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Evinrude Manuals
Outboard Motor
E-TEC E50DPLSCB
Service manual
Evinrude E-TEC E50DPLSCB Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Introduction
Safety Information
Units of Measurement
Abbreviations Used in this Manual
List of Abbreviations
Introduction
Engine Emissions Information
Manufacturer's Responsibility
Dealer's Responsibility
Owner's Responsibility
Epa Emission Regulations
Model Designation
Models Covered in this Manual
Identifying Model and Serial Numbers
Service Specifications
Standard Torque Specifications
Product Reference and Illustrations
Special Tools
Diagnostic Tools View
Special Tools
Universal Tools View
Electrical/Ignition Tools View
Special Tools
Fuel /Oil System Tools
Powerhead Tools
Gearcase Tools
Manual Starter Tools
Trim and Tilt Tools
Shop Aids View
Notes
Installation and Predelivery
Boat Rigging
Control Selection
Remote Controls
Battery Installation
Control Installation
Location and Preparation
Minimum 12 Volt Battery Recommendations
Battery Cable Requirements
Battery Switches and Multiple Batteries
Connections
Installation and Predelivery
Marine Style Battery Post Diagram
Battery Switch Location
Battery Switch Operation
Battery Switch Requirements
Typical Battery Functions
Battery and Switch Wiring Diagrams
One Outboard: Battery Disconnect Diagram
One Outboard: One Primary Starting Battery; One Secondary Battery Diagram
Wo Outboards: Two Starting Batteries for each Outboard Diagram
Two Outboards: One Primary Starting Battery for each Outboard Diagram
Fuel Hose
Fuel System Primer
Fuel System Requirements
Fuel Filters
Outboard Fuel System Recommendations
Portable Fuel Tanks
Cable and Hose Installation
Cable and Wire Harness Routing
Typical Large Splash Well Diagram
Typical Small Splash Well Diagram
Battery Cables
Protective Sleeve/Conduit
Clamp Identification Numbers View
Oetiker Clamp Servicing
Oetiker Stainless Steel Stepless Clamps Table
Clamp Installation
Clamp Removal
Control Cable Identification
Hull Preparation
Mounting Surface
Outboard Installation
Mounting Hardware
Transom Brackets and Jack Plates
Transom Clearances
Water Flow
Dual-Outboard Centerlines
Hull Centerline
Transom Height
Transom Measuring and Drilling
Transom Drilling Locations
Drilling and Hardware Diagrams
Lifting Fixtures
Lifting the Outboard
Mechanical Cables
Steering Systems
Drag Links
Manual Hydraulic Steering
Mounting Bolt Installation
Mounting Height
Outboard Mounting
Cable, Hose, and Wire Routing
Control Cable Adjustments
Outboard Rigging
Cable Retainer Clip Installation
Locked Retainer Clip View
Electrical Harness Connections
Seal View
Water Pressure Gauge
Water Pressure Hose Fitting View
Canbus Connections
Additives
Fuel and Oil Priming
Fuel Requirements
Minimum Octane
Engine Lubricant below 32°F (0°C)
Fuel System Priming
Oil Requirements
Vent Line Clamp
Oil Injection Rate
XD100 Outboard Oil Decal View
Break-In Oiling
Oil Supply Priming
Before Start-Up
Gearcase Lubricant
Oil Level
Trim and Tilt Fluid
Emergency Stop / Key Switch
Engine Monitoring System
Fuel System Checks
Remote Control Operation
Running Checks
Start-In-Gear Prevention
Tachometer Pulse Setting
Break-In
Idle Speed
Operating Temperature
Water Pump Overboard Indicator
Propeller Selection
Propeller Hardware Installation
Final Adjustments
Trim Sending Unit Adjustment
Dual Outboards, One Counter and One Standard Rotation
Dual Standard Rotation Outboards
Outboards with High Transom Heights
Trim Tab Adjustment
Alignment Adjustment
Confirm Alignment
Dual-Outboard Alignment
Measure Alignment
Maintenance
Inspection and Maintenance Schedule
Anti-Corrosion Protection
Exterior Finishes
Metallic Component Protection
Sacrificial Anodes
Testing Procedure – Continuity
Cooling System Maintenance
Flushing — Outboard Not Running
Flushing — Outboard Running
Additional Maintenance
Lubrication
Steering System Lubrication
Water Intake Screens
Swivel Bracket and Trailering Bracket
