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BRP EVINRUDE Johnson E115DPLAA Service Manual

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BRP US Inc.

Technical Publications

P.O. Box 597

Sturtevant, Wisconsin 53177 United States

www.evinrude.com or www.johnson.com

† AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II

are registered trademarks of Tyco International, Ltd.

† Amphenol is a registered trademark of The Amphenol Corporation.

† BEP is a registered trademark of Actuant Corporation.

† Champion is a registered trademark of Federal-Mogul Corporation.

† Deutsch is a registered trademark of The Deutsch Company.

† Dexron is a registered trademark of The General Motors Corporation.

† Fluke is a registered trademark of The Fluke Corporation

† GE is a registered trademark of The General Electric Company.

† GM is a registered trademark of The General Motors Corporation.

† Locquic and Loctite are registered trademarks of The Henkel Group.

† Lubriplate is a registered trademark of Fiske Brothers Refining Company.

† NMEA is a registered trademark of the National Marine Electronics Association.

† Oetiker is a registered trademark of Hans Oetiker AG Maschinen.

† Packard is a registered trademark of Delphi Automotive Systems.

† Permatex is a registered trademark of Permatex.

† STP is a registered trademark of STP Products Company.

† Snap-on is a registered trademark of Snap-on Technologies, Inc.

The following trademarks are the property of BRP US Inc. or its affiliates:

®

Evinrude

®

Johnson

®

®

Evinrude

E-TEC

FasTrak™

S.A.F.E.™

SystemCheck™

I-Command™

®

Evinrude

ICON™

®

®

Evinrude

/ Johnson

XD30™ Outboard Oil

®

®

Evinrude

/ Johnson

XD50™ Outboard Oil

®

®

Evinrude

/ Johnson

XD100™ Outboard Oil

Gel-Seal II™

Printed in the United States.

© 2012 BRP US Inc. All rights reserved.

TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

Twist Grip™

Nut Lock™

Screw Lock™

Ultra Lock™

Moly Lube™

®

Triple-Guard

Grease

DPL™ Lubricant

®

2+4

Fuel Conditioner

Carbon Guard™

HPF XR™ Gearcase Lubricant

HPF PRO™ Gearcase Lubricant

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Summary of Contents for BRP EVINRUDE Johnson E115DPLAA

