaft Bearing Housing And Gear Installation

    GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY Use Driveshaft Holding Socket, P/N 311875, Pin- Lightly apply Gasket Sealing Compound to a new Holder, P/N 334455, Wrench bearing housing O-ring. Install O-ring in groove in Retainer, P/N 341438, to tighten the pinion nut to the housing.

  • Page 338: Final Assembly And Adjustment

    GEARCASE SERVICE, 75 – 90 HP MODELS 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.
  • Page 339 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHARTS ..............340 SERVICE CHART .

  • Page 340: Service Charts

    TRIM AND TILT SERVICE CHARTS SERVICE CHARTS 40 - 60 HP M ODELS 30 to 50 in. lbs. (4 to 5.6 N·m) 60 to 85 ft. lbs. (82 to 115 N·m) 45 to 55 in. lbs. (5 to 6 N·m) 45 to 55 in.

  • Page 341: Service Chart

    TRIM AND TILT SERVICE CHART SERVICE CHART 75 - 90 HP M ODELS 30 to 50 In. lbs. (4 to 5.6 N·m) 60 to 85 ft. lbs. (82 to 115 N·m) 45 to 55 In. lbs. (5 to 6 N·m) 60 to 85 ft.

  • Page 342: System Description

    TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION The power trim/tilt hydraulic system is completely contained between the outboard's stern brackets. The system consists of: • Electric motor • Oil reservoir • Pump manifold assembly • Cylinder body assembly Optimal boat and outboard performance can be 1.
  • Page 343 TRIM AND TILT SYSTEM DESCRIPTION 75 – 90 HP M For mooring or storing the boat with the outboard ODELS tilted, a tilt support is provided to support the out- Use the trailering bracket to support the outboard board. when trailering in the tilted position. This bracket protects the hydraulic system from damage.

  • Page 344: 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 to be sure it is in good operating •...

  • Page 345: 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 346: Trim And Tilt Motor No Load Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Test results include three basic possibilities: Monitor motor RPM and current draw. A. Low current draw – Check for: • Valves leaking • Pump damaged • O-rings leaking • Manual release valve damaged B. High current draw – Check for: •...

  • Page 347: Trim Gauge Test

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

  • Page 348: Trim And Tilt Replacement

    TRIM AND TILT TRIM AND TILT REPLACEMENT TRIM AND TILT Separate the trim/tilt unit wires in the braided tube to permit removal through the hole in the stern REPLACEMENT bracket. Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector.
  • Page 349 TRIM AND TILT TRIM AND TILT REPLACEMENT Remove one of the locknuts from the angle adjust- Use a punch to remove the upper pin. ment rod. Remove the rod from the stern brack- ets. 25065 Retract the tilt cylinder rod. 18941 Remove the external snap rings from the lower pin.

  • Page 350: Installation

    TRIM AND TILT TRIM AND TILT REPLACEMENT Remove the unit from the stern brackets far Lubricate the angle adjustment rod with Triple- enough to remove the ground lead from the pump Guard grease. Install the rod. Tighten the locknuts motor mounting screw. to a torque of 20 to 25 ft.
  • Page 351 TRIM AND TILT TRIM AND TILT REPLACEMENT 75 – 90 HP M ODELS ODELS Install the ground lead. Place trim/tilt wires in braided tube and install through hole in the stern bracket. Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. Install external snap rings on lower pin with sharp edge of ring facing out.

  • Page 352: Trim And Tilt Service

    TRIM AND TILT TRIM AND TILT SERVICE TRIM AND TILT SERVICE Screw the manual release valve in. Remove the retaining ring using a small pick or screwdriver. Discard the retaining ring. Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from con- taminating internal parts.
  • Page 353 TRIM AND TILT TRIM AND TILT SERVICE Slowly remove the manual release valve. There Tighten the valve to a torque of 45 to 55 in. lbs. (5 may be pressure behind the valve—wear safety to 6 N·m). glasses. 40 - 60 HP Models 002529 40 - 60 HP Models 002529...