Throttle and Shift Linkage
Tilt Tube
Gearcase Lubricant Draining
Gearcase Lubricant Inspection
Propeller Shaft Lubrication
Gearcase Lubricant Filling
Trim and Tilt Lubrication
Battery and Battery Connections
Fuel and Oil Systems
Fuel Filter
Oil Filters and Oil Reservoir
Air Silencer
Hoses and Connections
Spark Plugs Indexing
Spark Plugs Removal
Fuel System Treatment
Internal Engine Treatment
Storage
Throttle Control Method
Additional Recommendations
Battery(S)
Gearcase Lubricant
Operational Checks
Outboard Mounting Bolts
Power Trim and Tilt
Pre-Season Service
Engine Dropped Overboard (in Salt Water)
Prolonged Submersion (Fresh or Salt Water)
Submerged Engines
Notes
Engine Cover Service
Latch Hook Installation
Lower Cover Removal
Lower Cover Service
Upper Cover Service
Lower Cover Installation
Engine Cover Service
Latch Handle Installation
Trim Switch Installation
Engine Maintenance Module (EMM)
EMM Connections
EMM Functions
Engine Maintenance Module (EMM) Description
LED Indicators
EMM Inputs and Outputs Diagram
12 V Circuit Sensor
55 V Circuit Sensor
EMM Temperature Sensor
Engine Management Module (Emm)
Internal Sensors
Air Temperature Sensor
Barometric Pressure Sensor
External Sensors
Engine Temperature Sensor
Low Oil Switch
Throttle Position Sensor
Crankshaft Position Sensor
Neutral Switch
Idle Controller
Internal EMM Functions
Neutral RPM Limiter
ROM Verification
Engine Running
Service Mode
System Self-Test
The Engine Monitoring System
SAFE Warning System
Shutdown Mode
Communication
Diagnostic Software Functions
Static Information
Dynamic Information
Hard Faults, Persistent Faults
Static Tests
Stored Service Codes (Faults)
Dynamic Test Screen View
Fuel Pump Test
Ignition Test
Oil Injector Test
Oil Control Settings
Powerhead Break-In
Set Oil Type
Tiller/Remote Programming
Idle Speed Control
Ignition Timing
TPS Calibration
Fuel Injector Servicing
Reports
EMM Transfer
Software Replacement
EMM Servicing
System Analysis
Diagnostic Procedures
Operational Inspections
Visual Inspections
Outboard Cranks, will Not Start
Outboard Runs, Low on Power, Misfires
Outboard will Not Crank, Starter Does Not Operate
Troubleshooting
Cylinder Drop Tests
Dynamic Tests
Fuel Control Adjustment
Inductive Amp Meter Test
System Analysis
EMM LED Indicators
Key on
Starting
Running
Ignition Output Tests
Ignition System Requirements
Stator Output Voltage Test
Wiring Inspection
Crankshaft Position Sensor (CPS) Test
System Voltage Test
Static Ignition Test
Running Ignition Tests
Capacitor Test
Control Signal Test
Ignition Coil Tests
Ignition Control Circuit Tests
Fuel Delivery Tests
Fuel Injector Static Test
Fuel Pump Static Test
Running Fuel System Tests
Exhaust Water Valve Dynamic Test
Exhaust Water Valve Static Test
Electrical and Ignition
Electrical and Ignition: Service Chart
Dash Connections, Instrument Harness
Electrical and Ignition
Instrument Harness Diagram (MWS)
Elecrtical Harness Connections
EMM J1-A Connector
Engine Harness to Stator Connector
EMM J1-B Connector
EMM J2 Connector
Additional Ground Tests
EMM Ground Tests
Fuse
Ground Circuits
Sensor Tests
Throttle Position Sensor (TPS) Test
Air Temperature Sensor (AT) Test
Stator Resistance Tests
Stator Tests
Stator Voltage Output Test
Stator Winding Resistance Specification
12V Charging Circuit Test
Battery Charging Graph
Charging System Tests
Variable Load Test Diagram
55 V Alternator Circuit Test
Electric Start Circuit
Start Circuit Diagram
Engine Wire Harness
Instrument Wire Harness
Solenoid Wiring
Start Circuit Operation
Electric Start Tests
Key Switch, START Position
Starter Solenoid Test
No Load Current Draw Test
Key Switch Test
Neutral Start Circuit Test
Remote Control Switch Tests
Emergency Stop Switch Test
Neutral Start Switch Test
Tilt/Trim Relay Test
Exhaust Water Valve Test
Gauge Self-Test Check
Systemcheck Circuit Tests
Check Engine Circuit Test
LOW OIL Circuit Test
NO OIL Circuit
Water Temp/ Hot Circuit Test
Flywheel and Stator Servicing