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: Table Of Contents
ERVICE ANUAL ONTENTS 1 REFERENCE INFORMATION ..... 3 2 ROUTINE SERVICE ......17 3 ENGINE COVER SERVICE .
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 propeller can continue to turn even after the engine is off.
Page 6: Abbreviations Used In This Manual
REFERENCE INFORMATION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft.
Page 7: Emission-Related Installation Instructions
REFERENCE INFORMATION EMISSION-RELATED INSTALLATION INSTRUCTIONS EMISSION-RELATED Owner’s Responsibility The owner/operator is required to have outboard INSTALLATION maintenance performed to maintain emission lev- els within prescribed certification standards. INSTRUCTIONS The owner/operator is not to, and should not allow Failing to follow these instructions when anyone to, modify the outboard in any manner installing a certified engine in a vessel violates that would alter the horsepower or allow emis-...
Page 8: Model Designation
REFERENCE INFORMATION MODEL DESIGNATION MODEL DESIGNATION DESIGN FEATURES: B Blue Paint MODEL IDENTIFICATION C Counter Rotation The first two characters identify D Evinrude E-TEC Model Version: Electric Start w/Remote Steering AA A First major variant G Graphite Paint AB A Second major variant H High Output AF A...
Page 9: Models Covered In This Manual
REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on the following Evinrude E-TEC models: • 105.4 cubic inch (1.7 L) 60° V4, starting with serial number 5346547. • 158.2 cubic inch (2.6 L) 60° V6, starting with serial number 5347612. Model Shaft Gearcase...
Page 10: Service Specifications Aa Models
REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS SERVICE SPECIFICATIONS AA MODELS 115, 130 150, 175, 200 Full Throttle 5500–6000 RPM 4850–5850 RPM Operating Range 150 HP: (110.3 kw) @ 5350 RPM 115 HP: (84.6 kw) @ 5750 RPM Power 175 HP: (128.7 kw) @ 5350 RPM 130 HP: (95.6 kw) @ 5750 RPM 200 HP: (147.1 kw) @ 5350 RPM 115: 625 ±...
Page 11 REFERENCE INFORMATION SERVICE SPECIFICATIONS AA MODELS 115, 130 150, 175, 200 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Predeliv- Alternator ery and Installation Guide for multiple battery applications.
Page 12: Service Specifications Ab Models
REFERENCE INFORMATION SERVICE SPECIFICATIONS AB MODELS SERVICE SPECIFICATIONS AB MODELS Full Throttle 5500–6000 RPM Operating Range Power 115 HP: (84.6 kw) @ 5500 RPM Idle RPM in Neutral 115: 580 ± 50 Weight 115-20 in. (L): 375 lbs. (170 kg) (may vary depending 115-25 in.
Page 13 REFERENCE INFORMATION SERVICE SPECIFICATIONS AB MODELS Minimum Battery 675 CCA (845 MCA); or 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation. Refer to Installa- Alternator tion and Predelivery Guide for multiple battery applications.
Page 14: 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 15: Wire Size Table
REFERENCE INFORMATION WIRE SIZE TABLE WIRE SIZE TABLE This table provides closest equivalent size cross references between American and metric wire sizes. American Wire Gauge Metric Wire Size American Wire Gauge (AWG) is a standardized Metric wire size is also standardized. Metric wire wire gauge system used in North America to iden- size is determined by the number of strands of tify the diameter of round, electrically conducting...
Page 16: Technician's Notes
REFERENCE INFORMATION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
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 LIFTING THE OUTBOARD RIGGING OUTBOARD CONNECTIONS IMPORTANT: For complete outboard rigging WARNING and remote control installation information, refer to To avoid personal injury, make sure the lift- the Predelivery and Installation Guide included ing capacity of the hoist is at least twice with the service manual set.
Page 20: Cable, Hose, And Wire Routing
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable Retainer Clip Installation Cable, Hose, and Wire Routing When installing retainer clips on control arm link- CAUTION age pins, clips should be locked and must not be bent or deformed. To prevent accidental starting while servic- ing, disconnect the battery cables at the For proper installation, review the following steps: battery.
Page 21: Control Cable Installation
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Refer to the following diagram to ensure proper same path to the starboard side of the powerhead. positioning of rigging components in grommet. Secure all cables with clamps. 1. Fuel supply hose 000095c 2. Fuel supply hose--alternate location 3.
Page 22 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Shift Cable Installation and Adjustment Throttle Cable Installation and Adjustment Place the shift cable on the shift lever pin and With remote control lever in NEUTRAL, pull firmly install the washer and retainer clip. Refer to Cable on throttle cable casing to remove slack.
Page 23: Battery Cable Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Install trunnion cover and screw. Tighten screw to SystemCheck Harness a torque of 60 to 80 in. lbs. (7 to 9 N·m). Connections Remove flywheel/harness connector cover. 1. Trunnion cover and screw, throttle cable 004958 004954 Battery Cable Connections Install battery cables on starter solenoid and main...
Page 24: I-Command Network Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS I-Command Network Connections Route oil tank sending unit harness around the front to the port side. Secure all cables with tie If the outboard will be used with I-Command, or straps. 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-...
Page 25 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Use an I-Command Ignition and Trim Harness to Secure all cables with tie-straps. connect the outboard to the key switch and trim/tilt control. Seal unused SystemCheck connector with 6-Pin Connector Seal, P/N 586076. 1. Anchor points 005270 For an I-Command oil level display, an accessory CANbus oil level sender must be installed in the...
Page 26: Icon Network Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS ICON Network Connections • Tighten locking rings of buss connectors finger tight. Do NOT use locking rings to force connec- If the outboard is equipped for an Evinrude ICON tors together. control system, connect the outboard to the net- work as follows.
Page 27: Water Pressure Gauge
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Water Pressure Gauge To send water pressure data to the EMM, along with an I-Command display, install a water pres- To display engine water pressure, install a water sure transducer kit. pressure hose fitting in the cylinder block as •...
Page 28: Battery And Battery Connections
ROUTINE SERVICE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from CONNECTIONS accessories. Finish this connection with a hex nut. WARNING Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion.
Page 29: Oetiker Clamp Servicing
ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide corrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
Page 30: Clamp Installation
ROUTINE SERVICE OETIKER CLAMP SERVICING Clamp Installation Clamp Removal A constant stress should be applied to close the Method 1: Position Oetiker pincers across clamp ear clamps. This method ensures a positive stress ear and cut clamp. on the hose and does not result in excessive com- pression or expansion of the band material.
Page 31: Adjustments
ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS Place the outboard in normal operating position. Rotate the LOWER adjustment tab UP to reduce Tilt Limit Switch Adjustment the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement.
Page 32: Trim Sending Unit Adjustment
ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not show center position, tilt the outboard up and Tilt the outboard and engage the tilt support. adjust the sending unit by pivoting it up or down. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.
Page 33: Trim Tab Adjustment
ROUTINE SERVICE ADJUSTMENTS Trim Tab Adjustment Tighten the trim tab screw as follows: • 115 – 200 HP: 35 to 40 ft. lbs. (47 to 54 N·m). WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface.
Page 34: Dual-Outboard Alignment
ROUTINE SERVICE ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.
Page 35: Operational Checks
ROUTINE SERVICE OPERATIONAL CHECKS OPERATIONAL CHECKS Fuel System Perform running checks of the fuel system by fol- lowing these steps: DANGER • Squeeze fuel primer bulb until hard or activate DO NOT run the engine indoors or without electric primer. Observe all fuel hoses and con- adequate ventilation or permit exhaust nections.
Page 36: Cooling System
ROUTINE SERVICE COOLING SYSTEM Tachometer Pulse Setting COOLING SYSTEM Confirm accuracy of tachometer reading. Check the condition of cooling system compo- • Adjust dial on back of tachometer to required nents regularly: setting (the outboard should not be running). • water intake screens Outboard Model Tachometer Setting...
Page 37: Running The Outboard Using A Hose And Flushing Adapter
ROUTINE SERVICE COOLING SYSTEM Flushing — Outboard Running Running the Outboard Using a Hose and Flushing Adapter WARNING To prevent injury from contact with rotat- WARNING ing propeller, remove the propeller before To prevent injury from contact with rotat- flushing. ing propeller, remove the propeller before running engine with a flushing adapter.
Page 38: Lubrication
ROUTINE SERVICE LUBRICATION LUBRICATION NOTICE Temporarily cover the small holes on the front of M2-Type gearcases with water- Steering System proof tape to make sure enough water travels to the powerhead. Water can drain from auxil- WARNING iary inlets, resulting in engine overheat. Failure to regrease as recommended could result in steering system corrosion.
Page 39: Swivel Bracket And Trailering Bracket
ROUTINE SERVICE LUBRICATION Swivel Bracket and Trailering • Inner casings of both the throttle and shift cables. Bracket Lubricate the swivel bracket with Triple-Guard grease. Apply grease until the grease begins to flow from the upper or lower swivel bracket areas. Coat the pivot points of the trailering bracket with Triple-Guard grease.
Page 40: Gearcase Lubricant
ROUTINE SERVICE LUBRICATION Gearcase Lubricant Inspection Inspect the lubricant and the magnets on the Draining plugs for metal chips. The presence of metal fuzz can indicate normal wear of the gears, bearings, WARNING or shafts within the gearcase. Metal chips can Gearcase lubricant may be under pressure indicate extensive internal damage.
Page 41: Trim And Tilt
ROUTINE SERVICE LUBRICATION Remove the lubricant level plug and the lubricant Trim and Tilt drain/fill plug. CAUTION Use Gearcase Filler, P/N 501882, to slowly fill the gearcase with HPF PRO lubricant through the Correct fluid level must be maintained to drain/fill hole until it appears at the oil level hole.
Page 42: Spark Plugs
ROUTINE SERVICE SPARK PLUGS • SPARK PLUGS Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, 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 43: Fuel And Oil Systems
ROUTINE SERVICE FUEL AND OIL SYSTEMS FUEL AND OIL SYSTEMS Apply Triple-Guard grease to the gasket surface of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m). Routine replacement of filters reduces the possi- bility of foreign material restricting the incoming If the mark is in unshaded area do not tighten any- fuel or oil supplies.
Page 44: Oil Filters And Oil Reservoir
ROUTINE SERVICE FUEL AND OIL SYSTEMS Oil Filters and Oil Reservoir Air Silencer Perform visual inspections to identify oiling system The air silencer on Evinrude outboards maximizes leaks. Make certain the oil tank is filled and oil air flow while minimizing noise. supply is not contaminated.
Page 45: Exhaust Pressure Fitting
ROUTINE SERVICE EXHAUST PRESSURE FITTING EXHAUST PRESSURE With key ON, outboard NOT running, the exhaust pressure sensor reading should be close to zero. FITTING With the outboard running, make sure the exhaust pressure reading changes with throttle setting. The exhaust pressure fitting is threaded into the This reading will vary, based on actual outboard cylinder/crankcase assembly and protrudes into exhaust pressure conditions.
