BRP EVINRUDE E-TEC BE225HGXABA Manual
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BRP EVINRUDE E-TEC BE225HGXABA Manual

BRP EVINRUDE E-TEC BE225HGXABA Manual

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BRP US Inc.
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.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
®
Evinrude
/ Johnson
®
Evinrude
/ Johnson
Original Instructions
Printed in the United States.
© 2017 BRP US Inc. All rights reserved.
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
®
XD30™ Outboard Oil
®
XD50™ Outboard Oil
®
XD100™ Outboard Oil
Twist Grip™
Nut Lock™
Screw Lock™
Ultra Lock™
Moly Lube™
®
Triple-Guard
Grease
DPL™ Lubricant
®
2+4
Fuel Conditioner
Carbon Guard™
Gel-Seal II™
HPF PRO™ Gearcase Lubricant

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Summary of Contents for BRP EVINRUDE E-TEC BE225HGXABA

  • Page 1 † 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: ® Twist Grip™...
  • Page 2 Service Manual Contents 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: 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 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 propel- ler 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: 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 8: Emission-Related Installation Instructions

    Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation- ship.
  • Page 9 Reference Information Emission-Related Installation Instructions The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifica- tions. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.

  • Page 10: Model Designation

    Reference Information Model Designation Model Designation Engine Identification MODEL IDENTIFICATION The first two characters identify DESIGN FEATURES: Model Version: C Counter Rotation AA A First major variant D Evinrude E-TEC AB A Second major variant Electric Start w/Remote Steering AF A Third major variant G Graphite Paint H High Output...

  • Page 11: Models Covered

    Reference Information Model Designation Models Covered This manual covers service information on the following Evinrude E-TEC models: • 200.1 cubic inch (3.3 L) 90° V6, starting with serial number 5370453. • 210 cubic inch (3.4 L), 90° V6, starting with serial number 5368446. Shaft Gearcase Model Number...

  • Page 12: Service Specifications 90° 3.3 L Models

    Reference Information Service Specifications 90° 3.3 L Models Service Specifications 90° 3.3 L Models 200, 225, 250 Full Throttle Operating Range 5250–6000 RPM Power 200 HP: (147.1 kw) @ 5700 RPM 225 HP: (165.5 kw) @ 5700 RPM 250 HP: (183.9 kw) @ 5700 RPM Idle RPM in Gear 500 ±...
  • Page 13 Reference Information Service Specifications 90° 3.3 L Models 200, 225, 250 Minimum Battery 675 CCA (845 MCA); or Requirements 750 CCA (940 MCA) below 32°F (0°C) (Use a 107 amp-hr battery for extreme applications.) Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Iso- lation.

  • Page 14: Service Specifications 90° 3.4 L Models

    Reference Information Service Specifications 90° 3.4 L Models Service Specifications 90° 3.4 L Models 250, 300 Full Throttle Operating Range 5300–6000 RPM Power 250 HP: (183.9 kw) @ 5600 RPM 300 HP: (220.6 kw) @ 5600 RPM Idle RPM in Gear 500 ±...
  • Page 15 Reference Information Service Specifications 90° 3.4 L Models 250, 300 Minimum Battery Requirements 675 CCA (845 MCA); or 750 CCA (940 MCA) below 32°F (0°C) (Use a 107 amp-hr battery for extreme applications.) Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Iso- lation.

  • Page 16: 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 American Wire Gauge (AWG) is a standardized wire gauge system used in North America to identify the diameter of round, electrically conducting wire.
  • Page 17 Routine Service Routine Service Table of Contents Inspection and Maintenance Schedule ..........18 Lifting the Outboard .

  • Page 18: Inspection And Maintenance Schedule

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

  • Page 19: Lifting The Outboard

    Routine Service Lifting the Outboard Engine Care Products The engine care products listed in the table below are referenced in this service manual, and are recom- mended for use with Evinrude E-TEC outboards. Engine Care Product Notes HPF Pro Gearcase Lubricant Containers available in various sizes, see PAC Catalog Biodegradable TNT Fluid, P/N 763439 Use only in Power Trim &...

  • Page 20: Outboard Rigging Connections

    Routine Service Outboard Rigging Connections Outboard Rigging Con- Cable Retainer Clip Installation When installing retainer clips on control arm link- nections age pins, clips should be locked and must not be bent or deformed. IMPORTANT: For complete outboard rigging For proper installation, review the following steps: and remote control installation information, refer to •...

  • Page 21: Cable, Hose, And Wire Routing

    Routine Service Outboard Rigging Connections Cable, Hose, and Wire Routing To route the fuel hose outside the sleeve, trim the material covering the alternate fuel hose slot in the grommet. CAUTION To prevent accidental starting while servicing, disconnect the battery cables at the battery. Disconnect the Crankshaft Position Sensor (CPS).

  • Page 22: Control Cable Installation

    Routine Service Outboard Rigging Connections Shift Cable Installation and Adjustment Place the shift cable on the shift lever pin and install the washer and retainer clip. Refer to Cable Retainer Clip Installation on p. 20. IMPORTANT: Do not bend or deform clip. Make sure the remote control, gearcase, shift link- age, and shift cable are in NEUTRAL.

  • Page 23: Battery Cable Connections

    Routine Service Outboard Rigging Connections Clip Installation on p. 20. Install trunnion cover and screw. Tighten screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). 1. Throttle cable retainer clip and washer 003967 1. Trunnion cover and screw, throttle cable 005039 Make sure that idle stop of the throttle lever is against the crankcase.

  • Page 24: I-Command Network Connections

    Routine Service Outboard Rigging Connections I-Command Network Connections Remove harness connector cover. 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: If using an Evinrude ICON control system, the I- Command Engine Interface Cable, Power Supply Kit, and Ignition and Trim Harness are not required.

  • Page 25: Icon Network Connections

    Routine Service Outboard Rigging Connections switch is on. I-Command Digital networks do not ICON Network Connections use this connection. NOTICE Do not connect boat accessories to the key switch of an ICON system. Connecting acces- sories to the key switch can cause low cur- rent, resulting in erratic operation of the remote control system.

  • Page 26: Water Pressure Gauge

    Routine Service Outboard Rigging Connections • Route the water pressure hose around the star- Tighten locking rings of buss connectors finger tight. Do NOT use locking rings to force connec- board side of the powerhead along the same path tors together. as the battery cables.

  • Page 27: Battery And Battery Connections

    Routine Service Battery and Battery Connections Battery and Battery Con- Connect the transducer lead to the engine wiring harness connector. nections WARNING Battery electrolyte is acidic—handle with care. If electrolyte contacts any part of the body, immediately flush with water and seek medical attention.
  • Page 28 Routine Service Battery and Battery Connections Connecting the Battery Outboard Battery Rating Model NOTICE 200 H.O. – 640 CCA (800 MCA) or Do not use wing nuts to fasten ANY battery 300 HP 800 CCA (1000 MCA) below cables. Wing nuts can loosen and cause elec- 32°...

  • Page 29: Oetiker Clamp Servicing

    Routine Service Oetiker Clamp Servicing Oetiker Clamp Servicing Oetiker pincers are available in the Evin- rude/Johnson Genuine Parts and Accessories Catalog. WARNING DO NOT re-use Oetiker clamps. Fuel leakage could contribute to a fire or explosion. 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.

  • Page 30: Adjustments

    Routine Service Adjustments Clamp Removal Adjustments Method 1: Position Oetiker pincers across clamp Tilt Limit Switch Adjustment ear and cut clamp. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement.

  • Page 31: Trim Sending Unit Adjustment

    Routine Service Adjustments Rotate the LOWER adjustment tab UP to reduce Temporarily install a thrust rod, P/N 436541, in the the maximum tilt. Rotate the UPPER adjustment number 3 hole. tab DOWN to increase the maximum tilt position. 29072 1. Lower adjustment tab DR4268 Loosen the sending unit screws, to allow the 2.

  • Page 32: Trim Tab Adjustment

    Routine Service Adjustments Lower the outboard against the thrust rod to check If the boat pulls to the left or right when its load is adjustment. Repeat adjustment, if necessary. evenly distributed, adjust the trim tab as follows: • With the remote control in NEUTRAL and the After adjustment is correct, tilt the outboard up, engine OFF, loosen the trim tab screw.
  • Page 33 Routine Service Adjustments Incorrect outboard alignment could cause one or combination of performance, steering, and cooling more of the following: is found. • Propeller ventilation A common practice is to set-up the outboards par- • Reduction of top speed allel, or with a small amount of “toe-out,” and •...

  • Page 34: Operational Checks

    Routine Service Operational Checks Operational Checks Fuel System Perform running checks of the fuel system by fol- DANGER lowing these steps: DO NOT run the engine indoors or without • Squeeze fuel primer bulb until hard or activate adequate ventilation or permit exhaust fumes electric primer.

  • Page 35: Cooling System

    Routine Service Cooling System Cooling System • Adjust dial on back of tachometer to required setting (the outboard should not be running). Check the condition of cooling system compo- Outboard Model Tachometer Setting nents regularly: 200–300 HP 6 Pulse or 12 Pole •...

  • Page 36: Running The Outboard Using A Hose And Flushing Adapter

    Routine Service Cooling System Keep water inlet pressure between 20 to 40 psi Leave the outboard in VERTICAL (DOWN) posi- (140 to 275 kPa). tion long enough for the powerhead to drain com- pletely. Flushing — Outboard Running Reinstall propeller. WARNING Flushing —...
  • Page 37 Routine Service Cooling System Be sure water supply is sufficient to run the engine Refer to Service Specifications 90° 3.3 L Mod- above idle speed. els on p. 12 for water pressure requirements. NOTICE Water Supply Requirements Engine will overheat if normal water pressure Model Water Flow @ WOT is not maintained.

  • Page 38: Lubrication

    Routine Service Lubrication Lubrication Swivel Bracket and Trailering Bracket Steering System Lubricate the swivel bracket with Triple-Guard WARNING grease. Failure to re-grease as recommended could result in steering system corrosion. Corro- Apply grease until the grease begins to flow from sion can affect steering effort, making opera- the upper or lower swivel bracket areas.

  • Page 39: Propeller Shaft

    Routine Service Lubrication • Gearcase Lubricant Inner casings of both the throttle and shift cables. Draining WARNING Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury. IMPORTANT: Always check the fill level of the gearcase lubricant at the upper plug before remov- ing the lower, drain/fill plug.

  • Page 40: Trim And Tilt

    Routine Service Lubrication Inspection and new seal. Tighten plugs to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Inspect the lubricant and the magnets on the plugs for metal chips. The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase.

  • Page 41: Spark Plugs

    Routine Service Spark Plugs Spark Plugs • Three Ram System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads. Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs.

  • Page 42: Fuel And Oil Systems

    Routine Service Fuel and Oil Systems Fuel and Oil Systems If the mark is in unshaded area do not tighten any- more. Routine replacement of filters reduces the possi- bility of foreign material restricting the incoming fuel or oil supplies. Replacement filter elements are available through Evinrude/Johnson Genuine Parts.

  • Page 43: Hoses And Connections

    Routine Service Exhaust Pressure Fitting Exhaust Pressure Fitting Air Silencer The air silencer on Evinrude outboards maximizes The exhaust pressure fitting is threaded into the air flow while minimizing noise. adapter housing and protrudes into the inner exhaust. 1. Exhaust pressure fitting 005026 004218 A hose is routed from this fitting to the EMM.

  • Page 44: Cleaning

    Routine Service Anti-Corrosion Protection Anti-Corrosion Protec- If the exhaust pressure readings are not as described, clean or replace exhaust pressure fit- tion tings. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion.