  • Page 354: Piston Seal And End Cap

    TRIM AND TILT TRIM AND TILT SERVICE Piston Seal and End Cap Drain remaining trim and tilt fluid from the cylinder of the trim and tilt assembly. Trim and Tilt Seal Tool Kit, P/N 5008918, is required for service of the piston and end cap Use hydraulic cylinder rod holder set, P/N 983213 assemblies.
  • Page 355 TRIM AND TILT TRIM AND TILT SERVICE Remove seal and o-ring from the piston. NOTICE Use of damaged components can result in leaks or incorrect operation of trim and tilt assembly. Assembly IMPORTANT: Always use the correct trim/tilt fluid. Some trim and tilt assemblies use Power Trim/Tilt and Steering Fluid, and some use Evinrude/Johnson Biodegradable Trim/Tilt Fluid.
  • Page 356 TRIM AND TILT TRIM AND TILT SERVICE NOT damaged or twisted. Remove and reinstall Assemble the piston as shown in the SERVICE the o-ring correctly if necessary. CHARTS on p. 340. Tighten fasteners to specified torque, SERVICE CHARTS on p. 340.. 1.
  • Page 357 TRIM AND TILT TRIM AND TILT SERVICE chart. Part number is stamped on the bottom of Place the loading mandrel, on the piston. Make the housing of trim and tilt assemblies. sure the edge of the loading mandrel is flush with the top edge of the seal groove in the piston.
  • Page 358 TRIM AND TILT TRIM AND TILT SERVICE Place the seal on the loading mandrel. Lift the resizing fixture up over the piston as shown. 1. Seal 008833 1. Resizing fixture 008835 Slowly move the seal pusher down the mandrel. Use the seal pusher to slide the seal into the Lift resizing fixture over the seal while observing groove of the piston.
  • Page 359 TRIM AND TILT TRIM AND TILT SERVICE Leave the resizing fixture in place for at least five cylinder could cause difficulty purging air from the minutes. trim and tilt assembly. 1. Bottom of the resizing fixture flush with the piston 008837 008839 2.

  • Page 360: Trim Motor

    TRIM AND TILT TRIM AND TILT SERVICE Trim Motor Installation Refer to Removal on p. 348 for trim and tilt IMPORTANT: Use only Evinrude/Johnson Bio- assembly removal procedure. degradable TNT Fluid to fill the hydraulic system. Removal Install drive coupler in pump assembly. Remove the four large motor flange retaining Install a new motor O-ring.
  • Page 361 TRIM AND TILT TRIM AND TILT SERVICE Fill the oil reservoir up to the fill plug with Evinrude/Johnson Biodegradable Fluid. Install the fill plug. 40 - 60 HP Models 007646 75 - 90 HP Models 004278 Run the motor, then recheck oil level. Cycle the unit several times and check the oil level when the cylinder is fully extended.
  • Page 362 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 363 MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS SERVICE CHART ..............364 RECOIL STARTER REMOVAL .

  • Page 364: Service Chart

    MANUAL STARTER SERVICE CHART SERVICE CHART 60 to 84 in lbs. (7 to 9.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) 96 to 120 in lbs. (11 to 13.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) Red Ultra Lock Blue Nut Lock Lubriplate 777...

  • Page 365: Recoil Starter Removal

    MANUAL STARTER RECOIL STARTER REMOVAL RECOIL STARTER RECOIL STARTER REMOVAL DISASSEMBLY WARNING WARNING To prevent accidental starting while ser- Wear safety glasses while disassembling vicing, twist and remove all spark plug and assembling manual starters because leads. of rewind spring tension. Remove the clamp holding the oiling system wir- Pull the starter rope out far enough to tie a slip ing harness.
  • Page 366 MANUAL STARTER RECOIL STARTER DISASSEMBLY Remove the nut from the starter pawl retaining Use a screwdriver to pry open the pulley lock ring, screw. and remove ring from the starter. 1. Lock ring COA1368 1. Nut 007855 Remove the friction plates and friction plate spring washer.

  • Page 367: Recoil Starter Cleaning And Inspection

    MANUAL STARTER RECOIL STARTER CLEANING AND INSPECTION RECOIL STARTER RECOIL STARTER CLEANING AND ASSEMBLY INSPECTION WARNING Wash metal components in solvent and dry with Wear safety glasses while disassembling compressed air. and assembling manual starters because of rewind spring tension. Inspect the rewind spring for broken end loops and weak tension.
  • Page 368 MANUAL STARTER RECOIL STARTER ASSEMBLY Apply Triple-Guard grease or Lubriplate 777 to the Install the rewind spring into the starter housing. rewind spring. Install the rewind spring into the Locate the outer loop of the rewind spring on the spring winder base with open loop of spring facing pin in the starter housing.
  • Page 369 MANUAL STARTER RECOIL STARTER ASSEMBLY inner loop of the spring in the slot of the pulley, Place the starter housing spring in the starter and install the pulley in the starter housing. housing. 1. Inside loop COA1365 1. Lock ring COA1361 2.
  • Page 370 MANUAL STARTER RECOIL STARTER ASSEMBLY Install the starter pawl plate retaining screw and If removed, install the starter handle bracket to the washer into the starter housing. Tighten screw to starter housing. Tighten screws securely. a torque of 96 to 120 in. lbs. (11 to 13.5 N·m). 1.

  • Page 371: Recoil Starter Installation

    MANUAL STARTER RECOIL STARTER INSTALLATION RECOIL STARTER Press the starter rope into the channel of the rope anchor, with end of starter rope firmly against end INSTALLATION of channel. Press the anchor into the handle. Apply Nut Lock to the threads of starter ratchet screws.
  • Page 372 MANUAL STARTER NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 373 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ......3 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 374 S–2...

  • Page 375: 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 376: 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 377 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 378: 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 379 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 380: 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 381 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 382 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 Check for leaks under engine cover Whenever possible, remove hose from outboard and from tank.