Page 46: Anti-Corrosion Protection
ROUTINE SERVICE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.
Page 47: Storage
ROUTINE SERVICE STORAGE STORAGE gauge indicates winterization complete and out- board shuts off (about one to two minutes). IMPORTANT: DO NOT start outboard without a IMPORTANT: If the digital gauge does not indi- water supply to the outboard’s cooling system. cate winterization mode active, or outboard runs Cooling system and/or powerhead damage could above fast idle, immediately turn off outboard and...
Page 48: Additional Recommendations
ROUTINE SERVICE STORAGE Digital Gauge Method Additional Recommendations The ICON Pro 5 inch and I-Command 3.5 inch • Top off oil reservoir. digital gauges provide a winterize feature for 2008 • inspect the fuel filter. If there is debris in the fuel and newer V4 and V6 models.
Page 49: Pre-Season Service
ROUTINE SERVICE PRE-SEASON SERVICE PRE-SEASON SERVICE Operational Checks • Refer to OPERATIONAL CHECKS on p. 35 If the outboard was removed from the boat for • Steering system storage, make sure it is reinstalled with factory • Remote controls specified hardware. Refer to the Predelivery and •...
Page 50: Submerged Engines
ROUTINE SERVICE SUBMERGED ENGINES SUBMERGED ENGINES Prime oil system and fuel system. Refer to Prim- ing the Fuel System on p. 145 and Oil Supply Priming on p. 177. Make sure all oil injection Once an outboard has been submerged in fresh hoses are clean and filled with oil.
Page 51: Engine Cover Service
ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 52 LATCH HOOK INSTALLATION .
Page 52: Upper Cover Service
ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Upper Cover Cap Replacement Place new upper cap into position. Latch Hook Installation Insert threaded bracket into pocket. 006815 Tighten self-tapping screws to a torque of 24 to 36 1. Bracket 006826 in.
Page 53: 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 54: Latch Handle Installation
ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006827 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
Page 55 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............56 EMM INPUTS AND OUTPUTS DIAGRAM .
Page 56: 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 57: Emm Inputs And Outputs Diagram
ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS INPUTS J1-A J1-B OUTPUTS OUTPUTS x 100 3550 M EN U 008028 1. Engine Management Module (EMM) 10. Engine Temperature Sensor(s) 19. Fuel Injector 2. Battery (12 volt) 11.
Page 58: 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 used to control outboard operation. Use Evinrude Stores service code 23 Diagnostics software to troubleshoot the sensors.
Page 59: 5 V Circuit Sensor
ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS 5 V Circuit Sensor Exhaust Pressure Sensor Monitors the EMM’s 5 V sensor circuit. The exhaust pressure sensor monitors exhaust pressure during all running conditions to compen- If sensor voltage is less than 4.75 volts, the EMM: sate for engine loads.
Page 60: External Sensors
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS If cylinder head temperature exceeds 248°F (120°C) for 3 seconds, the EMM: Sensor inputs and internal EMM controllers are Activates SHUTDOWN used to control outboard operation. Use Evinrude Stores service code 31 Diagnostics software to troubleshoot the sensors.
Page 61: 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: a second wire.
Page 62: Crankshaft Position Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Crankshaft Position Sensor Neutral Switch (V4 Models) Ribs spaced on the flywheel mark crankshaft posi- The powerhead mounted neutral switch controls a tion. As the ribs pass the magnetic field of the ground signal from the EMM to indicate shift link- CPS, an AC voltage signal is generated.
Page 63: Internal Emm Functions
ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM RPM Limiter This feature of EMM programming prevents FUNCTIONS engine damage due to excessive RPM. At 6250 RPM, fuel and ignition to the cylinders is shut off. Start Assist Circuit (SAC) Normal operation resumes when engine RPM When the ignition key is ON, the EMM Start Assist returns to the specified range.
Page 64: Engine Monitor System
ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITOR SYSTEM ENGINE MONITOR The EMM activates the warning horn and gauge displays as follows: SYSTEM • LOW OIL means that oil in the tank is at reserve level (about 1/4 full). All remote controlled outboards must be equipped •...
Page 65: Warning System
ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING Activation When one of these conditions occurs, the EMM SYSTEM interrupts fuel injector and ignition operation, reducing engine speed to 1200 RPM. The warning The S.A.F.E. (Speed Adjusting Failsafe Electron- horn sounds and an Engine Monitor message dis- ics) warning system alerts the operator and pro- plays.
Page 66: Shutdown Mode
ENGINE MANAGEMENT MODULE (EMM) SHUTDOWN MODE SHUTDOWN MODE DIAGNOSTIC SOFTWARE FUNCTIONS Outboard “shutdown” will occur if specific faults are detected by the EMM: The EMM stores valuable information about the Code 29 Excessive EMM temperature outboard and its running history. This information Code 31 Excessive engine temperature can be used for troubleshooting, for checking Code 33 Excessive NO OIL condition...
Page 67: Static Information
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Static Information Dynamic Information Static information is 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 68: 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. 83. exists. Active faults become occurred faults only if the outboard is running.
Page 69: Dynamic Tests
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Tests Oil Control Settings Dynamic tests are performed with the outboard Set Oil Type running. The TC-W3 oil type setting is the standard setting for all outboards. Set TC-W3 for: • Operation with all TC-W3 outboard oils includ- ing XD30, XD50, or XD100.
Page 70: Tiller/Remote Programming
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Powerhead Break-In Ignition Timing Use the diagnostic software to initiate break-in oil- Use the Ignition Timing screen to check and ing. Break-in is a predetermined oiling program adjust EMM timing. EMM timing must be synchro- that runs for five hours of outboard operation, nized to crankshaft position.
Page 71: Tps Calibration
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS TPS Calibration Reports TPS Calibration synchronizes throttle plate open- Engine reports provide service records and can ing with throttle position sensor voltage. be used to document the running history of an out- board. Reviewing this information can help iden- Refer to TPS Calibration on p.
Page 72: 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 73: Emm Servicing
ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING Installation Install J2 connector IMPORTANT: If a new EMM is being installed, Align slots in starboard side of EMM case with iso- refer to EMM Transfer on p. 72. lator mounts on electrical harness base. Slide EMM into position.
Page 74: Technician's Notes
ENGINE MANAGEMENT MODULE (EMM) NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 75 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............76 VISUAL INSPECTIONS .
Page 76: Diagnostic Procedures
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Operational Inspections Run the outboard to confirm actual symptoms PROCEDURES before performing any unnecessary procedures. Inspection should include the following: Visual Inspections • Make sure the outboard can be cranked easily, Inspect wiring and electrical connections. Disas- with no mechanical binding.
Page 77: Troubleshooting
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Troubleshooting • Use the diagnostics software Dynamic Tests to isolate a faulty cylinder. See DYNAMIC TESTS Outboard will not crank, starter does not on p. 78. operate: • Use an inductive timing light to check ignition •...
Page 78: 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 79: Emm Led Indicators
SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS LED 2 – CRANK POSITION OKAY – input from CPS, EMM powered ON. For NO LIGHT, check for: The EMM LED indicators provide a quick refer- • Code 16 – CPS, intermittent loss of sync ence to the status of several outboard systems.
Page 80: Running
SYSTEM ANALYSIS EMM LED INDICATORS Running • Code 23 – EMM temp. sensor circuit fault • Code 24 – EMM temp. below expected range When the outboard is running, all of the LEDs • Code 37 – Water in fuel should be off.
Page 81: Ignition Output Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS IGNITION OUTPUT Crankshaft Position Sensor • Provides EMM with input. TESTS • Outboard cranking speed exceeds 75 RPM and a steady CPS signal is generated. DANGER Alternator Output/System Voltage • System voltage from EMM (white/red) provides The electrical system presents a serious 55 VDC to the oil injection pump, the fuel injec- shock hazard.
Page 82: Crankshaft Position Sensor (Cps) Test
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Crankshaft Position Sensor (CPS) System Voltage Test Test The ignition system is powered by the 55 V sys- tem. When the CPS is working properly, EMM LED 2 turns on while the outboard is being started. Use the Evinrude Diagnostics software Monitor screen to check system voltage.
Page 83: Static Ignition Test
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Static Ignition Test IMPORTANT: You may need to remove shield- ing from wire if pickup does not read signal. Perform the static ignition test using Evinrude Diagnostics software and an inductive timing light. IMPORTANT: DO NOT use a spark checker tool.
Page 84: Running Ignition Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Running Ignition Tests Results: Steady voltage and strobe, engine misfires: Use Evinrude Diagnostics software to monitor • Inspect or replace spark plugs system voltage (55 V). • Refer to FUEL DELIVERY TESTS on p. 86. •...
Page 85: Ignition Control Circuit Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector and test the continuity of each ignition control cir- Use a digital multimeter to test the following: cuit (orange). Check resistance between J1-B •...
Page 86: Fuel Delivery Tests
SYSTEM ANALYSIS FUEL DELIVERY TESTS FUEL DELIVERY TESTS If the pump does not run: • The EMM controls power to the fuel pump (pur- ple/black wire). Check voltage at pin 1 of fuel WARNING pump connector. Voltage should be 12 V when KEY is first ON, when fuel pump test activated, Protect against hazardous fuel spray.
Page 87: Running Fuel System Tests
SYSTEM ANALYSIS FUEL DELIVERY TESTS Results: Results: No injectors actuate: No light activation on any injector wires (outboard • cranks and starter turns flywheel): Use the Monitor screen of the diagnostics soft- • Check stator input to EMM, CPS operation, and ware to make sure voltage is present on the system voltage circuit.
Page 88: Exhaust Valve (V4 Models)
SYSTEM ANALYSIS EXHAUST VALVE (V4 MODELS) EXHAUST VALVE Operational Symptoms: • If the exhaust valve is stuck in low speed mode, (V4 MODELS) the outboard may lose top speed RPM. • If the exhaust valve is stuck in high speed The inner exhaust housing on 60°...
Page 89 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............90 IGNITION SYSTEM CIRCUIT DIAGRAM S .
Page 90: Service Chart
ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 12-16 In. lbs. (1.5-2 N·m) 60-84 In. lbs. (7-9.5 N·m) 30-32 Ft. lbs. (40.5-43 N·m) A, X 12-16 In. lbs. 48 In. lbs. (1.5-2 N·m) (5.5 N·m) 50-70 In. lbs. (5.6-8 N·m) F, X 24-36 In.
Page 91 ELECTRICAL AND IGNITION SERVICE CHART 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. lbs (19-21.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 008030 Liquid Neoprene...