  • Page 45: Gearcase Removal And Installation

    Routine Service Gearcase Removal and Installation Gearcase Removal and Testing Procedure – Continuity Installation Connect ohmmeter leads between engine ground and anode surface. Gearcase Removal WARNING Turn the key switch OFF, and disconnect the Crankshaft Position Sensor (CPS), to prevent accidental starting while servicing.
  • Page 46 Routine Service Gearcase Removal and Installation Remove the 3/8-16 in. screw and washer, and Coat the driveshaft splines with Moly Lube. DO remove 7/16-14 x 3.5 in. screw and washer. NOT coat top surface of the driveshaft because lubricant may prevent seating of the driveshaft in the crankshaft.
  • Page 47 Routine Service Gearcase Removal and Installation Slide the gearcase into place, making sure: sion and lubricate threads with Triple-Guard • grease. Driveshaft engages the crankshaft. • Water tube enters the water pump. Install screws and washers and tighten to a torque •...

  • Page 48: Storage

    Routine Service Storage ment on p. 32. Storage IMPORTANT: DO NOT start outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur. Fuel System Treatment Stabilize the boat’s fuel supply with Evin- rude/Johnson 2+4 Fuel Conditioner following the instructions on the container.
  • Page 49 Routine Service Storage gauge indicates winterization complete and out- Use the “Mode” button (ICON Pro 5 inch), or board shuts off (about one to two minutes). “Menu” button (I-Command 3.5 inch) to access the winterize feature. IMPORTANT: If the digital gauge does not indi- cate winterization mode active, or outboard runs above fast idle, immediately turn off outboard and start the procedure again.

  • Page 50: Pre-Season Service

    Routine Service Pre-Season Service • Pre-Season Service Inspect outboard, steering system, and con- trols. Replace all damaged and worn compo- nents. Refer to manufacturer’s and lubrication WARNING recommendations. • Failure to check for fuel leakage could allow a Touch up painted surfaces as needed. Coat outer painted surfaces with automotive wax.

  • Page 51: Submerged Engines

    Routine Service Submerged Engines Submerged Engines Prime oil system and fuel system. Refer to Fuel System Priming on p. 142 and Oil Supply Prim- ing on p. 175. Make sure all oil injection hoses are Once an outboard has been submerged in fresh clean and filled with oil.
  • Page 52 Routine Service Submerged Engines...
  • 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 Tighten self-tapping screws to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m). Latch Hook Installation Place hook into position on bracket. 006962 1. Upper cap screws 006964 Apply Ultra-Lock to screw threads.

  • Page 55: Lower Cover Service

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

  • Page 56: Latch Handle Installation

    Engine Cover Service Lower Cover Service Latch Handle Installation Install nut on switch. Tighten nut to a torque of 10 to 16 in. lbs. (1 to 2 N·m). Apply a light coat of Triple-Guard grease to latch handle shaft. Insert handle into lower cover. 006747 1.
  • Page 57 Engine Management Module (EMM) Engine Management Module (EMM) Table of Contents Description ..............56 Internal Sensors .

  • Page 58: Description

    Engine Management Module (EMM) Description Description • Stator to EMM connections; one 6-pin AMP and J2 connector. 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.

  • Page 59: Internal Sensors

    Engine Management Module (EMM) Internal Sensors Internal Sensors If sensor reads less than -67°F (-55°C) or greater than 311°F (155°C) a sensor circuit fault is detected and the EMM: Sensor inputs and internal EMM controllers are Stores service code 23 used to control outboard operation.

  • Page 60: Circuit Sensor

    Engine Management Module (EMM) Internal Sensors 5 V Circuit Sensor If exhaust pressure is less than 40 in. water, the EMM: Monitors the EMM’s 5 V sensor circuit. Stores service code 88 EMM LED 3: OFF (Cranking) If sensor voltage is less than 4.75 volts, the EMM: EMM LED 3: ON (Running) Stores service code 78 EMM LED 3: OFF (Cranking)

  • Page 61: External Sensors

    Engine Management Module (EMM) External Sensors External Sensors If cylinder head temperature exceeds 194°F (90°C) above 2000 RPM for 3 seconds, the EMM: Activates S.A.F.E. Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude Diagnostics software to troubleshoot the sensors. If cylinder head temperature exceeds 248°F Refer to the EMM Service Code Chart at the (120°C) for 3 seconds, the EMM:...

  • Page 62: Oil Pressure Sensor

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

  • Page 63: Crankshaft Position Sensor

    Engine Management Module (EMM) External Sensors Crankshaft Position Sensor If the sensor circuit is OPEN, the EMM: Stores service code 7 (port sensor) Ribs spaced on the flywheel mark crankshaft posi- Stores service code 8 (stbd sensor) tion. As the ribs pass the magnetic field of the EMM LED 3: OFF (Cranking) CPS, an AC voltage signal is generated.

  • Page 64: Internal Emm Functions

    Engine Management Module (EMM) Internal EMM Functions Internal EMM Func- Engine Monitor and Warning Systems tions Refer to Engine Monitor System on p. 65. Start Assist Circuit (SAC) Refer to S.A.F.E. Warning System on p. 66. When the ignition key is ON, the EMM Start Assist Refer to Shutdown Mode on p.

  • Page 65: Engine Monitor System

    Engine Management Module (EMM) Engine Monitor System Engine Monitor Refer to the EMM Service Code Chart at the back of this manual for a complete list of all fault codes. System System Self-Test All remote controlled outboards, 40 HP and above, must be equipped with an engine monitor- During engine start-up, pause with the key switch ing system to warn the operator of conditions that...

  • Page 66: Warning System

    Engine Management Module (EMM) S.A.F.E. Warning System S.A.F.E. Warning Recovery The engine will operate in S.A.F.E. as long as the System fault condition exists. To recover normal operation, two conditions must be met: • Sensor or switch readings must return to normal The S.A.F.E.

  • Page 67: Shutdown Mode

    Engine Management Module (EMM) Shutdown Mode Shutdown Mode Diagnostic Soft- ware Functions WARNING If the engine shuts OFF and the “CHECK The EMM saves valuable information about the ENGINE” light or EMM SENSOR FAULT LED outboard and its running history. This information is flashing, the engine cannot be restarted.

  • Page 68: Static Information

    Engine Management Module (EMM) Diagnostic Software Functions Static Information Dynamic Information Refers to information viewed when the outboard is Dynamic information is viewed while the outboard NOT running. This includes manufacturing infor- is running. Changes in data, such as voltages or mation.

  • Page 69: Active Faults

    Engine Management Module (EMM) Diagnostic Software Functions Active Faults Ignition Test Use the diagnostics software to test each ignition An active fault is a service code that currently circuit. Refer to Static Ignition Test on p. 85. exists. Active faults become occurred faults only if the outboard is running.

  • Page 70: Dynamic Tests

    Engine Management Module (EMM) Diagnostic Software Functions Dynamic Tests Oil Control Settings Dynamic tests are performed with the outboard NOTICE running. Running an Evinrude E-TEC outboard on other grades of oil while set to XD100 oil will result in increased engine wear and short- ened outboard life.

  • Page 71: Ignition Timing

    Engine Management Module (EMM) Diagnostic Software Functions IMPORTANT: that runs for two hours of outboard operation, Make sure the timing pointer is set above 2000 RPM. and the outboard reaches operating temperature before making adjustments. TPS Calibration TPS Calibration synchronizes throttle plate open- ing with throttle position sensor voltage.

  • Page 72: Reports

    Engine Management Module (EMM) Diagnostic Software Functions Fuel Injector Service on p. 151. Click the print button in a window of the diagnos- tics software to print engine data, or to export the information to a computer file. 008573 Reports 1.

  • Page 73: Software Replacement

    Engine Management Module (EMM) Diagnostic Software Functions Software Replacement EMM Transfer Engine Management Software is loaded into the EMM Transfer is used to save engine history data EMM at the factory. Periodically, a new program when the EMM must be replaced. may be available to enhance the operation of an Select EMM Data Transfer from the Utilities menu.

  • Page 74: Emm Servicing

    Engine Management Module (EMM) EMM Servicing EMM Servicing Install two EMM retaining screws. Tighten screws 12 to 16 in. lbs. (1.5 to 2 N·m). IMPORTANT: If a new EMM is being installed, refer to EMM Transfer on p. 73. Removal Disconnect exhaust pressure hose and cooling hoses from EMM.
  • Page 75 System Analysis System Analysis Table of Contents Diagnostic Procedures ............74 Visual Inspections .

  • Page 76: Diagnostic Procedures

    System Analysis Diagnostic Procedures Diagnostic Procedures The Occurred Fault screen displays detailed infor- mation about the operating conditions of the engine at the time the code was set. Visual Inspections • Correct any problems and clear the codes Inspect wiring and electrical connections. Disas- before further troubleshooting.

  • Page 77: Operational Inspections

    System Analysis Diagnostic Procedures • The Engine Identity Report provides a snap-shot Check the Engine Temperature Profile for evi- dence of cold running or overheating. of current engine and sensor conditions. From the Identity screen, press the Print button. Next, press Printer to print, or PDF File to save the report.

  • Page 78: Emm Led Indicators

    System Analysis Diagnostic Procedures codes, inspect all 5 V sensor circuits for broken • Use the diagnostics software Logging function or grounded wiring. to record engine data as a problem is occurring. • Perform a Static Ignition test using Evinrude Diagnostics software and an inductive timing light.

  • Page 79: 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 80: Key On

    System Analysis EMM LED Indicators EMM LED Indicators • Code 16 – CPS, intermittent loss of sync LED 3 – SENSORS OKAY (5 V). For NO LIGHT, The EMM LED indicators provide a quick refer- check for: ence to the status of several outboard systems. •...

  • Page 81: Running Fuel System Tests

    System Analysis EMM LED Indicators • • Code 17 – System voltage (55 V) below range Code 28 – Shift switch malfunction • • Code 18 – System voltage (55 V) above range Code 37 – Water in fuel • •...

  • Page 82: Fuel Delivery Tests

    System Analysis Fuel Delivery Tests Fuel Delivery Tests If the pump runs: • Refer to Fuel System Pressure Test on p. 143. • Refer to Running Fuel System Tests on p. 83. WARNING Protect against hazardous fuel spray. Before Fuel Injector Static Test starting any fuel system service, carefully relieve fuel system pressure.

  • Page 83: System Voltage Test

    System Analysis Fuel Delivery Tests Running Fuel System Tests on p. 79. Run or crank the outboard. Use the Evinrude Diagnostics software Monitor screen to check system voltage. If voltage is low, or drops as RPM increases, refer to Stator Volt- age Output Test on p.

  • Page 84: Ignition Output Tests

    System Analysis Ignition Output Tests Ignition Output Tests • Outboard cranking speed exceeds 75 RPM and a steady CPS signal is generated. DANGER Alternator Output/System Voltage The electrical system presents a serious • System voltage from EMM (white/red) provides shock hazard. Allow outboard to sit for two 55 VDC to the oil injection pump, the fuel injec- minutes after running before handling capaci- tors, and the ignition module of EMM.

  • Page 85: Static Ignition Test

    System Analysis Ignition Output Tests Crankshaft Position Sensor (CPS) Use the Evinrude Diagnostics software Monitor screen to check system voltage. Test When the CPS is working properly, EMM LED 2 turns on while the outboard is being started. Use the Evinrude Diagnostics software CPS Sync and engine RPM displays to confirm a valid CPS signal while the outboard is cranking or running.
  • Page 86 System Analysis Ignition Output Tests The outboard must NOT be running and the emer- Running Ignition Tests gency stop switch lanyard must be installed. Use Evinrude Diagnostics software to monitor system voltage (55 V). • Voltage readings at a specific speed (RPM) should be steady.

  • Page 87: Capacitor Test

    System Analysis Ignition Output Tests IMPORTANT: If a running problem occurs at With EMM OFF, remove the EMM J1-B connector about 1200 RPM, the outboard may be in S.A.F.E. and test the continuity of each ignition control cir- Refer to S.A.F.E. Warning System on p. 66. cuit (orange).
  • Page 88 System Analysis Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 89 Electrical and Ignition Electrical and Ignition Table of Contents Service Charts ..............90 Ignition System Circuit Diagram .