Flywheel Removal
Tachometer Circuit Tests
Flywheel Installation
Stator Service
Timing Adjustments
Timing Pointer
Calibration of TPS
Timing Verification
Electric Starter Servicing
Starter Disassembly
Starter Removal
Starter Cleaning and Inspection
Starter Assembly
Connector Servicing
DEUTSCH Connectors
Starter Installation
Terminal Removal
AMP Connectors
Crimping Terminals
Terminal Installation
Packard Connectors
Fuel System
Service Chart - Injectors, Vapor Separator, Fuel Pump
Service Chart - Reed Plate Assembly and Throttle Body
Fuel System Hose Routing
Fuel System Circuit Diagram
Fuel Filter Info
Fuel Lift Pump
Fuel System Components
Vapor Separator
Electrical Circuit
Fuel Circulation Pump
Fuel Reservoir
Fuel Supply
Fuel Flow Compensation
Fuel Injectors
Fuel Manifolds
Injector Fuel Supply
Fuel System Pressure Test
Fuel System Tests
Fuel Injector Pressure Test
Pressure Regulator Test
Vapor Separator Vent Check
Circulation Pump Resistance Test
Fuel Injector Resistance Test
Lift Pump Pressure Test
Lift Pump Vacuum Test
Anti-Siphon Valve Test
Lift Pump Diaphragm Test
Fuel Component Servicing
Relieving Fuel System Pressure
Fuel Filter Service
Fuel Lift Pump Service
Fuel Manifold Service
Vapor Separator Service
Fuel Injector Service
Crush Ring Replacement
Intake Manifold Service
Oiling System
Oiling System Service Chart
Oil Supply Diagrams
Oil Recirculation Diagram
Oiling System
Oiling System Circuit Diagram
Electrical Circuit (55 V)
Oil Injection Pump
Oil Tank Assembly
Oiling System Components
Cylinder and Crankcase
LOW OIL Warning
NO OIL Warning
Oil Control Settings Info
Oil Priming
Oil Recirculation System
Oiling Rates, Break-In Oiling
Oil Injection Pump Voltage Test
Oiling System Tests
Oil Injection Pump Circuit Resistance Test
Oil Injection Pump Function Test
LOW OIL Sending Unit Test
Oil Injection Fittings Flow Test
Oil Component Servicing
Oil Distribution Hoses
Oil Tank Assembly Installation
Oil Tank Assembly Removal
Notes
Cooling System
Cooling System: Hose Routing and Water Flow Diagrams
Cooling System Components
Exhaust Housing
Pressure Relief Valve
Water Pump and Intakes
Block Venting
Cooling System
Thermostat
Water Pressure Connection
Cooling System Operation
Cylinder Block / Cylinder Head Cooling
EMM and Vapor Separator Cooling
Engine Temperature Check
Pyrometer Method
Software Method
Idle Operating Temperature Troubleshooting (below Range)
Thermostat Inspection
Assembly
Disassembly
Inspection
Thermostat Servicing
Assembly
Disassembly
Inspection
Pressure Relief Valve Servicing
Notes
Powerhead
Powerhead Service Chart
Powerhead Removal
Powerhead Removal (Rope Start Models)
General
Powerhead Disassembly
Shift Linkage Removal
Throttle Linkage Removal
Crankcase Disassembly
Connecting Rods and Pistons
Cylinder Head Removal
Crankshaft Removal
Cylinder Block Cleaning
Crankshaft Check
Cylinder Bore Check
Cylinder Head Check
Powerhead Inspection
Bearings Check
Piston Rings Check
Pistons Check
Bearings
Crankshaft Assembly
Powerhead Assembly
Pistons and Connecting Rods
Installing Pistons
Cylinder Head Installation
Crankshaft and Connecting Rod Installation
Crankcase Assembly
Shift Linkage Installation
Throttle Linkage Installation
Final Powerhead Assembly
Powerhead Installation
Powerhead Mounting
Shift Linkage Adjustment
Port Short Block View
Powerhead Views
Starboard Short Block View
Port Dressed Powerhead View
Starboard Dressed Powerhead View
Port Rope Start Models View
Starboard Rope Start Models View
Front View
Rear View
Top View
Top View, Rope Start Models
Midsection
Midsection Service Chart - Stern Bracket, Power Tilt Models
Midsection Service Chart - Stern Bracket, Manual Tilt Models
Exhaust Housing Diagram
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Table of
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Table of Contents
Troubleshooting
Troubleshooting
107
Idle Operating Temperature Troubleshooting (Below Range)
197
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