Page 92: Ignition System Circuit Diagram S
ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM – V4 IGNITION SYSTEM CIRCUIT DIAGRAM – V4 J1-B J1-A 007112 Key switch (stop circuit) Ignition coil Fuse Crankshaft position sensor Main harness ground Stator Capacitor +12 V from battery...
Page 93 ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM – V6 IGNITION SYSTEM CIRCUIT DIAGRAM – V6 J1-B J1-A 007095 Key switch (stop circuit) Ignition coil Fuse Crankshaft position sensor Main harness ground Stator Capacitor +12 V from battery...
Page 94: Electrical Harness Connections
ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
Page 95 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 1 Blue Injector, cylinder 2 Blue Injector, cylinder 3 Green V4 vacant Purple V6 Isolated B+ Red/Black +55 V, in, (ignition) –...
Page 96: Ground Circuits
ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS Additional Ground Tests Check connections and continuity at the following All ground circuits are essential to reliable out- locations: board performance. Make sure all ground connec- • Trim and Tilt module ground at main ground ter- tions are clean and tight.
Page 97: Sensor Tests
ELECTRICAL AND IGNITION SENSOR TESTS SENSOR TESTS (1.85 mm). The acceptable clearance is 0.036 to 0.110 in. (1 to 2.8 mm). All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the EMM.
Page 98: Engine Temperature Sensor Test
ELECTRICAL AND IGNITION SENSOR TESTS Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test meter lead to terminal “C.” Rotate the sensor lever Remove the electrical connector from the air tem- through its range of travel. Resistance reading perature sensor.
Page 99: Stator Tests
ELECTRICAL AND IGNITION STATOR TESTS STATOR TESTS To check for a grounded winding, connect one meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The stator consists of 3 windings (6 poles each) read no continuity.
Page 100: Charging System Tests
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS 12 V Charging Circuit To test the operation of the regulator in the EMM, you must be able to run the outboard continuously at approximately 5000 RPM, such as in a test tank or on a marine dynamometer.
Page 101: Auxiliary Battery Charge Wire
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Auxiliary Battery Charge Wire With outboard running at 1000 RPM, voltage must read higher than with key OFF and increase The auxiliary battery charge feature requires aux- steadily to approximately 14.5 V as the outboard iliary battery charge kit, P/N 5006253 (or equiva- RPM increases.
Page 102: Electric Start Circuit
ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 004112 1. Marine battery 10. 26-pin J1-B EMM connector 2. RED wire (POS) 11. 34-pin J1-A EMM connector 3. BLACK wire (NEG) 12. Engine Management Module (EMM) 4.
Page 103: Start Circuit Operation
ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The starter must engage and turn the flywheel. • Red/purple wire provides 12 V to key switch ter- The outboard must crank a minimum of 100 RPM minal “B”.
Page 104: Electric Start Tests
ELECTRICAL AND IGNITION ELECTRIC START TESTS Key Switch, START Position ELECTRIC START TESTS Key switch START: Starter Solenoid Test • Switches 12 V to terminal “S” of key switch and to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- •...
Page 105: No Load Current Draw Test
ELECTRICAL AND IGNITION ELECTRIC START TESTS Starter Voltage Drop Test • Observe voltage reading. STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to To prevent accidental starting of outboard, starter motor terminal. disconnect crankshaft position sensor •...
Page 106: Remote Control Switch Tests
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or continuity light to test the SWITCH TESTS continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
Page 107: Neutral Start Switch Test
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Switch Test Emergency Stop Switch Test Use an ohmmeter or a continuity light to test neu- This switch can be part of the key switch or tral start switch operation. installed as a separate switch. Either style con- nects the “M”...
Page 108: Tilt/Trim Relay Test
ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST Test Procedure Make sure red and black wires are connected to The tilt and trim (TNT) module contains the cir- 12 V battery power supply. cuitry and relays required for power trim and tilt operation.
Page 109: Exhaust Valve Relay Tests
ELECTRICAL AND IGNITION EXHAUST VALVE RELAY TESTS EXHAUST VALVE RELAY TESTS The exhaust valve relay module controls the exhaust valve actuator. 1. Exhaust valve relay module 005374 Exhaust Valve Relay Module Diagram 005429 1. Purple/Black wire 2. Red/Purple wire 3. Blue/Black wire 4.
Page 110 ELECTRICAL AND IGNITION EXHAUST VALVE RELAY TESTS Exhaust Valve Relay Module Test EMM Outputs to Relay Module Test High speed operation test: • Disconnect exhaust valve actuator connector Use back-probe to obtain results at engine har- from relay module ness connector. Start and run engine. Use the •...
Page 111: Systemcheck Circuit Tests
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS SystemCheck CIRCUIT instrument harness terminal 1 (purple wire) and terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...
Page 112: Water Temp/ Hot Circuit Test
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS WATER TEMP/ HOT Circuit Test the two connectors, replace SystemCheck gauge. The tan wire of engine harness and the MWS har- ness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head.
Page 113: Low Oil Circuit Test
ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT LOW OIL Circuit Test Turn the key switch ON. Using a jumper wire, con- TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW Check voltage at the battery.
Page 114: Flywheel And Stator Servicing
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING FLYWHEEL AND STATOR Lift the electrical harness base out of the way. SERVICING IMPORTANT: Weak flywheel magnets cause low alternator output and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as a peak-reading voltmeter, which might cause unnecessary parts replacement.
Page 115: Stator Service
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use two 3/8-24x2 in. screws from the adaptor kit Stator Service to attach the tool to the flywheel. Two holes are Remove six allen head screws to remove stator. tapped in the flywheel for the tool. 1.
Page 116 ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywheel Puller Adaptor Kit, P/N 5007181, Install the electrical harness base and secure with and Flywheel Service Kit, P/N 434649, to position four screws. Tighten screws to a torque of 60 to flywheel on top of crankshaft.
Page 117: Ignition Coil Servicing
ELECTRICAL AND IGNITION IGNITION COIL SERVICING IGNITION COIL Ignition Coil Bracket Installation Install injector screws through bracket. SERVICING Refer to Fuel Injector Service on p. 154 for Ignition Coil Removal proper injector installation procedure. Remove spark plug lead from ignition coil. Disconnect ignition coil electrical connector.
Page 118: Timing Adjustments
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TIMING ADJUSTMENTS Remove spark plugs. Rotate the flywheel clock- wise to approximately 30° ATDC. Timing Pointer WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.
Page 119: Timing Verification
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Rotate the flywheel clockwise until the piston Timing Verification contacts the tool. Mark the flywheel directly across Use Evinrude Diagnostics software to synchronize from the pointer. Label this mark “B.” Rotate fly- the mechanical timing of the outboard with the wheel counterclockwise slightly to release tool electronic timing of the EMM.
Page 120: Tps Calibration
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING TPS Calibration ELECTRIC STARTER Use Evinrude Diagnostics software to tell the SERVICING EMM what throttle position sensor voltage is when the throttle plates begin to open. Starter Removal Set TPS Calibration after replacing or adjusting IMPORTANT: Do not clean the starter drive any throttle body or throttle linkage parts.
Page 121: Starter Disassembly
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the screws, lock washers, and pinion Hit the socket with a mallet to lower the spacer housing. and expose the retaining ring under the spacer. 30373 30371 Starter Disassembly Lift and remove the wave washer and bushing. 30360 Remove the retaining ring, spacer, and spring from pinion shaft.
Page 122 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove pinion and plastic weather cover from Remove the two thru-bolts. Mark the end cap ori- pinion shaft. entation, and remove the cap. 30368 30365 Remove the driven gear and thrust washer. Gently tap the starter frame with a rubber mallet to loosen it.
Page 123: Starter Cleaning And Inspection
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Note the alignment marks by the positive terminal Starter Cleaning and Inspection stud. Hold the armature in place, and slide the Inspect the brushes for wear and damage. frame away from the gear housing. Replace brushes if damaged or worn.
Page 124: Starter Assembly
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Starter Assembly matter which could contribute to failure of wind- ings. IMPORTANT: If removed, apply Locquic Primer and Screw Lock to the brush card screws before installing. Route the brush leads and install the springs and brushes.
Page 125 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Align the starter frame and make sure the long Install the two thru-bolts. Tighten to a torque of 50 alignment mark matches the mark next to the pos- to 65 in. lbs. (5.6 to 7.3 N·m). itive terminal stud on the gear housing.
Page 126 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Guard grease. Install the thrust washer and driven Lightly coat the pinion shaft splines (helix) with gear. Starter Bendix Lube. Lower the pinion into place without displacing the driven gear or thrust washer. 30362 Install the weather cover.
Page 127: Starter Installation
ELECTRICAL AND IGNITION CONNECTOR SERVICING CONNECTOR To test the assembly and operation of the starter, refer to No Load Current Draw Test on p. 105. SERVICING Starter Installation DEUTSCH Connectors Apply Locquic Primer and Nut Lock to the threads of the four starter mounting screws. Position the IMPORTANT: Electrical Grease...
Page 128 ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire. AMP Connectors IMPORTANT: Always use the appropriate meter test probes and adapters when testing compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. UPERSEAL Disconnect 1.
Page 129 ELECTRICAL AND IGNITION CONNECTOR SERVICING UPER The J1-A and J1-B connectors of the EMM are AMP Super Seal connectors. Disconnect Depress BOTH latches and pull connector from plug. Connect Push connector into plug until latches engage. 1. Locking tab, plug 002447 2.
Page 130 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation OWER IMER ERIES The J2 connector of the EMM is a AMP Power Align terminal with connector housing and push Timer Series connector. terminal with seal into connector housing until seated. Disconnect Use a screw driver to open latch. Pull connector from plug.
Page 131 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Removal Terminal Installation A tab on the back side of the terminal engages a Install wire gasket on wires and feed wires shoulder in the connector housing to hold the ter- through the correct terminal position of the con- minal in place.
Page 132: Technician's Notes
ELECTRICAL AND IGNITION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 133 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............134 FUEL SYSTEM HOSE ROUTING .
Page 134: Service Chart
FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. 60-84 In. lbs. (7-9.5 N·m) (7-9.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant Pipe Thread Sealing Compound 007114 Permatex #2...