  • Page 90: Service Charts

    Electrical and Ignition Service Charts Service Charts IMPORTANT: Do NOT lubricate TPS to throttle shaft surface. X, J 50-70 In. lbs. (5.6-8 N·m) 60-84 In. lbs. (7-9.5 N·m) 14-16 Ft. lbs. (19-22 N·m) 15-30 Ft. lbs. (20-41 N·m) 30-42 In. lbs. 60-84 In.
  • Page 91 Electrical and Ignition Service Charts 30-42 In. lbs. (3-5 N·m) 140-160 Ft. lbs. (190-217 N·m) X, F 24-36 In. lbs. (2.7-4 N·m) 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) 60-84 In. lbs. (7-9.5 N·m) 168-192 in.

  • Page 92: Ignition System Circuit Diagram

    Electrical and Ignition Ignition System Circuit Diagram Ignition System Circuit Diagram 3 2 1 6 5 4 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 010361 1. Key switch (stop circuit) 4.

  • Page 93: Electrical Harness Connections

    Electrical and Ignition Electrical Harness Connections Electrical Harness Con- EMM J1-A Connector nections Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
  • Page 94 Electrical and Ignition Electrical Harness Connections EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Injector, cylinder 1 Blue Description of Circuit Wire Color Injector, cylinder 2 Blue Injector, cylinder 3 Purple Rear oil injector control (ground) Blue/Red vacant Fuel pump...

  • Page 95: Ground Circuits

    Electrical and Ignition Ground Circuits Ground Circuits • Check continuity between ground terminals at port cylinder head ground screw and the main harness ground. All ground circuits are essential to reliable out- board performance. Make sure all ground connec- tions are clean and tight. Refer to wiring diagrams for specific wiring details.

  • Page 96: Fuse

    Electrical and Ignition Fuse Fuse Sensor Tests The engine harness 12 V (B+) circuit is protected All sensor circuits are dependent on wiring and by one automotive style 10 amp minifuse. connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows The fuse is located on the starboard side of the through the wiring circuit and sensor before powerhead, fastened to the capacitor.

  • Page 97: Throttle Position Sensor (Tps) Test

    Electrical and Ignition Sensor Tests (1.85 mm). The acceptable clearance is 0.036 to through its range of travel. Resistance reading 0.110 in. (1 to 2.8 mm). must change evenly as the sensor lever is moved. Connect red meter lead on terminal “B” and black meter lead to terminal “C.”...

  • Page 98: Knock Sensor Test

    Electrical and Ignition Stator Tests Use a digital multimeter to measure sensor resis- Stator Tests tance. The stator consists of 3 windings (6 poles each) AT Sensor Resistance on a 7 inch diameter core and generates an out- 680 Ω ± 5.25% @ 212°F (100°C) put voltage of 55 VAC (1700 watts maximum).

  • Page 99: Charging System Tests

    Electrical and Ignition Charging System Tests Charging System Tests read no continuity. If meter reads continuity, replace stator. WARNING Stator Voltage Output Test Excessive battery discharge rates might Use a voltmeter to check the stator output voltage. overheat battery causing electrolyte gas- Set meter to read 110 VAC output.

  • Page 100: Auxiliary Battery Charge Wire

    Electrical and Ignition Charging System Tests Snap-On model MT540D are examples of testers • If results vary, check stator BEFORE replacing available. the EMM. See Stator Tests on p. 98. Auxiliary Battery Charge Wire The auxiliary battery charge feature requires aux- iliary battery charge kit, P/N 5006253 (or equiva- lent).

  • Page 101: 55 V Alternator Circuit

    Electrical and Ignition Charging System Tests 55 V Alternator Circuit Check battery ground cable for continuity. With the key switch ON, check battery voltage at battery (12 V). Then, use Electrical Test Probe Kit, P/N 342677, and a digital multimeter set to read 55 VDC to check voltage on white/red wires at J2 connector of EMM.

  • Page 102: Electric Start Circuit

    Electrical and Ignition Electric Start Circuit Electric Start Circuit Start Circuit Diagram 26 25 24 23 22 21 20 34 33 32 31 30 29 28 27 26 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 19 18 17 16 15 14 13 12 11...
  • Page 103 Electrical and Ignition Electric Start Circuit Start Circuit Operation • Switches 12 V to terminal “A” of key switch and to the purple wires of the wire harnesses. The starter must engage and turn the flywheel. • Provides 12 V input to terminal 21 of EMM J1-B The outboard must crank a minimum of 100 RPM connector.

  • Page 104: Electric Start Tests

    Electrical and Ignition Electric Start Tests • Electric Start Tests EMM grounds brown/white wire to activate sole- noid. Starter Solenoid Test Disconnect the B+ (POS) battery cable at the bat- tery. IMPORTANT: Disconnect all wiring from sole- noid terminals before proceeding with this test. Use a digital multimeter to measure resistance.
  • Page 105 Electrical and Ignition Electric Start Tests Use a digital voltmeter to measure the voltage No Load Current Draw Test drop on each section of the start circuit. Securely fasten starter in a vise or suitable fixture before proceeding with this check. If any voltage reading is greater than 0.5 VDC check that connections are clean, tight and free of Use a battery rated at 500 CCA (60 amp-hr) or...

  • Page 106: Remote Control Switch Tests

    Electrical and Ignition Remote Control Switch Tests Remote Control Switch Neutral Start Circuit Test Use an ohmmeter or continuity light to test the Tests continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
  • Page 107 Electrical and Ignition Remote Control Switch Tests IMPORTANT: All wiring must be disconnected wire (black) and one “M” terminal is the stop circuit from the switch before proceeding with this test. wire (black/yellow). Disassemble the remote control and remove the neutral start switch.

  • Page 108: 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 109: Systemcheck Circuit Tests

    Electrical and Ignition SystemCheck Circuit Tests SystemCheck Circuit instrument harness terminal 1 (purple wire) and terminal 2 (black wire). Tests Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...
  • Page 110 Electrical and Ignition SystemCheck Circuit Tests the two connectors, replace SystemCheck Using a jumper wire, connect tan wire (pin 6) of gauge. the engine harness connector to a clean engine ground. 1. Purple wire DRC6280 1. Tan wire (pin 6 of engine harness) 002079 2.

  • Page 111: Tachometer Circuit Tests

    Electrical and Ignition Tachometer Circuit Tests Tachometer Circuit Tests If the LOW OIL light does not turn on after con- necting the terminal to ground, test circuit for con- tinuity. Check voltage at the battery. Use this reading as a reference for battery voltage.

  • Page 112: Flywheel And Stator Servicing

    Electrical and Ignition Flywheel and Stator Servicing Flywheel and Stator Ser- Place the puller on flywheel with body flat side up. Attach the puller body with the three shoulder vicing screws and washers. Hold puller body with han- dle, and tighten pressing screw until flywheel releases.
  • Page 113 Electrical and Ignition Flywheel and Stator Servicing Install the outer edge of flywheel key parallel with Sealing Compound. Install the nut and tighten to a centerline of crankshaft. torque of 140 to 160 ft. lbs. (190 to 217 N·m). 1. Flywheel key 009754 DP0567 IMPORTANT:...

  • Page 114: Ignition Coil Servicing

    Electrical and Ignition Ignition Coil Servicing Ignition Coil Servicing Remove four screws and bracket. Ignition Coil Removal Remove spark plug lead from ignition coil. Disconnect ignition coil electrical connector. Remove two ignition coil retaining screws. Do not lose the rubber washers between coil and bracket.

  • Page 115: 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 of outboard: • Disconnect the battery cables at the bat- tery. • Disconnect crankshaft position sensor (CPS).

  • Page 116: Timing Verification

    Electrical and Ignition Timing Adjustments Repeat the entire adjustment process to make Set TPS Calibration after replacing or adjusting sure pointer is aligned correctly. any throttle body or throttle linkage parts. Install spark plugs. Refer to Spark Plug Indexing Remove the air silencer. on p.
  • Page 117 Electrical and Ignition Timing Adjustments All Models All Models On the Settings/Adjustments screen of the diag- Connect the crankshaft position sensor (CPS). nostics software, click the “Set TPS Calibration” Install the air silencer. button. 1. TPS Calibration button 008571 While holding the throttle plates closed, advance the throttle linkage until it stops.

  • Page 118: Electric Starter Servicing

    Electrical and Ignition Electric Starter Servicing Electric Starter Remove the screws, lock washers, and pinion housing. Servicing Starter Removal IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator.
  • Page 119 Electrical and Ignition Electric Starter Servicing Hit the socket with a mallet to lower the spacer Remove pinion and plastic weather cover from and expose the retaining ring under the spacer. pinion shaft. 30368 Remove the driven gear and thrust washer. 30371 30367 Using No.
  • Page 120 Electrical and Ignition Electric Starter Servicing Remove the two thru-bolts. Mark the end cap ori- Note the alignment marks by the positive terminal entation, and remove the cap. stud. Hold the armature in place, and slide the frame away from the gear housing. 30365 Gently tap the starter frame with a rubber mallet to loosen it.
  • Page 121 Electrical and Ignition Electric Starter Servicing Starter Cleaning and Inspection matter which could contribute to failure of wind- ings. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. TYPICAL 24058 Check permanent magnets. Make sure they strongly attract any steel or iron object held inside 30349 frame.
  • Page 122 Electrical and Ignition Electric Starter Servicing Starter Assembly Push the armature down firmly and slide the frame into place. Align the notches in the gear IMPORTANT: If removed, apply Locquic Primer housing and frame. and Screw Lock to the brush card screws before installing.
  • Page 123 Electrical and Ignition Electric Starter Servicing Install the two thru-bolts. Tighten to a torque of 50 Install the weather cover. to 65 in. lbs. (5.6 to 7.3 N·m). 30361 30363 If removed, install the spring and spacer (large Lightly coat the drive gear with Triple-Guard diameter up) on the pinion shaft.
  • Page 124 Electrical and Ignition Electric Starter Servicing without displacing the driven gear or thrust To test the assembly and operation of the starter, washer. refer to No Load Current Draw Test on p. 105. Starter Installation Apply Locquic Primer and Nut Lock to the threads of the four starter mounting screws.

  • Page 125: Connector Servicing

    Electrical and Ignition Connector Servicing Connector Servicing Use needle-nose pliers to remove wedge from 3-pin receptacle. Deutsch Connectors IMPORTANT: Electrical Grease is recommend- ed. Incorrect grease application can cause electri- cal or warning system problems. To disconnect the connector, press the latch and pull the connectors apart.

  • Page 126: Amp Connectors

    Electrical and Ignition Connector Servicing Terminal Installation AMP Connectors Push terminal through seal until it locks into place. IMPORTANT: Always use the appropriate meter Fill connector with Electrical Grease to 1/32 in. test probes and adapters when testing compo- (0.8 mm) below ledge or end of plug. nents fitted with these terminals.
  • Page 127 Electrical and Ignition Connector Servicing tab and pull on wire to remove from connector Crimping Terminals housing. Crimping Superseal 1.5 terminals requires AMP Crimp Tool with dies, P/N 777281. 1. Anti backout device, plug 002449 002450 2. Anti backout device, receptacle 1.
  • Page 128 Electrical and Ignition Connector Servicing Terminal Removal Connect Open lock mechanism and remove terminal from Push connector until seated in plug. Close latch connector housing. completely. 1. Latch 002453 1. J2 connector 002120 2. Lock mechanism 2. Latch (closed) Terminal Installation Terminal Removal Push terminal through seal until it is seated in con- Use Terminal Release Tool, P/N 351413, to...

  • Page 129: Packard Connectors

    Electrical and Ignition Connector Servicing Terminal Installation Insert a thin tool into the connector above the ter- minal to release tab. Align terminal with connector housing and push terminal with seal into connector housing until seated. 1. Tab DRC5940a Terminal Installation 1.
  • Page 130 Electrical and Ignition Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 131 Fuel System Fuel System Table of Contents Service Charts ............. . . 132 Fuel System Hose Routing .