  • Page 383: 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 384: If Weakened, Parts Could Fail Later On The Water, When Not Expected

    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 385: 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 386: 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 387 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 388: 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 389: 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 390 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 391 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 392 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 393: 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 394: 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 395: 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 396: 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 397 INDEX INDEX Pinion Gear 301, 325 Propeller Shaft 306, 331, 332 Abbreviations 6 Wrist Pin 201, 209 Accessories Break-In Battery Cable, P/N 584348 68 EMM Programming 169, 224 XD100 Outboard Oil Decal, P/N 352369 Gearcase 294, 313, 316, 338 Oiling 169 Adjustments Procedure 71 Control Cable 23, 273, 283...
  • Page 398 INDEX Anodes 48, 255, 257, 260, 297, 306, 320, 331 Oiling Rate 70, 168 Cylinder walls 204 Reports 73 Long Term Storage 49 Sensor Monitoring 99 Metal components 48 Service Codes 69 Steering Cable 41 Static Ignition Test 85 Cover Service 54 Timing Verification 71, 118 Crankcase TPS Calibration 72, 118...
  • Page 399 INDEX TPS Calibration 118 Minimum Octane 10, 12, 14, 135 Transfer 74 Pressure Tests 141 Engine Monitor Priming 140 Description 65 Relieving Pressure 146 Low Oil Warning 62, 166, 172 Requirements 134 No Oil Warning 166 Troubleshooting 80, 88, 141 Operation Check 37 Vapor Separator 136, 148 Engine Temperature Check 184...
  • Page 400 INDEX Tachometer Setting 38 Removal 196 Intake Manifold Servicing 247 Assembly 155 Disassembly 154 Inspection 155 New Engines Installation 155 Outboard Rigging Procedure 21 Removal 154 Oetiker Clamp Servicing 29 Key Switch Oil Injector Operation Check 37 Electrical Circuit (55 V) 165 Start Circuit 106 Electrical Tests 170 Functional Test 172...
  • Page 401 INDEX Installation 210 Removal 201 S.A.F.E. Pistons Description 66 Assembly 209 Low Oil 62 Inspection 206 No Oil 166 Installation 210 Temperature 60, 61 Removal 200 Safety 1 Powerhead Sensor Tests 99 Assembly 207 Sensors Cleaning 204 Air Temperature Sensor 61, 100 Cylinder Compression Testing 194 Barometric Pressure Sensor 61 Disassembly 197...
  • Page 402 INDEX Specifications 10, 12 Starter Tachometer Assembly 367 Pulse Setting 38 Circuit Description 104 Technical Data 10, 12 Current Draw Test 107 Temperature Installation 119, 371 Operating 38, 184 Removal 119 Operation below freezing 164 Rope Replacement 370 Sensors 61 Solenoid Test 106 Temperature Sender Voltage Drop Test 107...
  • Page 403 INDEX Ball Socket Remover tool, P/N 342226 154, Injector Puller Kit, P/N 356461 150 268, 274 Injector Test Fitting Kit, P/N 5005844 142 Battery Cable, P/N 584348 68 Key Switch Assembly, P/N 176408 68 Bearing Installation Tool, P/N 326562 307, Large Puller Jaws, P/N 432129 203, 305, 306, 330, 331 Bearing Installation Tool, P/N 339750 332...
  • Page 404 INDEX Temperature Gun, P/N 772018 184, 185 Ignition 83, 86 Terminal Release Tool, P/N 351413 122 Oiling System 170 Thermal Joint Compound, P/N 322170 185 Sensors 99 Tilt Tube Service Kit, P/N 434523 244 Stator Resistance Test 101 Torquing Socket, P/N 331638 200, 214 Strategy 79 Trim and Tilt Seal Tool Kit, P/N 5008918 Trim and Tilt 344, 345...
  • Page 405 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 406 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 407 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 408 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 409 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE SystemCheck light Outboard is in S.A.F.E. Check Service Codes and SystemCheck warning Refer to specifications, check recommended WOT Incorrect propeller RPM; water test and install correct pitch propeller Setup or rigging change Incorrect outboard mounting...
  • Page 410 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 411 Hose Routing and Water Flow Diagram 40 – 65 E-TEC Inline 2 Cylinder 60, 65 HP 1. Intake water screens 2. Water pump 3. Water tube 4. Cylinder block 5. Pressure valve 6. Thermostat 7. Water supply to EMM 8. Water supply, EMM to vapor separator 9.
  • Page 412 Hose Routing and Water Flow Diagram 75-90 HP EVINRUDE ETEC 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 418 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 419 40 – 65 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 420 75 – 90 HP E-TEC 1. Air Temperature Sensor 2. Throttle Position Sensor 3. Neutral Switch 4. Stator 5. Crankshaft Position Sensor 1 2 3 4 B A C 6. Trim/Tilt Connector 7. SystemCheck Connector 8. Key Switch Connector 9. High Pressure Fuel Pump 10.
  • Page 421 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 422 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Air temperature < -58° F (-49.9° C), or > 218° F (103.2° C). 47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω...

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