Page 135 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Bond seals to air silencer Important: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 96-120 in. lbs. (11-13.5 N·m) Start at center and use a spiral torque pattern 60-80 in.
Page 136 FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Tighten in 3 stages 60-84 in. lbs. (7-9.5 N·m) 120 in. 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 Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...
Page 137: Fuel System Hose Routing
FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Return V4 Models 007116 Fuel Supply Fuel Return V6 Models 007117 Fuel supply from boat fuel system Electric fuel circulation pump (20 to 35 psi) Fuel lift pump (2 to 8 psi) Fuel supply manifold Pulse hose(s) from cylinder/crankcase Fuel injector(s)
Page 138: Fuel System Circuit Diagram - V4
FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM – V4 FUEL SYSTEM CIRCUIT DIAGRAM – V4 J1-B J1-A 007115 Injectors Capacitor High pressure fuel pump Grounds (neg) Fuel filter/water separator 55 V circuit (white/red) Fuel Injector grounds...
Page 139: Fuel System Circuit Diagram - V6
FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM – V6 FUEL SYSTEM CIRCUIT DIAGRAM – V6 J1-B J1-A 007118 Injectors Capacitor High pressure fuel pump Grounds (neg) Fuel filter/water separator 55 V circuit (white/red) Fuel Injector grounds...
Page 140: Fuel System Requirements
FUEL SYSTEM FUEL SYSTEM REQUIREMENTS FUEL SYSTEM Portable Fuel Tanks REQUIREMENTS WARNING If engine is equipped with a quick-discon- Regulations and Guidelines nect fuel hose, you MUST disconnect the Vessel manufacturer, and/or installer of an EPA fuel hose from the engine and the fuel tank certified outboard, must meet minimum specifica- to prevent fuel leaks: tions for boat fuel systems established by:...
Page 141: Fuel Requirements
FUEL SYSTEM FUEL SYSTEM REQUIREMENTS Fuel Requirements When using alcohol-extended fuels, be aware of the following: • The boat’s fuel system may have different WARNING requirements regarding the use of alcohol fuels. Gasoline is extremely flammable and Refer to the boat’s owner guide. highly explosive under certain conditions.
Page 142: Components
FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The fuel system includes the following compo- high-pressure components of the fuel system from nents: contaminants. Refer to INSPECTION AND MAIN- • Fuel Lift Pump TENANCE SCHEDULE on p.
Page 143: Flow Diagrams
FUEL SYSTEM COMPONENTS Fuel Reservoir to flow to the intake manifold through the vent hose. The vapor separator accumulates fuel in an inter- nal fuel reservoir and supplies fuel to the electric As the vapor pressure in the vapor separator circulation pump.
Page 144: Fuel System Components
FUEL SYSTEM COMPONENTS Fuel Manifolds The EMM is programmed to compensate for vari- ations in fuel flow. Each injector and its location on The fuel supply and return manifolds route fuel the outboard is identified by the EMM. DO NOT through the high pressure side of the fuel system.
Page 145: Fuel System Priming
FUEL SYSTEM FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System Vent Line Clamp WARNING Federal Regulations require that all outboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp installed.
Page 146: Fuel System Tests
FUEL SYSTEM FUEL SYSTEM TESTS FUEL SYSTEM TESTS Shut OFF outboard. Monitor pressure gauge. Pressure should not drop below 15 psi (103 kPa). WARNING IMPORTANT: If outboard does not run, prime fuel system and crank outboard; check circulation Use caution when working on any pres- pump operation;...
Page 147: Pressure Regulator Test
FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 152 to This test requires Injector Test Fitting kit, remove vapor separator. P/N 5005844. Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.
Page 148: Fuel Injector Resistance Test
FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Resistance Test Circulation Pump Resistance Test Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter with appropriate adapter coil resistance.
Page 149: Lift Pump Vacuum Test
FUEL SYSTEM FUEL SYSTEM TESTS Results: START outboard and run at FULL THROTTLE for at least two minutes. Monitor clear vinyl hose for Normal pressure the presence of air. Air bubbles indicate a faulty • Perform the Lift Pump Vacuum Test on hose, connection, or fuel tank pick-up.
Page 150: Anti-Siphon Valve Test
FUEL SYSTEM FUEL COMPONENT SERVICING Anti-Siphon Valve Test FUEL COMPONENT Remove anti-siphon valve from fuel tank. Install SERVICING adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve. WARNING Gasoline is extremely flammable and highly explosive under certain conditions.
Page 151: Fuel Filter Service
FUEL SYSTEM FUEL COMPONENT SERVICING Wrap a shop towel completely around the pres- Fuel Filter Service sure test valve while connecting fitting from Fuel Removal Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly. Disconnect the battery cables at the battery. Use an appropriate filter wrench to turn the filter in a counterclockwise direction.
Page 152: Fuel Lift Pump Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Vapor Separator Service The fuel lift pump is serviceable as a complete Removal assembly. Refer to parts catalog for service parts. Disconnect the battery cables at the battery. Removal Relieve fuel system pressure. Refer to Relieving Disconnect the battery cables at the battery.
Page 153: Fuel Manifold Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Manifold Service Installation Check condition of sealing O-rings on fuel mani- Removal fold fittings. Lubricate O-rings with outboard lubri- Disconnect the battery cables at the battery. cant and insert fuel manifold fittings into injector. Both fittings must be fully seated into the injector Relieve fuel system pressure.
Page 154: Fuel Injector Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injector Service Remove injector screws. Mark fuel injectors to show cylinder locations. NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers.
Page 155 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 156 FUEL SYSTEM FUEL COMPONENT SERVICING Install injector into mount housing. Press on injec- Select the Replace Injector button. tor face until injector seats in mount housing. 1. “Replace Injector” button 008568A 002318 Use the drop down menu to navigate to the saved Installation coefficient file location.
Page 157 FUEL SYSTEM FUEL COMPONENT SERVICING Make sure the serial number displayed on the through ignition coil brackets, injector cup, and screen matches the serial number printed on the insulator. Thread into cylinder head. serial number label of the replacement injector. 002316 Tighten screws in stages, starting with the lower screw.
Page 158: Intake Manifold Service
FUEL SYSTEM FUEL COMPONENT SERVICING Intake Manifold Service Remove oil distribution hoses from oil pump/mani- fold and reed plate bracket. Refer to OIL COMPO- Removal NENT SERVICING on p. 183. Disconnect vapor separator vent hose, throttle Remove oil recirculation hose from starboard side position sensor connector, and throttle link arm.
Page 159 FUEL SYSTEM FUEL COMPONENT SERVICING Use caution to prevent damaging reed valve Assembly assemblies. Remove old adhesive from reed valve retaining screws. Install gasket on reed plate assembly. DO NOT use sealer on the gasket. Prime screw threads with Locquic Primer and let dry.
Page 160 FUEL SYSTEM FUEL COMPONENT SERVICING Place gasket on throttle body. Install throttle body, Install oil filter and oil and fuel supply hoses. with oil pump bracket, on reed plate and install screws. Tighten the center screws first and expand out- ward.
Page 161 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............162 OILING SYSTEM CIRCUIT DIAGRAM .
Page 162: Service Chart
OILING SYSTEM SERVICE CHART SERVICE CHART Engine Oil Programming Labels NOTICE NOTICE XD 100 XD 30 This outboard has This outboard has been programmed been programmed for use of for use of XD 50 Evinrude®/Johnson® Evinrude®/Johnson® XD25™, XD30™, XD100™ oil. XD50™...
Page 163: Oiling System Circuit Diagram
OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM J1-B J1-A Oil Injection Pump 007094 55 V Circuit (WHITE/RED) Grounds, NEG (BLACK) EMM to Oil Solenoid (BLUE) Oil Pressure Sensor, +5 V analog (RED) Oil Pressure Sensor Signal (TAN/WHITE) Capacitor Low Oil Switch Low Oil Signal...
Page 164: Oil Supply Diagrams - V4
OILING SYSTEM OIL SUPPLY DIAGRAMS – V4 OIL SUPPLY DIAGRAMS – V4 Primary oil manifold delivers oil to: • Rear oil manifold • #1, #2, #3 and #4 crankcase fittings Primary Oil Manifold 1. Cylinder #2 2. Cylinder #4 3. Cylinder #3 4.
Page 165 OILING SYSTEM OIL SUPPLY DIAGRAMS – V4 Port Side View Starboard Side View 005354R...
Page 166: Oil Supply Diagrams - V6
OILING SYSTEM OIL SUPPLY DIAGRAMS – V6 OIL SUPPLY DIAGRAMS – V6 Primary oil manifold delivers oil to: • Rear oil manifold • #1, #2, #3, #4, #5 and #6 crankcase fittings Primary Oil Manifold 1. Cylinder #6 2. Cylinder #5 3.
Page 167 OILING SYSTEM OIL SUPPLY DIAGRAMS – V6 Port Side View Starboard Side View 005356R...
Page 168: Oil Recirculation Diagrams - V4
OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V4 OIL RECIRCULATION DIAGRAMS – V4 Port Side View Starboard Side View Check Valve 005351...
Page 169 OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V4 Direction of flow * Check valves: Main bearings to cylinders Direction of flow * Check valves: Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards the cylinders 005350...
Page 170: Oil Recirculation Diagrams - V6
OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V6 OIL RECIRCULATION DIAGRAMS – V6 Port Side View Oil from auxiliary oil manifold Starboard Side View Check Valves 005353...
Page 171 OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V6 Direction of flow * Check valves: Main bearings to cylinders Direction of flow * Check valves: Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards the cylinders 005352...
Page 172: Oil System Requirements
OILING SYSTEM OIL SYSTEM REQUIREMENTS OIL SYSTEM COMPONENTS REQUIREMENTS The oiling system consists of the following compo- nents: Recommended Lubricants • Oil tank • Oil injection pump and manifold assembly Evinrude/Johnson XD100, XD50, or XD30 out- • Rear oil manifold assembly board oils are recommended for use in Evinrude •...
Page 173: Oil Injection Pump
OILING SYSTEM COMPONENTS Oil Injection Pump The sensor provides an output voltage to the EMM based on oil manifold pressures. The oil injection pump is an electric (55 V) actua- • 5 VDC Input on RED wire tor style pump. It draws oil from the oil tank •...
Page 174: Electrical Circuit (55 V)
OILING SYSTEM COMPONENTS Electrical Circuit (55 V) Cylinder and Crankcase The oil injector is powered by the 55 V electrical The primary oil distribution manifold provides circuit. The EMM controls pump operation by rap- crankcase lubrication through oil distribution idly connecting and disconnecting the pump’s hoses and pressed-in fittings at the front of the internal coil to ground.
Page 175: Oil Recirculation System
OILING SYSTEM COMPONENTS Oil Recirculation System Crankcase / Main Bearing Recirculation The movement of oil through the main bearings is External hoses fittings, internal cylin- controlled by internal passages, external fittings der/crankcase passages, and intake manifold pas- and hoses, and check valves. sages are used to recirculate any accumulation of oil from various locations in the powerhead.
Page 176: Oil Control Settings
OILING SYSTEM OIL CONTROL SETTINGS OIL CONTROL SETTINGS NOTICE Running an Evinrude E-TEC out- board on other grades of oil while set to the Oil Injection Rate XD100 oil ratio will result in increased engine wear and shortened outboard life. The Engine Management Module (EMM) controls the oil injection rate based on engine RPM.
Page 177: Break-In Oiling