  • Page 132: Service Charts

    Fuel System Service Charts Service Charts Fuel Pump, Fuel Filter, Vapor Separator 30-42 In. lbs. (3.5-4.7 N·m) 60-84 In. lbs. 60-84 In. lbs. (7-9.5 N·m) (7-9.5 N·m) (Lower screw only) 100-110 In. lbs. (11-12 N·m) 60-84 In. lbs. 60-84 In. lbs. (7-9.5 N·m) (7-9.5 N·m) Hand tighten the fuel filter until the seal...
  • Page 133 Fuel System Service Charts Reed Plate Assembly and Throttle Body IMPORTANT: Do NOT lubricate TPS to throttle shaft surface. Bond seals to air silencer 10-18 in. lbs. (1-2 N·m) 60-84 in. lbs. (7-9.5 N·m) 60-80 in. lbs. (7-9.5 N·m) 30-42 in. lbs. (3.5-4.7 N·m) 72-96 in.
  • Page 134 Fuel System Service Charts Fuel Manifolds and Injector Tighten in 3 stages 5 ft. lbs. (7 N·m) 10 ft. lbs. (14 N·m) 24-26 Ft. lbs. 24-36 in. lbs (33-35 N·m) (2.7-4 N·m) S = Supply R = Return A Triple-Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube...

  • Page 135: Fuel System Hose Routing

    Fuel System Fuel System Hose Routing Fuel System Hose Routing 3.3 L Models 3.4 L Models Fuel Supply 010368 Fuel Return 1. Fuel supply from boat fuel system 8. Electric fuel circulation pump (20 to 35 psi) 2. Fuel lift pump (2 to 8 psi) 9.

  • Page 136: Fuel System Circuit Diagram

    Fuel System Fuel System Circuit Diagram Fuel System Circuit Diagram 010369 1. Injectors 4. Capacitor 7. High pressure fuel pump 2. EMM 5. Grounds (neg) 8. Fuel filter/water separator 3. 55 V circuit (white/red) 6. Fuel Injector grounds...

  • Page 137: Fuel System Requirements

    Fuel System Fuel System Requirements Fuel System Require- Portable Fuel Tanks ments WARNING If engine is equipped with a quick-disconnect Regulations and Guidelines fuel hose, you MUST disconnect the fuel hose from the engine and the fuel tank to pre- Vessel manufacturer, and/or installer of an EPA vent fuel leaks: certified outboard, must meet minimum specifica-...

  • Page 138: Fuel Requirements

    Fuel System Fuel System Requirements Fuel Requirements or fuel leakage are found. Inspect at least annu- ally. WARNING IMPORTANT: Always use fresh gasoline. Gaso- Gasoline is extremely flammable and highly line will oxidize, resulting in loss of octane and vol- explosive under certain conditions.

  • Page 139: Components

    Fuel System Components Components nance Schedule on p. 18 for service frequency. The fuel system includes the following compo- nents: • Fuel Lift Pump • Fuel Filter • Vapor Separator • Fuel Circulation Pump • Fuel Supply Manifolds • Fuel Injectors •...

  • Page 140: Fuel Circulation Pump

    Fuel System Components separator self-drains when the outboard is stored Pressure Regulator vertically. Refer to Hose Routing and Water The fuel pressure regulator helps maintain consis- Flow Diagram 3.3 L on p. 190. tent fuel pressure in the fuel system. Fuel returning from the injectors enters the fuel Venting chamber of the vapor separator through a pres-...

  • Page 141: Fuel Injectors

    Fuel System Components Fuel Supply Manifold Each service injector includes its fuel flow infor- mation on a 3.5 in. floppy disk. This software The fuel supply manifold supplies pressurized fuel allows the EMM to be reprogrammed for this injec- to the inlet port of each fuel injector. tor’s unique fuel flow characteristics.

  • Page 142: Fuel System Priming

    Fuel System Fuel System Priming Fuel System Priming The high-pressure fuel circuits and injectors will prime as the outboard is cranked with the starter. Vent Line Clamp Observe all fuel lines, both in the boat and on the Federal Regulations require that all outboards outboard.

  • Page 143: Fuel System Tests

    Fuel System Fuel System Tests Fuel System Tests IMPORTANT: If outboard does not run, prime fuel system and crank outboard; check circulation pump operation; check fuel system pressure. WARNING Results: Use caution when working on any pressur- ized fuel system. Wear safety glasses and Normal pressure work in a well ventilated area.

  • Page 144: Vapor Separator Vent Check

    Fuel System Fuel System Tests Apply oil to valve and connect pressure pump and Relieve fuel system pressure. See Relieving Fuel hose to the fuel return fitting of vapor separator. System Pressure on p. 147. IMPORTANT: Perform test with injector mounted Apply pressure to check regulator operation.

  • Page 145: Circulation Pump Resistance Test

    Fuel System Fuel System Tests Use a digital multimeter with appropriate adapter Lift Pump Pressure Test leads to measure resistance of the complete injec- Install a 0 to 15 psi (0 to 103 kPa) Fuel Pressure tor circuit, including injector and associated wiring. Gauge, P/N 5006397 or equivalent, to the lower fuel pressure test fitting.

  • Page 146: Lift Pump Vacuum Test

    Fuel System Fuel System Tests Lift Pump Vacuum Test Remove both pulse hoses from the crankcase fit- tings. NOTICE Apply 15 psi (103 kPa) to each of the pulse hoses Do not use fuel primer bulb, manual fuel of the pump. Replace lift pump if either side of primer, or electric fuel pump primer to restart pump fails to hold pressure.

  • Page 147: Fuel Component Servicing

    Fuel System Fuel Component Servicing Fuel Component Servic- 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. Use cau- tion when working on any part of the fuel sys- tem.

  • Page 148: Fuel Lift Pump Service

    Fuel System Fuel Component Servicing Clean up any spilled fuel with shop towels. Disconnect the fuel outlet hose from tee. ENVIRONMENTAL NOTE Disconnect the fuel lift pump pulse hoses at the crankcase fittings. Dispose of fuel contaminated towels in an envi- ronmentally responsible manner, or according to local regulations.

  • Page 149: Vapor Separator Service

    Fuel System Fuel Component Servicing Apply Nut Lock to screws and install screws into Remove clamps and fuel return manifold and fuel throttle body. Tighten screws to a torque of 24 to supply hose from bottom of vapor separator. 36 in. lbs. (2.8 to 4.0 N·m). Remove the vapor separator housing retainer clip.
  • Page 150 Fuel System Fuel Component Servicing • Install retainer in the outer groove of the manifold Fuel return manifold to vapor separator fittings. Install and tighten screw to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m). 1. Fuel supply manifold 004189 2.

  • Page 151: Fuel Injector Service

    Fuel System Fuel Component Servicing Fuel Injector Service Remove injector screws. NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM program- ming matches injector positioning. The Injec- tor Coefficients screen displays injector serial numbers for each cylinder.
  • Page 152 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 153 Fuel System Fuel Component Servicing Installation Select the Replace Injector button. NOTICE All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure. Installation of a replacement injector requires that coefficient data for the new injector is uploaded to the EMM.

  • Page 154: Intake Manifold Service

    Fuel System Fuel Component Servicing • • Injector Final torque is 24 to 26 ft. lbs. (33 to 35 N·m). • Cylinder head • Adapter • Screws • Threaded areas Place injector and insulator in the proper cylinder location. IMPORTANT: Be careful not to pinch any wiring or hoses during assembly.
  • Page 155 Fuel System Fuel Component Servicing Remove screws and reed plate assembly from the Use caution to prevent damaging reed valve crankcase. assemblies. 004190 004192 Disassembly NOTICE All reed plate assembly and reed valve assem- DO NOT disassemble reed valve assemblies. blies must be cleaned before reassembly.
  • Page 156 Fuel System Fuel Component Servicing Assembly Tighten the center screws first and expand out- ward. Final torque is 60 to 84 in. lbs. (7 to 9.5 Remove old adhesive from reed valve retaining N·m). screws. Prime screw threads with Locquic Primer and let dry.
  • Page 157 Fuel System Fuel Component Servicing Position clamps as shown. 1. Clamps 006990 2. Idle air hose 3. Oil/fuel pump bracket Refer to TPS Calibration on p. 116.
  • Page 158 Fuel System Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 159 Oiling System Oiling System Table of Contents Service Chart ..............160 Oiling System Circuit Diagram .

  • Page 160: Service Chart

    Oiling System Service Chart Service Chart Engine Oil Programming Labels XD30, XD50 XD100 Boat Label This outboard has This outboard has been programmed been programmed for use of for use of Evinrude®/Johnson® Evinrude®/Johnson® This outboard has been programmed for XD100™ oil. XD25™, XD30™, XD50™...

  • Page 161: Oiling System Circuit Diagram

    Oiling System Oiling System Circuit Diagram Oiling System Circuit Diagram 1 2 3 4 5 6 5 4 3 2 1 010370 1. Crankcase Oil Injection Pump 9. Oil Pressure Sensor Signal (Tan/White) 2. Cylinder Oil Injection Pump (3.4 L models only) 10.

  • Page 162: Oil Supply Diagrams

    Oiling System Oil Supply Diagrams Oil Supply Diagrams 200 – 250 HP (3.3 L) Models Rear oil manifold delivers oil to: • #1, #2, #3, #4, #5 & #6 cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4.
  • Page 163 Oiling System Oil Supply Diagrams Port Side View Starboard Side View 008208R...
  • Page 164 Oiling System Oil Supply Diagrams 250 – 300 HP (3.4 L) Models Rear oil manifold delivers oil to: • Cylinder sleeves 1. Cylinder 2 2. Cylinder 4 3. Cylinder 6 4. Cylinder 1 5. Cylinder 3 6. Cylinder 5 Primary oil manifold delivers oil to: •...
  • Page 165 Oiling System Oil Supply Diagrams Port Side View Starboard Side View 008432R...

  • Page 166: Oil Recirculation Diagrams

    Oiling System Oil Recirculation Diagrams Oil Recirculation Diagrams Complete View 008205R Top View 008206R...
  • Page 167 Oiling System Oil Recirculation Diagrams Port View Starboard View 008207R...

  • Page 168: Oil System Requirements

    Oiling System Oil System Requirements Oil System Requirements Components The oiling system consists of the following compo- NOTICE nents: Failure to follow these recommendations • Oil tank could void the outboard warranty if a lubrica- • Oil injection pump and manifold assembly tion-related failure occurs.

  • Page 169: Electrical Circuit (55 V)

    Oiling System Components fold. The EMM supplies 55 V and controls Oil Pressure Sensor activation of the pump. The oil pressure sensor reacts to changes in oil manifold pressure. The EMM supplies and moni- tors electrical current to the sensor. 1.

  • Page 170: Rear Oil Manifold (3.3 L Models)

    Oiling System Components Rear Oil Manifold (3.3 L models) rapidly connecting and disconnecting the pump’s internal coil to ground. The rear oil manifold receives oil from the primary The EMM monitors the oil injection pump electri- manifold and distributes it to the cylinder sleeves. cal circuit.

  • Page 171: Oil Recirculation System

    Oiling System Components hoses and pressed-in fittings at the front of the crankcase, port side. 1. Cylinder sleeve oil fittings – stbd 008457 Oil Recirculation System 1. Pressed-in fitting 008456 External hoses fittings, internal cylin- The rear oil distribution manifold provides lubrica- der/crankcase passages, and intake manifold pas- tion for each cylinder.
  • Page 172 Oiling System Components cylinders into the incoming air stream in front of hoses which route to a fitting at the top of the the top reed valve. block, above #2 cylinder. 1. Check valves 004337 1. Lower to upper main bearing oiling circuit 005043 2.

  • Page 173: Oil Control Settings

    Oiling System Oil Control Settings Oil Control Settings • Moderate applications NOTICE Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil ratio will result in increased engine wear and shortened outboard life. Oil Injection Rate The Engine Management Module (EMM) controls the oil injection rate based on engine RPM.

  • Page 174: Break-In Oiling

    Oiling System Oil Control Settings • that have been programmed for the reduced oil Use the diagnostics software to start break-in injection ratio. oiling after a powerhead rebuild. This outboard has been programmed for ® ® the use of Evinrude /Johnson XD100™...

  • Page 175: Oil Supply Priming

    Oiling System Oil Supply Priming Oil Supply Priming Start the outboard. Use the oil priming functions in the software to make sure the system is com- pletely primed. WARNING IMPORTANT: The outboard should be running Always use caution while working around during the priming procedure to avoid pumping too machinery with moving parts.
  • Page 176 Oiling System Oil Supply Priming Use the Prime Oil System button of the Dynamic Small bubbles are acceptable. Large bubbles Test screen to prime the front oil pump. must be eliminated through continued priming. 1. Oil distribution hose 004398 2. Small bubbles 3.
  • Page 177 Oiling System Oil Supply Priming Observe oil flow through all oil distribution hoses. The oiling system on these models can also be Air must be purged during the priming procedure. primed using the Self-Winterizing feature if diag- nostics software is not available. Refer to Storage on p.

  • Page 178: Oiling System Tests

    Oiling System Oiling System Tests Oiling System Tests Oil Injection Pump Voltage Tests Use a digital multimeter calibrated to a scale that IMPORTANT: Always perform visual inspections reads 55 V (DC) to measure voltage between the to identify oiling system leaks. Make sure the oil oil pump electrical connector and engine ground.

  • Page 179: Oil Injection Pump Circuit Resistance Test

    Oiling System Oiling System Tests Use the Oil Injector test of Evinrude Diagnostic Oil Injection Pump Circuit software Static Test screen to activate the oil Resistance Test pump. IMPORTANT: The complete oil injection pump electrical circuit includes EMM alternator output, the engine wire harness, the injection pump wind- ing and connectors, and the oil injector control cir- cuit of the EMM.

  • Page 180: Cylinder Oil Pump Voltage Tests

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

  • Page 181: Cylinder Oil Pump Resistance Test

    Oiling System Oiling System Tests Cylinder Oil Pump Resistance Use low pressure air to purge oil from hose. Test Disconnect the battery cables at the battery. Disconnect the electrical connector from the oil injection pump. Use a digital multimeter to measure the resistance between the pins of the oil pump connector.

  • Page 182: Oil Injection Pump Function Test

    Oiling System Oiling System Tests Check height of pickup assembly. Running Test Start the outboard and observe oil flow. Confirm Pickup Assembly Height that a small amount of oil is discharged while 1.8 gallon tank 6.84 to 6.96 in. injection pump is activated. (174 to 177 mm) 3.0 gallon tank 8.74 to 8.86 in.

  • Page 183: Low Oil Sending Unit Test

    Oiling System Oil Component Servicing Oil Component Servicing Clean up any spilled oil with shop towels. ENVIRONMENTAL NOTE WARNING Dispose of used oil or oil contaminated towels in To prevent accidental starting while servic- an environmentally responsible manner, or ing, disconnect the Crankshaft Position Sen- according to local regulations.

  • Page 184: Oil Injection Pump

    Oiling System Oil Component Servicing Once hose is removed from the manifold, make Remove oil injection pump clamp screw. sure hose support is in the end of the hose. 1. Clamp screw 004220 1. Hose support 008070 Remove the oil injection pump assembly. Installation Clean up any spilled oil with shop towels.

  • Page 185: Rear Oil Pump

    Oiling System Oil Component Servicing Connect oil hose to rear oil manifold. Reconnect oil supply hose to the inlet fitting of oil pump. Fasten with Oetiker clamp. 1. Oil to rear manifold 007148 1. Oil supply hose 005519 2. Oetiker clamp Install oil pump on bracket with clamp and retain- ing screw.
  • Page 186 Oiling System Oil Component Servicing Remove two mounting bracket screws. Installation Clean threads of screws and apply Nut Lock to threads. Install oil pump assembly into mounting bracket with two screws. Tighten screws to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m). Install the oil injection pump and bracket with two mounting bracket screws.
  • Page 187 Oiling System Oil Component Servicing Connect oil hoses to cylinder sleeve oil fittings on Reconnect the oil supply hose to the inlet fitting of the crankcase and fasten with tie straps. the oil pump. Fasten with Oetiker clamp. Orient clamp as shown. 1.
  • Page 188 Oiling System Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 189 Cooling System Cooling System Table of Contents Hose Routing and Water Flow Diagram 3.3 L ........190 Hose Routing and Water Flow Diagram 3.4 L .

  • Page 190: Hose Routing And Water Flow Diagram 3.3 L

    Cooling System Hose Routing and Water Flow Diagram 3.3 L Hose Routing and Water Flow Diagram 3.3 L PORT REAR Water intake screens Water pump Water tube Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) Water supply, EMM to vapor separator Vapor separator water outlet to adapter Port thermostat tower to blow-off valve...

  • Page 191: Hose Routing And Water Flow Diagram 3.4 L

    Cooling System Hose Routing and Water Flow Diagram 3.4 L Hose Routing and Water Flow Diagram 3.4 L PORT REAR Water intake screens Water pump Water tube Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) Water supply, EMM to vapor separator Vapor separator water outlet to adapter Port thermostat tower to blow-off valve...

  • Page 192: Components

    Cooling System Components Components Water Supply Tube The water pump outlet connects with the water Water Pump and Intakes supply tube located in the outboard’s midsection. External water intakes mounted in the gearcase Grommets seal the water tube to the water pump housing collect water and must supply the inlet housing and the inner exhaust housing.

  • Page 193: Pressure Relief Valve

    Cooling System Components • Overcooling: Debris may prevent the valve from Provides exhaust passages which connect to the gearcase. closing completely. Adapter housing – 3.3 L models 000695 Pressure Relief Valve Components DRC8113 Thermostats Thermostats control water flow and operating tem- perature at lower speeds (below 1200 RPM).

  • Page 194: Operation

    Cooling System Operation Operation When the thermostat opens, water flows down through the cylinder head to a passage in the cyl- inder block. Water flows through the block to the NOTICE exhaust housing and then out of the outboard. Restricted or inadequate water flow through At higher speeds, water pressure opens the the outboard reduces cooling system perfor- pressure relief valve at approximately 1200 RPM.

  • Page 195: Emm And Vapor Separator Cooling

    Cooling System Engine Temperature Check Engine Temperature adapter. The water reduces inner exhaust tem- peratures and cools the propeller hub. Check CAUTION When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the Crankshaft Position Sensor (CPS) to prevent accidental engine starting.

  • Page 196: Software Method

    Cooling System Engine Temperature Check Software Method Typical pyrometer readings at IDLE speed should be 143°F ± 15°F (62°C ± 8°C) Use Evinrude Diagnostics software to read tem- IMPORTANT: If you get low or inaccurate read- perature displays. ings with a digital pyrometer, coat the probe loca- tion with Thermal Joint Compound, P/N 322170.
  • Page 197 Cooling System Engine Temperature Check If IDLE temperature is too low, pinch off the water Thermostats outlet hoses from pressure relief valve to cylinder Remove thermostat cover(s) and inspect thermo- heads. stat(s). 1. Outlet hoses DSC00827 004338 2. Pliers Check position of thermostat seal and how ther- Use hose pinching pliers (acquired through local mostat seals against cylinder head.

  • Page 198: Temperature Sensor Servicing

    Cooling System Temperature Sensor Servicing Temperature Sensor Wait 10 minutes for trapped air to bleed from cav- ity. Thermal compound may seep past threads. Servicing Retighten sensor. Removal Loosen sensor and remove by hand. Use care to avoid breaking threads. 007209 Clean sensor threads, sensor, and sensor cavity.

  • Page 199: Thermostat Servicing

    Cooling System Thermostat Servicing Thermostat Servicing Pressure Relief Valve Servicing Disassembly Remove the thermostat cover and O-ring from cyl- The pressure relief valve assembly should be ser- inder head. viced at the same time as the thermostats. Disassembly Remove hose clamps and hoses from pressure valve.

  • Page 200: Assembly

    Cooling System Pressure Relief Valve Servicing Assembly Assembly is the reverse of disassembly. Pay close attention when performing the following additional tasks. Tighten bracket and cap screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Install valve on powerhead.
  • Page 201 Evinrude ICON Remote Control System Evinrude ICON Remote Control System Table of Contents Service Chart ..............202 Components .

  • Page 202: Service Chart

    Evinrude ICON Remote Control System Service Chart Service Chart 1. ICON buss cable connector 5. ESM power supply 2. ESM to EMM connector 6. ESM to shift actuator connector 3. ESM to engine harness key switch connector 7. ESM to throttle actuator connector 4.

  • Page 203: Components

    Evinrude ICON Remote Control System Components Components Shift Actuator The shift actuator converts electronic signals from The ICON remote control system consists of the the ESM into the mechanical motion required to following components: shift the outboard into and out of gear. •...

  • Page 204: Throttle Actuator

    Evinrude ICON Remote Control System Components Throttle Actuator ICON System Failsafe Mode The throttle actuator converts electronic signals Fault code 108 will appear with another code that from the ESM into the mechanical motion required explains why the engine(s) entered RPM reduc- to move the throttle of the outboard.

  • Page 205: Icon Component Servicing

    Evinrude ICON Remote Control System ICON Component Servicing ICON Component Servic- Installation Install grommets on ESM. Apply soapy water to grommets and push assembly on to studs. WARNING To prevent accidental starting while servic- ing: • Disconnect the battery cables at the bat- tery.
  • Page 206 Evinrude ICON Remote Control System ICON Component Servicing Continue harness routing under pressure relief to harness from ESM and attach to clip on mount- valve hoses to EMM connector. Clip connector to ing plate. fuel rail. Make sure harness is not strained and NOTICE does not rub against EMM mounting boss.
  • Page 207 Evinrude ICON Remote Control System ICON Component Servicing Secure shift actuator harness with tie strap, Install ESM ground, star washer, battery cable, P/N 317893. and nut on main ground stud. Tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1.

  • Page 208: Shift Actuator

    Evinrude ICON Remote Control System ICON Component Servicing IMPORTANT: Connect ESM harness to engine harness key Calibrate shift and throttle actua- switch and trim/tilt connectors. tors. Refer to Calibrate Actuator Stroke on p. 213. Secure connectors in bracket as shown and install connector cover.
  • Page 209 Evinrude ICON Remote Control System ICON Component Servicing Remove the shift actuator connector from the clip Apply Nut Lock to the threads of the screws. on the mounting plate. Disconnect the shift actua- Install shift actuator on mounting plate with three tor harness.

  • Page 210: Throttle Actuator

    Evinrude ICON Remote Control System ICON Component Servicing Secure shift actuator harness with tie strap, Observe and note all wire routings before disas- P/N 317893. sembling. 1. Shift harness tie strap 007872 Route all ESM harnesses as shown and secure to shift actuator with tie straps, P/N 907833.
  • Page 211 Evinrude ICON Remote Control System ICON Component Servicing Use Ball Socket Remover tool, P/N 342226, to Do not install clamp until wiring harnesses have remove throttle link from actuator arm. been secured. 1. Ball Socket Remover tool, P/N 342226 1. Long screws 008034 007302 2.

  • Page 212: Icon System Settings

    Evinrude ICON Remote Control System ICON System Settings ICON System Settings Place clamp over actuator motor. Install and tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Set Engine Identity (Instance) In a multi-engine application, the transom position of the outboard must be identified on the network.

  • Page 213: Calibrate Actuator Stroke

    Evinrude ICON Remote Control System ICON System Settings IMPORTANT: If the ICON tab is not available, Identity Numbers make sure the engine management software has been updated to the correct revision. Number of Outboards IMPORTANT: The Engine Identity Plug over- rides any previous EMM instance setting.
  • Page 214 Evinrude ICON Remote Control System ICON System Settings • • When the link and pins are exactly aligned, With the shift link disconnected, rotate the pro- install the link and click the Save button. The peller and manually shift the outboard into for- actuator will move to the neutral position.
  • Page 215 Evinrude ICON Remote Control System ICON System Settings • Install the shift link and secure with retainer clips With the shift link disconnected, rotate the pro- peller and manually shift the outboard into and washers. reverse gear with the shift lever. 008509 1.