OILING SYSTEM OIL CONTROL SETTINGS Install decals in a highly visible location, such as Oil Supply Priming one of the following: • Dashboard/deck of boat, next to key switch WARNING • Deck of boat, next to the remote oil fill Always use caution while working around •...
Page 178 OILING SYSTEM OIL CONTROL SETTINGS Use the Prime Oil System button of the Dynamic Make sure that oil flows through the rear oil distri- Test screen to prime the oil pump. bution manifold to the cylinder block fittings. 1. Rear oil distribution manifold 008016 Dynamic Test Screen 008570A...
Page 179: 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: reads 55 V (DC) to measure voltage between the Always perform visual inspections oil pump electrical connector and engine ground. to identify oiling system leaks.
Page 180: 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 181: Oil Supply Vacuum Test
OILING SYSTEM OILING SYSTEM TESTS Oil Supply Vacuum Test Attach a vacuum tester to the outboard side of oil supply hose and draw 7 in. Hg (24 kPa) vacuum on the hose for at least five minutes. Repair or WARNING replace any leaking components.
Page 182: Oil Injection Pump Function Test
OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Function Test Results: • Oil flows from hose, compare to oil flow at other Remove oil distribution hose from fitting at crank- distribution hoses case. Squeeze oil supply primer bulb to provide oil •...
Page 183: Oil Component Servicing
OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Once hose is removed from the manifold, make sure hose support is in the end of the hose. SERVICING WARNING To prevent accidental starting while ser- vicing, twist and remove spark plug leads. Oil Distribution Hoses The oil distribution hoses from each manifold MUST be the same length.
Page 184: Oil Injection Pump
OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Route oil distribution hoses from the oil distribu- Removal tion manifold to the crankcase oil delivery fittings Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP- PLY DIAGRAMS –...
Page 185 OILING SYSTEM OIL COMPONENT SERVICING Install oil pump bracket and retaining screws. Reconnect oil supply hose to the inlet fitting of oil Tighten small screw to a torque of 24 to 36 in. lbs. pump. Fasten with Oetiker clamp. (3 to 4 N·m) and longer screw to 96 to 120 in. lbs. (11 to 13.5 N·m).
Page 186: Technician's Notes
OILING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 187 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........188 COMPONENTS .
Page 188: Hose Routing And Water Flow Diagrams
COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V4 M ODELS Hose Routing & W ater Flow Diagra m 115H.O. – 130HP/60°V4 Water intake screens 1. W ater intake screen s Water pump 2. W ater pum p Exhaust housing 3.
Page 189 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V6 M ODELS Water intake screens Water pump Water tube Adapter housing Cylinder block Thermostat Pressure valve Cylinder head, water outlet Cylinder block vent Water supply to EMM Water supply, EMM to vapor separator Vapor separator to overboard indicator Outgoing water (warm/hot)
Page 190: Components
COOLING SYSTEM COMPONENTS COMPONENTS Water Supply Tube The water pump outlet connects with the water Water Pump and Intakes supply tube located in the outboard’s midsection. Grommets seal the water tube to the water pump External water intakes mounted in the gearcase housing and the inner exhaust housing.
Page 191: Pressure Relief Valve
COOLING SYSTEM COMPONENTS Overcooling: Debris may prevent the valve from closing completely. 20 in. models 25 in. models Pressure Relief Valve Components 005391 Thermostats Thermostats control water flow and operating tem- perature at lower speeds (below 2500 RPM). Overheating: A restricted or faulty thermostat typ- ically results in LOW SPEED overheating.
Page 192: Cooling System Operation
COOLING SYSTEM OPERATION OPERATION The thermostat opens when the water tempera- ture reaches approximately 143°F (62°C). All models use a two-stage cooling system When the thermostat opens, water flows down design. The cooling system is dependent on water through the cylinder head to a passage in the cyl- pump pressure and controlled by thermostat and inder block.
Page 193: Engine Temperature Check
COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use Evinrude Diagnostics software to read tem- CHECK perature displays. IMPORTANT: The engine temperatures listed below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and place outboard in a test tank or in the water.
Page 194: Idle Operating Temperature Troubleshooting (Below Range)
COOLING SYSTEM ENGINE TEMPERATURE CHECK To test pressure relief valve operation, monitor temperature at the thermostat housing with Tem- perature Gun, P/N 772018, or digital pyrometer. Confirm normal IDLE operating temperature. Slowly increase engine speed from IDLE, up through 3000 RPM. Engine temperature should decrease from normal IDLE temperatures as pressure relief valve opens.
Page 195: Temperature Sender Servicing
COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 007196 005394 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Page 196: Inspection
COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING Inspection Loosen electrical harness connections as neces- sary to lift harness base away from the pressure Inspect all parts for cracks, heat damage, or signs relief valve. of corrosion. Replace damaged parts. Clean debris from housing and parts. Remove screws and cover from pressure valve assembly.
Page 197 EVINRUDE ICON REMOTE CONTROL SYSTEM EVINRUDE ICON REMOTE CONTROL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............198 COMPONENTS .
Page 198: Service Chart
EVINRUDE ICON REMOTE CONTROL SYSTEM SERVICE CHART SERVICE CHART ESM to throttle ESM to shift actuator connector ESM power actuator connector supply harness ESM to trim/tilt connector ESM to engine harness – key switch connector ESM to EMM connector ICON buss cable connector 60 to 84 in.
Page 199: 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 200: Throttle Actuator
EVINRUDE ICON REMOTE CONTROL SYSTEM COMPONENTS Throttle Actuator If the throttle cannot move toward open position, the FORWARD or REVERSE indicator LED The throttle actuator converts electronic signals flashes (depending on gear position when fault from the ESM into the mechanical motion required occurred).
Page 201: Icon Component Servicing
EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING ICON COMPONENT Installation Install grommets on ESM. Apply soapy water to SERVICING grommets and push assembly on to studs. WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
Page 202 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Route the CANbus harness from the ESM around Route ESM harnesses as shown and secure with the flywheel cover to the EMM as shown and tie straps. ESM to boat network cable should go secure with tie straps.
Page 203 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Route ESM power supply harness positive (+) ter- Route battery cable and ESM to boat network minal to solenoid positive terminal. Install copper cable out through the rigging grommet. crush washer over ESM positive ring terminal. 1.
Page 204: Shift Actuator
EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Shift Actuator Remove the four shift actuator retaining screws. Removal Disconnect the battery cables at the battery. Remove the starboard lower engine cover. Observe and note all wire routings before disas- sembling. Remove clips and washers from the shift link.
Page 205: Throttle Actuator
EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Connect the shift actuator harness. Attach to clip Throttle Actuator on mounting plate. Removal Disconnect the battery cables at the battery. Remove the flywheel cover and air silencer. Observe and note all wire routings before disas- sembling.
Page 206 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON COMPONENT SERVICING Use Ball Socket Remover tool, P/N 342226, to Installation remove throttle link from actuator arm. Remove old adhesive from clamp retaining screw and shift actuator retaining screws. Apply Nut Lock on the threads of the screws. Install throttle actuator on mounting plate with three long screws and one short screw.
Page 207: Icon System Settings
EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS ICON SYSTEM SETTINGS Route all harnesses as shown and secure with tie straps. Set Engine Identity (Instance) In a multi-engine application, the transom position of the outboard must be identified on the network. Engine identity is set by an Engine Identity Plug installed in the ESM.
Page 208: Calibrate Actuator Stroke
EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS Calibrate Actuator Stroke Throttle Actuator Stroke To set throttle stroke, click the Calibrate Throttle button. The actuator arm will move forward and CAUTION back to find the mechanical limits of the throttle After installation, dealer...
Page 209 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS • To set reverse gear shift stroke: Select FORWARD under Shift Position on the • Remove shift link, but keep it installed on the ICON screen. The actuator arm will move for- ward.
Page 210 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM SETTINGS After forward and reverse strokes have been cali- Lock the retainers by moving the angled section brated, the ESM calculates neutral position. behind the straight section. Install the shift link and secure with retainer clips and washers.
Page 211: 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 212: 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 213: 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 214 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULT CODE CHART Possible Causes and Fault Code Description LED Indicators Flowchart Reference Trim and tilt switch panel harness is damaged or not connected to the remote control. Trim Switch Module Com- Trim and tilt switch panel harness munication Fault is damaged or not connected to the switch panel.
Page 215 EVINRUDE ICON REMOTE CONTROL SYSTEM ICON SYSTEM FAULT CODE CHART Possible Causes and Fault Code Description LED Indicators Flowchart Reference Throttle link arm from ICON add- Throttle Actuator Motion on kit is not assembled to the out- Fault board. FORWARD or REVERSE LED The ESM tries to move the Throttle linkage components are flashes (depending on gear...
Page 216: Technician's Notes
EVINRUDE ICON REMOTE CONTROL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 217 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............218 COMPRESSION TESTING .
Page 218: Service Chart
POWERHEAD SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 168-192 In. lbs. (19-21.7 N·m) 50-70 In. lbs. (5.6-8 N·m) 60-84 In. lbs. (7-9.5 N·m) 15-30 Ft. lbs. (20-41 N·m) 40-50 In. lbs. (4.5-5.5 N·m) 40-50 In.
Page 219 POWERHEAD SERVICE CHART 48 In. lbs. (5.5 N·m) 30-32 Ft. lbs. (41-43 N·m) H, X Triple-Guard Grease Gasket Sealing Compound Red Ultra Lock Needle Bearing Grease Outboard Engine Lubricant See Service Manual Text 005229 DSS135...
Page 220: 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. Disconnect crankshaft position sensor (CPS) con- Before starting any fuel system service, nector. Remove all spark plugs. carefully relieve fuel system pressure.
Page 221 POWERHEAD POWERHEAD REMOVAL Disconnect power trim connectors. Disconnect electrical harness from exhaust valve actuator (V4 models). It is not necessary to remove actuator from exhaust housing. 1. Tilt limit switch connector 005254 2. Sending unit connector 1. Actuator connector 005247 Disconnect water overflow hose from vapor sepa- rator.
Page 222: Powerhead Disassembly
POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist. DISASSEMBLY Remove the four small powerhead screws, seven large powerhead screws, and the upper mount Systems Removal screws. To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location.
Page 223: Throttle Linkage Removal
POWERHEAD POWERHEAD DISASSEMBLY Throttle Linkage Removal Crankcase Disassembly Remove throttle cam and throttle lever. Use a 1/8 in. diameter pin punch to push crank- case taper pin toward the front side of the engine. IMPORTANT: Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin.
Page 224: Cylinder Head Removal
POWERHEAD POWERHEAD DISASSEMBLY Connecting Rods and Pistons Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or Use a permanent marker to identify each connect- rubber mallet to loosen. ing rod cap, connecting rod, and piston by cylinder number.
Page 225: Crankshaft Removal
POWERHEAD POWERHEAD DISASSEMBLY The wrist pin fit is loose on both sides. Push the NOTICE Reattach each rod cap to its rod as wrist pin through to free the piston from the con- soon as the piston is removed. Each cap is necting rod.
Page 226 POWERHEAD POWERHEAD DISASSEMBLY Remove upper seal from crankshaft. Discard the Use a punch to remove the housing seal. Discard seal. A new upper seal must be installed on seal. assembly. 1. Punch 002053 49068 Inspect housing and replace if necessary. Remove the lower bearing seal housing.
Page 227 POWERHEAD POWERHEAD DISASSEMBLY Remove the lower main bearing only if it needs to Remove and inspect crankcase seal rings. Iden- be replaced. Use external retaining ring pliers to tify each ring for installation in original location. remove the lower bearing retaining ring. 49069 24384 Remove center main bearings and split sleeves...
Page 228: Cylinder Block Cleaning
POWERHEAD CYLINDER BLOCK CLEANING CYLINDER BLOCK Use Gel Seal and Gasket Remover to remove all traces of gaskets, adhesives, and Gel-Seal II™ CLEANING sealant from the cylinder block and crankcase. WARNING IMPORTANT: Before inspecting or assembling To avoid personal injury, wear eye protec- powerhead, all internal components must be com- tion and rubber gloves when using Gel pletely clean and free of contaminants.
Page 229: Powerhead Inspection
POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diameter of each crankpin and main INSPECTION bearing journal. The lower main bearing journal would only be measured if the bearing was For dimensions, refer to SERVICE SPECIFICA- removed for another reason. TIONS AA MODELS on p. 10. IMPORTANT: Before any inspection process can begin, all internal components must be com-...
Page 230: Cylinder Bore
POWERHEAD POWERHEAD INSPECTION Cylinder Bore Pistons Use a Cylinder Bore Gauge to inspect each cylin- Visually inspect pistons for signs of abnormal der bore for an out-of-round, oversize, or tapered wear, scuffing, cracks, or burning. condition. Be sure the gauge is perfectly square in Piston Rings the bore when measuring.
Page 231: Powerhead Assembly
POWERHEAD POWERHEAD ASSEMBLY POWERHEAD Bearings Inspect center main bearing and split sleeves for ASSEMBLY excess wear, nicks, or scratches. Replace, if nec- essary. 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 232 POWERHEAD POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installa- lower housing with extended lip facing down. tion, thread Slide Hammer, P/N 391008, into Lubricate seal lip with Triple-Guard grease. installer and pull it off. IMPORTANT: Inspect sleeve after installation. Sleeve must not be used if surface is damaged.
Page 233: Pistons And Connecting Rods
POWERHEAD POWERHEAD ASSEMBLY Thoroughly clean upper seal area of the crank- ment dots and the diagonal oil hole facing up, shaft. Install new upper seal on crankshaft. Do not toward the flywheel. apply sealer to outside edge of the seal. 1.
Page 234 POWERHEAD POWERHEAD ASSEMBLY Install wrist pin through piston and connecting rod, Installing Pistons pushing bearing tool out through the piston. 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 235: Cylinder Head Installation
POWERHEAD POWERHEAD ASSEMBLY Cylinder Head Installation Apply a 1/16 in. (2 mm) bead of RTV adhesive around each water passage on the block and cyl- Install a new thermostat seal in cylinder head with inder head as shown. side marked “TO CYL HEAD” facing toward ther- mostat.
Page 236: Crankshaft And Connecting Rods
POWERHEAD POWERHEAD ASSEMBLY Crankshaft and Connecting dowel pin hole will help in the alignment pro- cess. Rods Apply Gasket Sealing Compound to lower oil seal groove in cylinder block. DO NOT put any sealer in upper seal groove. Check that main bearing alignment dowel pins are seated in the block.
Page 237 POWERHEAD POWERHEAD ASSEMBLY Install rod cap screws finger tight (NO MORE than setting (one line showing). Rotate adjustment 6 in. lbs. (1 N·m) maximum). knob 180° to lock in position. 1. Center position, one line showing 002484 49080 Secure restraining jaw “C” and forcing jaw “D” to frame.
Page 238 POWERHEAD POWERHEAD ASSEMBLY Apply a light coat of outboard lubricant to the cor- Use Torquing Socket, P/N 331638, to tighten rod ners of the connecting rod and rod cap. Place cap screws in three stages: frame on connecting rod using the following pro- •...
Page 239: Crankcase Assembly
POWERHEAD POWERHEAD ASSEMBLY Crankcase Assembly Apply outboard lubricant to the main bearing screws. Install screws finger tight, no more than Thoroughly clean and degrease the mating 60 in. lbs. (7 N·m). flanges of the crankcase and cylinder block with a non-petroleum based solvent, such as isopropyl alcohol or acetone, and let air dry.
Page 240: Shift Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Start in the center and work outward in a spiral Shift Linkage Installation pattern. Lubricate shift linkage bosses at the base of the crankcase with Triple-Guard grease. Insert bush- ings into bosses. Apply Triple-Guard grease to the shaft of the shift lever assembly.
Page 241: Throttle Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Throttle Linkage Installation Final Powerhead Assembly Apply Nut Lock to threads of throttle lever screw. Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 158. Insert spring into cavity of throttle lever. Install oil recirculating hoses and check valves.
Page 242: Upper Mount Servicing
POWERHEAD UPPER MOUNT SERVICING UPPER MOUNT Dislodge mount assemblies and remove. SERVICING Removal Remove mount retainer screw. 005312 Inspect mounts and replace if necessary. IMPORTANT: The motor mount, washer, and screw are serviced as an assembly. Do not disas- 1. Mount retainer screw 005309 semble.
Page 243: Powerhead Installation
POWERHEAD POWERHEAD INSTALLATION POWERHEAD Installation Place mount assemblies in position, with flats fac- INSTALLATION ing away from each other. Apply Permatex No. 2 to both sides of a new base Apply Moly Lube to all sides of retainer and install gasket as shown.
Page 244 POWERHEAD POWERHEAD INSTALLATION Install pins from Alignment Pin Kit, P/N 5007167, With alignment pins in place, loosely install as shown. Tighten pins until fully seated. remaining powerhead screws and upper mount screws. 005274 1. Large powerhead screws 005277 2. Small powerhead screws 3.
Page 245 POWERHEAD POWERHEAD INSTALLATION Place the shift rod in the shift rod lever. Install the Connect the power trim connectors. retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1. Tilt limit switch connector 005254 2.
Page 246: Final Adjustments
POWERHEAD POWERHEAD INSTALLATION Install flywheel cover. Final 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. 42. •...
Page 247: Powerhead Views
POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS V4 Starboard – Hose Routings 007156 V4 Port – Hose Routings 008452...
Page 248: V4 Starboard
POWERHEAD POWERHEAD VIEWS V4 Starboard 007158 V4 Port 008375...
Page 249: V4 Front
POWERHEAD POWERHEAD VIEWS V4 Front 007160...
Page 250: V4 Rear
POWERHEAD POWERHEAD VIEWS V4 Rear 007161...
Page 251: V4 - V6 Top - Hose Routings
POWERHEAD POWERHEAD VIEWS V4 – V6 Top – Hose Routings 007162...
Page 252: V4 - V6 Top
POWERHEAD POWERHEAD VIEWS V4 – V6 Top 007163...
Page 253: V6 Starboard - Hose Routings
POWERHEAD POWERHEAD VIEWS V6 Starboard – Hose Routings 007164...
Page 254: V6 Port - Hose Routings
POWERHEAD POWERHEAD VIEWS V6 Port – Hose Routings 008453...
Page 255: V6 Port
POWERHEAD POWERHEAD VIEWS V6 Port 007167...
Page 256: V6 Starboard
POWERHEAD POWERHEAD VIEWS V6 Starboard 007166...
Page 257: V6 Starboard Icon Models
POWERHEAD POWERHEAD VIEWS V6 Starboard ICON Models 008257...
Page 258: V6 Front
POWERHEAD POWERHEAD VIEWS V6 Front 007168...
Page 259: V6 Rear
POWERHEAD POWERHEAD VIEWS V6 Rear 007169...
Page 260: Technician's Notes
POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 261 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............262 TILT TUBE .
Page 262: Service Chart
MIDSECTION SERVICE CHART SERVICE CHART 8-12 In. lbs. 40-50 In. lbs. (0.9-1.4 N·m) (4.5-5.5 N·m) 110-130 Ft. lbs. (149-176 N·m) 10-16 In. lbs. (1.1-1.8 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.5 N·m) 28-30 Ft.
Page 263 MIDSECTION SERVICE CHART V4 M XHAUST OUSING ODELS 60-84 In. lbs. (7-9.5 N·m) 20-22 Ft. lbs. (27-30 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 20-22 Ft. lbs. (27-30 N·m) 156-180 In. lbs. (18-20 N·m) 120-144 In. lbs. (13.5-16.5 N·m) Triple-Guard Grease Gasket Sealing Compound...
Page 264 MIDSECTION SERVICE CHART V6 M XHAUST OUSING ODELS 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. 216-240 In. lbs. (7-9.5 N·m) (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 20-22 Ft. lbs. (27-30 N·m) 156-180 In. lbs. (18-20 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube...
Page 265 MIDSECTION SERVICE CHART 005204...
Page 266: 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 267: Installation
MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of thread are WARNING engaged. Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.
Page 268: Exhaust Housing Service
MIDSECTION EXHAUST HOUSING SERVICE EXHAUST HOUSING Remove the exhaust housing. SERVICE Exhaust Housing Removal Before removing the exhaust housing: • Remove the gearcase. Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p. 294. • Remove the powerhead. Refer to POWER- HEAD REMOVAL on p.
Page 269: Exhaust Housing Installation
MIDSECTION EXHAUST HOUSING SERVICE If removed, coat the lower mounts with soapy Exhaust Housing Installation water and press into the exhaust housing with the Bring the exhaust housing into position with the “OUTSIDE” mark facing outward. stern bracket. Install four new lower mount screws with lock- patch.
Page 270: Exhaust Housing Disassembly - V6 Models
MIDSECTION EXHAUST HOUSING SERVICE Exhaust Housing Disassembly – Exhaust Housing Disassembly – V6 Models V4 Models Remove the front and rear screws retaining the Remove three screws and exhaust valve actuator. adapter/inner exhaust housing to the exhaust housing. 1. Actuator screws 007182 Remove collar only if replacing exhaust housing.
Page 271: Cleaning And Inspection
MIDSECTION EXHAUST HOUSING SERVICE Cleaning and Inspection Inspect the water tube for obstructions or kinks, which may restrict water flow. WARNING Exhaust Housing Assembly – V6 Wear safety glasses to avoid personal Models injury, and set compressed air to less than Apply Adhesive 847 to the bottom flange of the 25 psi (172 kPa).
Page 272: Exhaust Housing Assembly - V4 Models
MIDSECTION EXHAUST HOUSING SERVICE Exhaust Housing Assembly – Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing. V4 Models Install the collar on shaft. Use a 0.030 in. (0.762 mm) feeler gauge to set the gap between the collar and exhaust housing as shown.
Page 273 MIDSECTION EXHAUST HOUSING SERVICE Check that exhaust valve linkage is oriented as Rotate and push actuator into position. Apply Tri- shown. ple-Guard grease to screw threads. Install screws and washers. Tighten screws to 60 to 84 in. lbs. (7 to 9.5 N·m). 007184 Apply a small amount of Triple-Guard grease to 1.
Page 274: Extension Service - V4 Models
MIDSECTION EXTENSION SERVICE – V4 MODELS EXTENSION SERVICE – STERN BRACKET V4 Models Stern Bracket Disassembly Before servicing the stern bracket: Removal • Remove gearcase. Refer Gearcase Remove six screws retaining extension. GEARCASE REMOVAL AND INSTALLATION on p. 294. • Remove powerhead.