  • Page 216: Icon System Faults

    Evinrude ICON Remote Control System ICON System Faults ICON System Faults The ICON System exhibits two types of faults: Recoverable and Non-recoverable. ICON System faults are visually indicated by the remote control, the switch panels, the gateway, and the 6-port hub LED’s. ICON System faults are also displayed on the Faults page of Evinrude Diagnostics and on the NMEA 2000 gauges.

  • Page 217: Non-Recoverable Faults

    Evinrude ICON Remote Control System ICON System Faults Non-recoverable Faults When a non-recoverable fault occurs, the ICON System: • Flashes all gear position LED’s of the affected engine five times per second • Sends a fault message to the outboard EMM, which in turn sends a “Check Engine” message to the NMEA 2000 gauges •...

  • Page 218: Icon System Fault Code Chart

    Evinrude ICON Remote Control System ICON System Fault Code Chart ICON System Fault Code Chart Use this chart and Evinrude Diagnostics software to identify ICON Remote Control System fault codes. Use the ICON System Troubleshooting Flowcharts to resolve a problem on an ICON System. Refer to the Evinrude ICON System Troubleshooting Guide.
  • Page 219 Evinrude ICON Remote Control System ICON System Fault Code Chart Fault Code Description LED Indicators Possible Causes and Flowchart Reference None Trim and tilt switch panel harness Trim Switch Module Com- is damaged or not connected to munication Fault the remote control. Remote control cannot com- Trim and tilt switch panel harness municate with trim and tilt...
  • Page 220 Evinrude ICON Remote Control System ICON System Fault Code Chart Fault Code Description LED Indicators Possible Causes and Flowchart Reference FORWARD or REVERSE LED Throttle link arm from ICON add- Throttle Actuator Motion flashes (depending on gear on kit is not assembled to the out- Fault position when fault occurred).
  • Page 221 Powerhead Powerhead Table of Contents Service Charts ............. . . 222 Taper Pin Tool .

  • Page 222: Service Charts

    Powerhead Service Charts Service Charts IMPORTANT: Apply Pipe Thread Seal- 60-84 In. lbs. ant to all pipe fitting threads. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 30-42 In. lbs. (3.5-5 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (14-16 N·m) A, X P, X 84-108 In.
  • Page 223 Powerhead Service Charts 96-120 In. lbs. (11-13.5 N·m) 60-65 Ft. lbs. (81-88 N·m) 96-120 In. lbs. (11-13.5 N·m) 004108R A Triple-Guard Grease D Moly Lube G Needle Bearing Grease B Gasket Sealing Compound E Red Ultra Lock M RTV Sealant C Adhesive 847 F Blue Nut Lock X See Service Manual Procedure...

  • Page 224: Taper Pin Tool

    Powerhead Taper Pin Tool Taper Pin Tool NOT to Scale 0.5 in. (13 mm) Hole for Storage 0.3125 in. (8 mm) 11.5 in. (292 mm) 0.5 in. 9.5 in. (241 mm) (13 mm) 0.625 in. 5 in. (127 mm) (16 mm) 0.375 in.

  • Page 225: Compression Testing

    Powerhead Compression Testing Compression Testing Powerhead Removal Start and run outboard until it achieves operating WARNING temperature, then shut OFF. Protect against hazardous fuel spray. Before Disconnect crankshaft position sensor (CPS) con- starting any fuel system service, carefully nector. Remove all spark plugs. relieve fuel system pressure.
  • Page 226 Powerhead Powerhead Removal Remove water hoses and exhaust back pressure Remove trim/tilt harness from clamp. hose from adapter. 1. Trim harness 005041 2. Clamp Port Side 008443 1. Cooling hose (to exhaust plenum) 2. Cooling hose (from vapor separator) Remove pin and washer from shift rod lever to release the lower shift rod.

  • Page 227: Powerhead Disassembly

    Powerhead Powerhead Disassembly Powerhead Disassembly Remove all powerhead retaining screws and nuts. 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 228: Throttle Linkage Removal

    Powerhead Powerhead Disassembly IMPORTANT: Throttle Linkage Removal Do not use a tapered punch or any other tool that could jam in or damage the taper Remove throttle cam and throttle lever. bore when removing the pin. 1. Throttle cam screw 006866 1.

  • Page 229: Cylinder Head Removal

    Powerhead Powerhead Disassembly IMPORTANT: DO NOT remove the four inside Carefully remove the crankcase from the cylinder retaining screws on the lower crankcase head. block to avoid damaging the crankshaft seal rings. 004137 004146 Cylinder Head Removal Loosen in stages, and remove the main bearing screws and nuts.

  • Page 230: Connecting Rods And Pistons

    Powerhead Powerhead Disassembly Connecting Rods and Pistons Use one hand to support the piston, and remove the rod cap screws with your other hand. Remove each piston and rod assembly. NOTICE Reattach each rod cap to its rod as soon as the piston is removed.

  • Page 231: Crankshaft Removal

    Powerhead Powerhead Disassembly Use a Piston Pin Retainer Tool on p. 224, or Carefully lift crankshaft straight up and remove equivalent to remove wrist pin retaining rings. Dis- from crankcase. card retaining rings. 31809 000689 Use a punch to remove the upper crankshaft seal. Use Wrist Pin Pressing Tool, P/N 396747, to Remove and discard two crankcase head O-rings.
  • Page 232 Powerhead Powerhead Disassembly Use a punch to remove the lower crankshaft seal. Remove the lower main bearing only if it needs to Remove and discard two crankcase head O-rings. be replaced. Use external retaining ring pliers to remove the lower main bearing retaining ring. 1.

  • Page 233: Cylinder Block Cleaning

    Powerhead Cylinder Block Cleaning Cylinder Block Cleaning Remove and inspect crankcase seal rings. Iden- tify each ring for installation in original location. WARNING To avoid personal injury, wear eye protection and rubber gloves when using Gel Seal and Gasket Remover. IMPORTANT: Before inspecting or assembling powerhead, all internal components must be com-...

  • Page 234: Powerhead Inspection

    Powerhead Powerhead Inspection Use Gel Seal and Gasket Remover to remove all Powerhead Inspection traces of gaskets, adhesives, and Gel-Seal II™ sealant from the cylinder block and crankcase. For dimensions, refer to Service Specifications 90° 3.3 L Models on p. 12. IMPORTANT: Before any inspection process can begin, all internal components must be com-...
  • Page 235 Powerhead Powerhead Inspection Crankshaft condition. Be sure the gauge is perfectly square in the bore when measuring. Measure the diameter of each crankpin and main bearing journal. The lower main bearing journal would only be measured if the bearing was removed for another reason.
  • Page 236 Powerhead Powerhead Inspection Pistons Bearings Visually inspect pistons for signs of abnormal Inspect center main bearing and split sleeves for wear, scuffing, cracks, or burning. excess wear, nicks, or scratches. Replace if nec- essary. Piston Rings For new ring sets, place each ring separately in its respective bore.

  • Page 237: Powerhead Assembly

    Powerhead Powerhead Assembly Powerhead Assembly If the installer sticks on the sleeve after installa- tion, thread Slide Hammer, P/N 391008, into installer and pull it off. IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant.
  • Page 238 Powerhead Powerhead Assembly Lubricate the center main bearings and split Lightly coat two new O-rings with Gasket Sealing sleeves with outboard lubricant and install them in Compound and install on lower crankcase head. their original positions. The split sleeve ring Keep sealer away from oil passage.

  • Page 239: Pistons And Connecting Rods

    Powerhead Powerhead Assembly Lightly coat the outside edge of a new upper seal bowl on the dome of the piston will be located with Gasket Sealing Compound. Use the flat end toward the flywheel and opposite the exhaust port. of Seal Installation Tool, P/N 325453, to install seal flush in upper crankcase head with the lip facing down.
  • Page 240 Powerhead Powerhead Assembly Install wrist pin through piston and connecting rod. Installing Pistons When all pistons and connecting rods are assem- bled, install piston ring sets. Be sure rings are installed in the cylinder used to test ring end gap. Refer to Powerhead Inspection on p.

  • Page 241: Cylinder Head Installation

    Powerhead Powerhead Assembly necting rod through cylinder block to avoid Following sequence stamped on cylinder head, scratching cylinder wall. tighten all screws in stages to a torque of 17 to 19 ft. lbs. (23 to 26 N·m). 49435 004133 Cylinder Head Installation Crankshaft and Connecting Lightly coat both sides of a new cylinder head Rods...
  • Page 242 Powerhead Powerhead Assembly • Install rod cap screws finger tight (NO MORE than Tap the crankshaft upward with a rawhide mallet to seat crankshaft and lower crankcase head. 6 in. lbs. (1 N·m) maximum). • Loosely secure upper and lower crankcase heads with two screws.
  • Page 243 Powerhead Powerhead Assembly est setting (two lines showing). Rotate adjustment • Tighten forcing screw until jaws contact con- knob 180° to lock the stop in position. necting rod. • Slide frame down until adjustment stop contacts the rod cap. The groove lines on the jaws must be centered on the rod/crankpin diameter.

  • Page 244: Crankcase Assembly

    Powerhead Powerhead Assembly IMPORTANT: If a new screw is used, it must be Lightly coat the upper and lower crankcase head installed as above. Then, it must be removed, re- flange surfaces with a thin layer of Gel-Seal II. lubricated, and installed again. Loosen forcing screw and remove the frame.

  • Page 245: Shift Linkage Installation

    Powerhead Powerhead Assembly Start in the center and work outward in a spiral Apply Nut Lock to the upper and lower crankcase pattern. head screws. Install and tighten screws to a torque of 96 to 120 in. lbs. (11 to 13.5 N·m). 004141 004142 Apply Permatex No.

  • Page 246: Throttle Linkage Installation

    Powerhead Powerhead Assembly Install shift rod lever and tighten retaining screw and tighten screw to a torque of 120 to 144 in. lbs. 60 to 84 in. lbs. (7 to 9.5 N·m). (13.5 to 16.5 N·m). Apply Triple-Guard grease to shoulder of shift arm screw and Nut Lock to threads.

  • Page 247: Powerhead Installation

    Powerhead Powerhead Installation Powerhead Installation Install stator. Refer to Stator Service on p. 112. Install electrical harness and EMM. Refer to EMM Apply Permatex No. 2 to both sides of a new base Servicing on p. 74. gasket around the exhaust port only. Install gasket on adapter.
  • Page 248 Powerhead Powerhead Installation Tighten the 3/8 in. diameter powerhead screws to Install two front and one rear powerhead nuts. a torque of 20 to 22 ft. lbs. (27 to 30 N·m) in the Tighten nuts 144 to 168 in. lbs. (16.5 to 19 N·m). sequence shown.
  • Page 249 Powerhead Powerhead Installation Install water hoses and exhaust back pressure Route power trim harness through clamp and con- hose. nect to engine harness. Port side 008443 1. Trim harness 006992 1. Cooling hose (from exhaust plenum) 2. Clamp 2. Cooling hose (from vapor separator) 3.

  • Page 250: Pre-Service Adjustments

    Powerhead Powerhead Installation Pre-Service Adjustments NOTICE After installing a new or rebuilt powerhead, perform the following procedures before returning outboard to service: • Adjust timing pointer. • Index all spark plugs. Refer to Spark Plug Indexing on p. 41. • Use Evinrude Diagnostics software to start pow- erhead break-in oiling.

  • Page 251: Powerhead Views

    Powerhead Powerhead Views Powerhead Views Port Hose Routings – 3.3 L models 007153...

  • Page 252: Starboard Hose Routings - 3.3 L Models

    Powerhead Powerhead Views Starboard Hose Routings – 3.3 L models 007154...

  • Page 253: Port Hose Routings - 3.4 L Models

    Powerhead Powerhead Views Port Hose Routings – 3.4 L models 008503...

  • Page 254: Starboard Hose Routings - 3.4 L Models

    Powerhead Powerhead Views Starboard Hose Routings – 3.4 L models 008502...

  • Page 255: Port - 3.3 L Models

    Powerhead Powerhead Views Port – 3.3 L models 008448...

  • Page 256: Starboard - 3.3 L Models

    Powerhead Powerhead Views Starboard – 3.3 L models 008449...

  • Page 257: Port - 3.4 L Models

    Powerhead Powerhead Views Port – 3.4 L models 008441...

  • Page 258: Starboard - 3.4 L Models

    Powerhead Powerhead Views Starboard – 3.4 L models 008442...

  • Page 259: Front - 3.3 L Models

    Powerhead Powerhead Views Front – 3.3 L models 008450...

  • Page 260: Front - 3.4 L Models

    Powerhead Powerhead Views Front – 3.4 L models 008439...

  • Page 261: Rear - 3.3 L Models

    Powerhead Powerhead Views Rear – 3.3 L models 007142...

  • Page 262: Rear - 3.4 L Models

    Powerhead Powerhead Views Rear – 3.4 L models 008440...

  • Page 263: Top

    Powerhead Powerhead Views 008438...

  • Page 264: Starboard - Icon Models

    Powerhead Powerhead Views Starboard – ICON models 008504...
  • Page 265 Midsection Midsection Table of Contents Service Charts ............. . . 266 Exhaust Housing –...

  • Page 266: Service Charts

    Midsection Service Charts Service Charts Exhaust Housing – 3.3 L models 22-24 Ft. lbs. (30-33 N·m) 60-84 In. lbs. P, X 120-144 In. lbs. (7-9.5 N·m) (14-16 N·m) 60-84 In. lbs. 144-168 In. lbs. (7-9.5 N·m) (16-19 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In.

  • Page 267: Exhaust Housing - 3.4 L Models

    Midsection Service Charts Exhaust Housing – 3.4 L models 22-24 Ft. lbs. (30-33 N·m) P, X 120-144 In. lbs. (14-16 N·m) 144-168 In. lbs. (16-19 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In. lbs. (7-9.5 N·m) 40-42 Ft. lbs. 144-168 In. lbs. (54-57 N·m) (16-19 N·m) 60-84 In.

  • Page 268: Stern Bracket

    Midsection Service Charts Stern Bracket IMPORTANT: Use Triple-Guard grease on all pivot points. 60-84 In. lbs. (7-9.5 N·m) 110-130 Ft. lbs. (149-176 N·m) 40-50 In. lbs. (4.5-5.5 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 28-30 Ft. lbs. (38-41 N·m) 45-50 Ft. lbs. (61-68 N·m) 170-190 In.

  • Page 269: Muffler

    Midsection Service Charts Muffler 004117R...

  • Page 270: Tilt Tube

    Midsection Tilt Tube Tilt Tube Remove the nut from the starboard side. The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist. Pull the locking tabs on the tilt limit cam loose from 30747 the collar.

  • Page 271: Installation

    Midsection Tilt Tube Thread Slide Hammer, P/N 432128, into the Make sure the lock tab is in correct position. adapter until at least 2 in. (51 mm) of thread are engaged. 1. Lock tab 30742 Install the starboard locknut. 30744 Tighten starboard tilt tube nut to a torque of 45 to Pull tilt tube from stern bracket with the slide ham- 50 ft.

  • Page 272: Exhaust Housing Service

    Midsection Exhaust Housing Service Exhaust Housing Service Remove two upper mount screws. Exhaust Housing Removal Before removing the exhaust housing: • Remove the gearcase. Refer to Gearcase Removal and Installation on p. 45. • Remove the powerhead. Refer to Powerhead Removal on p.

  • Page 273: Exhaust Housing Installation

    Midsection Exhaust Housing Service If replacement is necessary, lubricate mount with Exhaust Housing Installation soapy water and carefully pry at both ends to Bring the exhaust housing into position with the remove. stern bracket. Install four new lower mount screws with lock- patch.

  • Page 274: Exhaust Housing Disassembly - 3.3 L Models

    Midsection Exhaust Housing Service Attach the ground lead and lockwasher to the star- Loosen and remove the upper mount plate screws board side of the steering arm. and remove the mount plate. 32588 32586 Lubricate the upper mount with soapy water and Install gearcase.

  • Page 275: Exhaust Housing Disassembly - 3.4 L Models

    Midsection Exhaust Housing Service Loosen retaining screws and remove water plate Loosen and remove the upper mount plate screws from the adapter. and remove the mount plate. 1. Cover 13641 32588 2. Water plate Lubricate the upper mount with soapy water and Exhaust Housing Disassembly –...

  • Page 276: Exhaust Housing Assembly - 3.3 L Models

    Midsection Exhaust Housing Service Before checking the exhaust housing for distor- and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 tion, thoroughly clean the top and bottom mating N·m). surfaces and remove all sealer and corrosion. Check the exhaust housing for distortion.
  • Page 277 Midsection Exhaust Housing Service Coat the outside diameter of a new water tube Apply Adhesive 847 to the bottom flange of the grommet with Adhesive 847. Install grommet in inner exhaust housing. Install a new seal. Apply the inner exhaust housing. Install the water tube. Triple-Guard grease to outer seal surface.
  • Page 278 Midsection Exhaust Housing Service Place the adapter/inner exhaust housing into the Install four mount plate screws and washers and exhaust housing. Align the water tube. tighten to a torque of 22 to 24 ft. lbs. (30 to 33 N·m). Loosely install the small retaining screws, nuts, and washers.

  • Page 279: Exhaust Housing Assembly - 3.4 L Models

    Midsection Exhaust Housing Service Exhaust Housing Assembly – Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing. 3.4 L models Apply Adhesive 847 to the bottom flange of the inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.
  • Page 280 Midsection Exhaust Housing Service radius must face aft with the “TOP” mark facing Tighten the small adapter to exhaust housing screws and nuts to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Apply Locquic Primer and Nut Lock to the upper mount plate screws and install the plate and screws loosely.

  • Page 281: Stern Bracket

    Midsection Stern Bracket Stern Bracket Remove the steering shaft and thrust washer. It may be necessary to tap the steering shaft out using a wood dowel and mallet. Stern Bracket Disassembly Before servicing the stern bracket: • Remove gearcase. Refer Gearcase Removal and Installation on p.
  • Page 282 Midsection Stern Bracket Remove the anode. Remove the tilt limit switch and retainer from the swivel bracket. 1. Anode 30762 Remove the swivel bracket. Inspect and, if neces- sary, replace the tilt tube bushings. 1. Tilt limit switch 30758 2. Retainer Disconnect the trail lock spring and remove it from the swivel bracket.

  • Page 283: Stern Bracket Assembly

    Midsection Stern Bracket Remove the two trim rod rollers from the swivel bushing to a torque of 28 to 30 ft. lbs. (38 to 41 bracket. Discard the screws. New screws MUST N·m). be used when installing the trim rod rollers. 30752 1.
  • Page 284 Midsection Stern Bracket Install the trail lock and bushings in the swivel Install the tilt limit switch and retainer on the swivel bracket. Apply Ultra Lock (red) to the threads of bracket. Tighten screws to a torque of 40 to 50 in. the screws.
  • Page 285 Midsection Stern Bracket • Install the steering shaft keeper. Apply Locquic Coat the bushings and seal lips with Triple- Guard grease. Primer and Nut Lock to the splines of the steering shaft and lower mount bracket. 010312 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.

  • Page 286: Exhaust Relief Muffler Assembly

    Midsection Exhaust Relief Muffler Assembly Exhaust Relief Muffler housing assembly with a hose. This hose is not connected to the muffler assembly. Assembly The exhaust relief muffler is located at the rear of the adapter housing and concealed by the lower motor covers.
  • Page 287 Trim and Tilt Trim and Tilt Table of Contents Service Charts ............. . . 288 System Description .

  • Page 288: Service Charts

    Trim and Tilt Service Charts Service Charts 25 in. V4 Models and All V6 Models with Three Piston System) 35 to 52 In. lbs. (4 to 6 N·m) 12 to 24 In. lbs. (1.4 to 2.7 N·m) 60 to 84 In. lbs. (7 to 10 N·m) 58 to 87 Ft.

  • Page 289: System Description

    Trim and Tilt System Description System Description Trailering Bracket and Tilt Support Use the trailering bracket to support the outboard The power trim/tilt hydraulic system is completely when trailering in the tilted position. This bracket contained between the outboard's stern brackets. protects the hydraulic system from damage.

  • Page 290: Modes Of Operation

    Trim and Tilt Modes Of Operation Modes Of Operation (Three Piston System) The trim/tilt hydraulic assembly achieves trim and tilt movement through the following modes of operation. Trim-OUT / Tilt-UP Mode When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.

  • Page 291: Tilt-Down / Trim-In Mode

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

  • Page 292: Impact Relief

    Trim and Tilt Modes Of Operation Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is com- pressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact.

  • Page 293: Shallow Water Drive Tilt Relief

    Trim and Tilt Modes Of Operation Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.

  • Page 294: Manual Release - Up

    Trim and Tilt Modes Of Operation Manual Release – UP Tilting Outboard UP WARNING The outboard can be positioned manually by first opening (loosening) the manual release valve. Do not attempt to hold the outboard up by closing the manual release valve. The out- Open the manual release valve (turn it slowly board must be held manually, and lowered to counterclockwise) with a screwdriver, about 3 1/2...

  • Page 295: Manual Release - Down

    Trim and Tilt Modes Of Operation Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylin- ders (in the trim range), and past the manual release valve.

  • Page 296: Routine Inspections

    Trim and Tilt Routine Inspections Routine Inspections Troubleshooting General If the power trim/tilt system has malfunctioned and the cause has not been determined, the Symp- Check for external signs of fluid leakage. Correct toms Chart on p. 297 should help locate the causes as necessary.
  • Page 297 Trim and Tilt Troubleshooting retest. Refer to Tilt Limit Switch Adjustment on STEP 4 p. 33. Remove trim motor and check condition of drive coupling. If coupling is damaged, replace it. Symptoms Chart STEP 5 If any of these symptoms describe the unit, follow Temporarily install a known good pump manifold the indicated Service Procedures, in the order assembly and retest.
  • Page 298 Trim and Tilt Troubleshooting • bypass the reservoir cap. These steps will relieve The “B” adapter, P/N 336659, checks operation of the DOWN circuit. the pressure in the unit. 1. A Adapter 27340 1. Manual release valve 41739 2. B Adapter 2.
  • Page 299 Trim and Tilt Troubleshooting again, and add fluid if necessary. Remember that extended, run the unit down momentarily to all rods must be completely extended to check reduce pressure. Check fluid level again, and add fluid level. fluid if necessary. Remember that all rods must be completely extended to check fluid level.

  • Page 300: 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 301: Trim And Tilt Motor No Load Test

    Trim and Tilt Electrical Circuit Tests • applied to the green lead, and negative (–) is Motor binding • applied to the blue lead. Cylinder binding • Valves sticking Blue lead (+) Green lead (+) Green lead (-) Blue lead (-) C.

  • Page 302: Trim Sender Test

    Trim and Tilt Electrical Circuit Tests • • If results agree, refer to Trim Sender Test on If results are different, replace trim sender. p. 302. DRC6246A Trim Sender Test IMPORTANT: To avoid immediate meter dam- age, never apply a multimeter to an electrical cir- cuit where voltage is present.

  • Page 303: Trim And Tilt Replacement

    Trim and Tilt Trim and Tilt Replacement Trim and Tilt Replace- Separate the trim/tilt unit wires in the braided tube to permit removal through the hole in the stern ment bracket. Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector.
  • Page 304 Trim and Tilt Trim and Tilt Replacement Use a punch to remove the upper pin. Installation Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. Install external snap rings on lower pin with sharp edge of ring facing out.

  • Page 305: Trim And Tilt Servicing

    Trim and Tilt Trim and Tilt Servicing Trim and Tilt Servicing Place trim/tilt wires in braided tube and install through hole in the stern bracket. Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down momentarily and loosen the reservoir cap one full turn.
  • Page 306 Trim and Tilt Trim and Tilt Servicing Inspect O-ring and two plastic split rings on the Remove the three Pozidrive screws securing the manual release valve for nicks and cuts. Inspect reservoir to cylinder body. Remove reservoir. tip of valve for damage. The two plastic split rings are not available separately.
  • Page 307 Trim and Tilt Trim and Tilt Servicing Remove the four screws securing motor to pump solvent and inspect it for tears, clogging, or other manifold assembly. damage. 41760 1. Coupler 41763 2. Filter screen Remove the wire shield from the pump manifold. Remove the three Allen head screws securing the Remove the motor and inspect the motor O-ring pump manifold assembly to cylinder body.

  • Page 308: Tilt Piston Removal

    Trim and Tilt Trim and Tilt Servicing Tilt Piston Removal Inspect the bore of the tilt cylinder for excessive scoring. If the bore of the tilt cylinder is scored or Use Tilt Cylinder End Cap Remover/Installer, damaged, the hydraulic assembly must be P/N 326485, or Universal Spanner Wrench, replaced.

  • Page 309: Tilt Piston Identification

    Trim and Tilt Trim and Tilt Servicing Remove the washer. Slide the tilt piston off the Three of the four springs are one length, and the rod. Be careful not to lose the springs, plungers, fourth spring is shorter. On assembly, the shorter or small check valves in the piston assembly.

  • Page 310: Tilt Rod Assembly

    Trim and Tilt Trim and Tilt Servicing Use a screwdriver to carefully pry the scraper out the lip facing out. Lubricate and install a new of the end cap. Discard the scraper. Remove and O-ring on the outside of the end cap. discard the large outer O-ring.
  • Page 311 Trim and Tilt Trim and Tilt Servicing remove the seal protector. Slide the end cap down washer over the threads and install the nut. the tilt rod. Torque to 58 to 87 ft. lbs. (79 to 118 N·m). 41783 To ensure that the tilt piston has been properly assembled and the impact relief balls are properly 1.

  • Page 312: Trim Rod Removal

    Trim and Tilt Trim and Tilt Servicing Trim Rod Removal Drain the remaining fluid from the cylinders. Inspect both bores of the trim cylinders for exces- Unscrew trim cylinder end caps using Trim Cylin- sive scoring. If one or both trim bores are scored der End Cap Remover/Installer, P/N 436710, or or damaged, the hydraulic assembly must be Universal Spanner Wrench, P/N 912084, and a...

  • Page 313: Trim Rod Assembly

    Trim and Tilt Trim and Tilt Servicing Remove the rod from the vise. Use a small screw- facing out. Lubricate and install a new O-ring on driver to carefully pry the scraper out of the end the outside of the end cap. cap.

  • Page 314: Manifold And Reservoir Installation

    Trim and Tilt Trim and Tilt Servicing Apply Ultra Lock (red) to the threads of the thrust Attach the valve pump assembly to the cylinder pads. Install thrust pads and tighten to a torque of body with three Pozidriv screws. Torque screws to 84 to 108 in.

  • Page 315: Trim Rod Installation

    Trim and Tilt Trim and Tilt Servicing 6 mm Allen wrench to install the plug. Tighten the Trim Rod Installation plug securely. Lubricate the trim rod pistons. Place the rod assemblies into the body. Push them in until the end caps just clear the tops of the cylinders. Fill the cylinders with Power Trim/Tilt &...

  • Page 316: Tilt Rod Installation

    Trim and Tilt Trim and Tilt Servicing Tilt Rod Installation Motor Installation Lubricate the tilt rod piston. Slide the end cap all Position the pump manifold so the pump mounting the way up on the rod assembly. Place the piston surface is level.
  • Page 317 Trim and Tilt Trim and Tilt Servicing Lubricate and place a new O-ring on the motor. valve in until it seats. Cycle the unit up and down Make sure the cable is on the transom side of the several times to purge air. unit;...
  • Page 318 Trim and Tilt Trim and Tilt Servicing Check the tilt rod bushings. Replace them if they are worn excessively. 41888 Check the bushings on the bottom of the manifold body. Replace them if they are worn excessively. 41878 Check system operation in both trim and tilt range.
  • Page 319 Safety Safety Table of Contents Marine Products and The Safety Of People Who Use Them ..... . . S–323 Outboard Shift Systems and Safety ........... S–324 Outboard Speed Control System and Safety .
  • Page 320 S–322...

  • Page 321: Marine Products And The Safety Of People Who Use Them

    Safety Marine Products and The Safety Of People Who Use Them Marine Products and The Safety Of Peo- ple 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 fol- low common shop safety practices.

  • Page 322: Outboard Shift Systems And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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.

  • Page 323: Outboard Speed Control System And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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 324: Outboard Steering Control System And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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: •...
  • Page 325 Safety Marine Products and The Safety Of People Who Use Them 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 •...

  • Page 326: Outboard Fuel, Electrical System, And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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.
  • Page 327 Safety Marine Products and The Safety Of People Who Use Them 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 •...
  • Page 328 Safety Marine Products and The Safety Of People Who Use Them 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 329: Outboard Mounting System And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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...

  • Page 330: If Weakened, Parts Could Fail Later On The Water, When Not Expected

    Safety Marine Products and The Safety Of People Who Use Them If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only When rigging or fixing any boat, if transom looks weak, tell the owner.

  • Page 331: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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. •...

  • Page 332: Outboard Emergency Stop System And Safety

    Safety Marine Products and The Safety Of People Who Use Them 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? •...
  • Page 333 Safety Marine Products and The Safety Of People Who Use Them 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.

  • Page 334: Summary

    Safety Marine Products and The Safety Of People Who Use Them Summary 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 “ ”...

  • Page 335: Marine Products And The Safety Of People Who Fix Them

    Safety Marine Products and the Safety of People Who Fix Them 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.
  • Page 336 Safety Marine Products and the Safety of People Who Fix Them 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.
  • Page 337 Safety Marine Products and the Safety of People Who Fix Them 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.
  • Page 338 Safety Marine Products and the Safety of People Who Fix Them 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.

  • Page 339: Handling Lead/Acid Batteries

    Safety Marine Products and the Safety of People Who Fix Them 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.

  • Page 340: Gasoline - Handle With Care

    Safety Marine Products and the Safety of People Who Fix Them 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.

  • Page 341: Hazardous Products

    Safety Marine Products and the Safety of People Who Fix Them 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 •...

  • Page 342: Safety Awareness Test

    Safety Marine Products and the Safety of People Who Fix Them 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?
  • Page 343 INDEX Index Bearing Connecting Rod 242 Abbreviations 6 Crankshaft 237, 238 Accessories Break-In I-Command Water Pressure Transducer EMM Programming 174, 250 Kit, P/N 765353 26 Oiling 174 XD100 Outboard Oil Decal, P/N 352369 Procedure 70 Adapter Housing 192 Service 272 Cable, Hose, and Wire Routing 21 Adjustments Capacitor Test 87...
  • Page 344 INDEX Crankcase Dual-Outboard Assembly 244 Alignment 32 Disassembly 228 I-Command Settings 25 Crankshaft Assembly 237 Bearings 236 Electrical Circuits Disassembly 231 EMM Pin Locations 93 Inspection 235 Fuse 96 Installation 241 Ground Circuits 95 Crankshaft Position Sensor Key Switch 103 Description 63 Start Circuit 102 Operation Test 85...
  • Page 345 INDEX Engine Temperature Sensor Vapor Separator 139, 149 Description 61 Fuse 96 Resistance Test 97 Exhaust Housing Assembly 276, 279 Gauges Cleaning and Inspection 275 Tachometer 34 Disassembly 274, 275 Trim Gauge Test 301 Installation 273 Gearcase Removal 272 Installation 46 Exhaust Pressure Fitting 43 Lubricant 39 Exterior Finish Protection 45...
  • Page 346 INDEX ICON System Settings Midsection Calibrate Actuator Stroke 213 Stern Bracket Servicing 281 Set Engine Identity (Instance) 212 Tilt Tube Servicing 270 Shift Actuator Stroke 213 Models Throttle Actuator Stroke 213 Included Models 11 Idle Controller 64 Model Designation 10 Ignition Serial Number Location 10 Electrical Circuits 92...
  • Page 347 INDEX Oil Pressure Sensor 62 Rigging Oil Recirculation 166, 171 Outboard 20 Oil Supply and Distribution 162 RPM Limit 62, 64 Oiling Rate 70 Priming 175 Servicing 183 S.A.F.E. Tests 178 Description 66 Oil Pressure 62 Temperature 59, 61 Packard Connector Servicing 129 Voltage 59 Piston Rings Sensors 96...
  • Page 348 INDEX Solenoid Test 104 Inspection 199 Voltage Drop Test 104 Temperature 13, 15 Start-In-Gear Protection 34, 106 Throttle Actuator Removal 210 Stator Throttle Linkage Resistance Test 98 Installation 246 Servicing 112 Lubrication 38 Voltage Output Test 99 Removal 228 Steering System Throttle Position Sensor Lubrication 38 Calibration 116...
  • Page 349 INDEX Lifting Fixture, P/N 396748 226, 247 Fluid 317 Oetiker Pincers, P/N 787145 29 Inspection 296 Piston Pin Retainer Pin Tool 224 Lubrication 40 Piston Stop Tool, P/N 342679 115 Modes of Operation 290 Plug/Holder, P/N 329661 181 Motor Installation 316 Primary Lock Tool, P/N 777077 126 Pressure Leakdown Test 297 Rod Cap Alignment Fixture, P/N 396749...
  • Page 350 INDEX Vapor Separator Description 139 Installation 149 Removal 149 Voltage Drop Test 104 Water Intake Screens 35 Inspection 35 Water Pressure Gauge 26 Water Pump Description 192 Water Supply Tube 192 Winterizing 48 Wiring Harness Connections 24 Wrist Pin Installation 239 Removal 231 I–352...
  • Page 351 Trouble Check Chart Outboard Will Not Start Trouble Check Chart Outboard Will Not Start Observation Possible Cause Procedure Outboard does not Battery switch not ON Check battery switch operation turn over Discharged battery Check battery, recharge or replace Battery cables and connectionsClean and tighten connections. Check for voltage drop in starter circuit.
  • Page 352 Trouble Check Chart Outboard Will Not Start Outboard Will Not Start Observation Possible Cause Procedure Outboard turns over Stop circuit grounded Check wiring and emergency stop switch. Check the safety lanyard is installed and stop circuit is not grounded. No Fuel Check for fuel in fuel tank Water in fuel Check fuel filter, sample fuel from fuel return man-...
  • Page 353 Trouble Check Chart Outboard Hard To Start Outboard Hard To Start Observation Possible Cause Procedure Outboard eventually Weak battery Check battery, recharge or replace starts, may or may Battery cables and connectionsClean and tighten connections, check voltage not run properly once drop on high amperage circuit started Starter or bendix/drive gears...
  • Page 354 Trouble Check Chart Outboard Will Not Shut Off Outboard Will Not Shut Off Observation Possible Cause Procedure Outboard starts and Key switch or wire harness Check key switch and ground to key switch, refer runs, normal perfor- ground to System Analysis and Electrical and Ignition mance while running Stop circuit wiring Check EMM LED indicators.
  • Page 355 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. Access EMM service codes and check System- Check warning Setup or rigging Incorrect propeller Refer to specifications, check recommended change WOT RPM;...
  • Page 356 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 May be erratic or Incorrect, fouled, or worn spark Replace spark plugs inconsistent plugs Water in fuel system Check water separator/fuel filter, sample fuel from fuel return manifold test port Contaminated or poor fuel...

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