Page 275 MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer. It Remove the anode. may be necessary to tap the steering shaft out using a wood dowel and mallet. 1. Anode 30762 Remove the swivel bracket. Inspect and, if neces- 30735 sary, replace the tilt tube bushings.
Page 276 MIDSECTION STERN BRACKET Remove the tilt limit switch and retainer from the Remove the two trim rod rollers from the swivel swivel bracket. bracket. 1. Tilt limit switch 30758 1. Trim rod roller 30754 2. Retainer Remove the tilt support and bushing from the Disconnect the trail lock spring and remove it from swivel bracket and inspect the detent roller and the swivel bracket.
Page 277: Stern Bracket Assembly
MIDSECTION STERN BRACKET Stern Bracket Assembly Install the two trim rod rollers on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. IMPORTANT: (25 to 27 N·m). Before proceeding, make sure all components have been thoroughly cleaned. Replace any seals that have been removed.
Page 278 MIDSECTION STERN BRACKET Install the tilt limit switch and retainer on the swivel • Coat the bushings and seal lips with Triple- bracket. Tighten screws to a torque of 40 to 50 in. Guard grease. lbs. (4.5 to 5.5 N·m). 30765 / 30764 Coat tilt tube bushings with Triple-Guard grease 1.
Page 279 MIDSECTION STERN BRACKET Install the steering shaft and thrust washer. and tighten the nut to a torque of 130 to 150 ft. lbs. (176 to 204 N·m). 30735 30767 Install the steering shaft keeper. Apply Locquic Primer and Nut Lock to the splines of the steering Fill the swivel bracket with Triple-Guard grease shaft and lower mount bracket.
Page 280: Exhaust Relief Muffler Assembly
MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY EXHAUST RELIEF The overboard indicator and flush port in the exhaust relief grommet connect to the vapor sepa- MUFFLER ASSEMBLY rator with a hose. This hose is not connected to the muffler assembly. The exhaust relief muffler is located at the rear of the powerhead and concealed by the lower motor covers.
Page 281 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHARTS ..............283 GEARCASE TYPES .
Page 282 GEARCASE GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY ............333 PRE-DISASSEMBLY INSPECTION .
Page 283: Service Charts
GEARCASE SERVICE CHARTS SERVICE CHARTS V4 20 “S2”–T TANDARD OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. 47-51 Ft. lbs. (24-27 N·m) (64-69 N·m) 26-28 Ft.
Page 284 GEARCASE SERVICE CHARTS V6 20 V4 25 “O”–T TANDARD OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft.
Page 285 GEARCASE SERVICE CHARTS V4 25 “O”–T OUNTER OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft.
Page 286 GEARCASE SERVICE CHARTS V6 S , 25 “M2”– TANDARD OTATION ODELS TYPE EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft.
Page 287 GEARCASE SERVICE CHARTS V6 C “M2”–T OUNTER OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 60-84 in. lbs. 18-20 Ft.
Page 288 GEARCASE SERVICE CHARTS V6 P “L2”–T ERFORMANCE ODELS EARCASE 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. 24-36 In. lbs. (13.5-16.5 N·m) (3-4 N·m) 60-84 In. lbs. (7-9.5 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft. lbs. 26-28 Ft. lbs. (24-27 N·m) (35-38 N·m) 60-84 in.
Page 289: Gearcase Types
GEARCASE GEARCASE TYPES GEARCASE TYPES Housing Outboard Model Description of Features Gear Ratio Type* V4 20 in. “S2” unique driveshaft with bolted pinion, oversized gearset 13:26 (.500) V4 25 in. special gear ratio, uses V6 style prop 12:27 (.444) V4 25 in. “O”...
Page 290 GEARCASE GEARCASE TYPES Housing Profiles V4 “S2” Type V4, V6 “O” Type 19.079 19.20 4.124 4.625 V6 “M2” Type V6 “L2” Type 19.20 19.20 006832 4.918 5.082...
Page 291: Propeller Service
GEARCASE PROPELLER SERVICE PROPELLER SERVICE Propeller Selection Inspection CAUTION Carefully examine propeller and outboard for the Selection of the wrong propeller could following: reduce engine service life, affect boat per- • Damaged blades and signs of propeller cavita- formance, or cause serious damage to the tion (burned paint, etc.) powerhead.
Page 292: Propeller Hardware Installation
GEARCASE PROPELLER SERVICE When selecting a propeller, consider the following: Propeller Hardware Installation • Use an accurate tachometer to determine the engine’s full-throttle RPM. WARNING • The outboard should be trimmed for top speed. To prevent accidental starting while servic- •...
Page 293: Gearcase Leak Test
GEARCASE GEARCASE LEAK TEST GEARCASE LEAK TEST If cotter pin holes in the nut (without keeper) and shaft do not align, tighten further. Do not loosen. Drain lubricant before testing. Install keeper (if applicable). Install new cotter pin. Use Gearcase Pressure Tester, P/N 507977. Aluminum or stainless steel Install lubricant drain/fill plug and seal, thread Small diameter hub...
Page 294: Gearcase Removal And Installation
GEARCASE GEARCASE REMOVAL AND INSTALLATION GEARCASE REMOVAL Remove the 3/8-16 in. screw and washer, and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads.
Page 295: Gearcase Installation
GEARCASE GEARCASE REMOVAL AND INSTALLATION Gearcase Installation Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. WARNING • Water tube enters the water pump. • Lower inner exhaust housing installs correctly. During service, the outboard may drop •...
Page 296 GEARCASE GEARCASE REMOVAL AND INSTALLATION IMPORTANT: ft. lbs. (47 to 54 N·m). For adjustment, refer to New gearcase screws are treated Trim Tab Adjustment on p. 33. with a thread-locking material. Apply Triple-Guard grease to threads to ensure that the correct clamping force is achieved when tightening—If a previously installed screw is re-used, use a wire brush to remove any old thread-locking material or...
Page 297: Water Pump Service
GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE IMPORTANT: During break-in period of a reas- sembled gearcase, change the gearcase lubricant Disassembly between 10 to 20 hours of operation. Rotate the driveshaft counterclockwise to unlock the impeller key. Remove the four impeller hous- ing screws.
Page 298: Assembly
GEARCASE WATER PUMP SERVICE Assembly On V6 models, install the water tube grommet with the inside taper facing up. Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs. IMPORTANT: Do not allow any sealer to get into the air bleed groove in the impeller housing.
Page 299 GEARCASE WATER PUMP SERVICE Apply Triple-Guard grease to a new impeller O- ring. Slide the O-ring down the driveshaft and half way over installed impeller key to temporarily hold key in place. V4models 32001 1. Impeller housing grommet 2. Triple-Guard grease Lightly coat the inside of the liner with Triple- 1.
Page 300: Shift Rod Adjustment
GEARCASE SHIFT ROD ADJUSTMENT and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 SHIFT ROD N·m). ADJUSTMENT On 25 in. and 30 in. V6 models, place the appro- priate water tube spacer and grommet on the Check the shift rod height from the shift rod hole to impeller housing cover.
Page 301: Gearcase - Standard Rotation
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY GEARCASE – STANDARD ROTATION GEARCASE • Hydrostatic Seal Grooves — Must be in good condition to help prevent propeller ventilation. DISASSEMBLY Pre-Disassembly Inspection WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).
Page 302: Propeller Shaft Bearing Housing Removal - "S2" And "O" Type
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the propeller shaft bearing housing from the gearcase using the following: Removal – “S2” and “O” Type • Puller body, screw, and handle from Universal Puller Set, P/N 378103. IMPORTANT: Identify gearcase type before dis- •...
Page 303: Propeller Shaft Bearing Housing Removal - "L2" And "M2" Type
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the propeller shaft bearing housing from the gearcase using: Removal – “L2” and “M2” Type • Propeller Shaft Bearing Housing Puller Kit, P/N 354060. IMPORTANT: Identify gearcase type before dis- assembly.
Page 304: Pinion Gear And Driveshaft Removal - "S2" Type
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Pull propeller shaft and bearing housing far Pinion Gear and Driveshaft enough to loosen the PRESSED bearing housing Removal – “S2” Type from the gearcase housing. IMPORTANT: To separate the upper driveshaft from the lower driveshaft, the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft.
Page 305 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Lift and remove upper driveshaft from lower drive- shaft. Refer to Propeller Shaft Bearing Housing Removal – “S2” and “O” Type on p. 302. Remove propeller shaft bearing housing and reverse gear, thrust bearing and thrust washer. Push down on shift rod to move the clutch dog to reverse position.
Page 306 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY With driveshaft bearing housing and screws in counterclockwise direction. Loosen screw com- place, insert Lower Driveshaft Spline Tool, pletely P/N 5007052, into lower driveshaft. 1. Lower Driveshaft Spline Tool 005407 005409 Insert Lower Driveshaft Wrench, P/N 352877, Remove the four driveshaft bearing housing through Lower Driveshaft Spline Tool and lower screws and then the bearing housing.
Page 307: Pinion Gear And Driveshaft Removal - "O", "L2", And "M2" Type
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove pinion gear from gearcase housing. Remove the four driveshaft bearing housing screws. 005420 1. Driveshaft bearing housing screws 006876 Pinion Gear and Driveshaft Remove the driveshaft from the gearcase. The Removal – “O”, “L2”, and “M2” bearing housing, shims, thrust bearing, and thrust Type washer will come out with the driveshaft.
Page 308: Driveshaft Service
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Locked Driveshaft Removal Driveshaft Service The driveshaft to pinion taper is a locking taper. If To separate the upper driveshaft (if needed) from necessary, use Driveshaft Puller, P/N 390706, and the lower driveshaft, remove the roll pin. Replace Backing Plate, P/N 325867, to break the lock.
Page 309: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Install the roll pin to the specified dimension. Remove propeller shaft assembly from gearcase. 0.125 in. (3.2 mm) 1. Roll pin DR4610 006839 Shift Housing, Gear and Water Intake Screens Propeller Shaft Removal Remove and clean water intake screens. Replace if damaged.
Page 310: Gearcase Housing Inspection
GEARCASE – STANDARD ROTATION GEARCASE HOUSING INSPECTION GEARCASE HOUSING NOTICE Alignment Gauge Puller, P/N 354718, to install and remove press fit pro- INSPECTION peller shaft bearing housing in L2 and M2 Type gearcase housings. Thoroughly clean gearcase housing to remove all Failure to follow this procedure will result in dirt and debris prior to inspection.
Page 311: Shifter, Bearing And Seal Service
GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE SHIFTER, BEARING AND “O”, “L2”, “M2” T EARCASES Use a 7/8 in. wrench to hold the remover in place. SEAL SERVICE Use a 3/4 in. wrench to turn flange nut clockwise. Draw the bearing up from the housing.
Page 312: Shift Housing Disassembly
GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE “O”, “L2”, “M2” T Place a new O-ring on the pinion bearing retaining EARCASES screw. Apply Gasket Sealing Compound to O- ring. Apply Nut Lock to screw threads. Install the screw and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Page 313 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Push the pin out of the clutch dog. Remove all shifter detent as needed to help ease removal of parts. parts. 1. Pin COA3561 1. Shift lever pin 006890 2. Shift shaft 3.
Page 314: Shift Housing Assembly
GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Shift Housing Assembly Thoroughly grease 25 needle bearings with Nee- dle Bearing grease and place in the bearing case. IMPORTANT: (Note: “S2” Type has caged roller bearing.) Clean and inspect all parts before beginning assembly procedures.
Page 315 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro- shift cradle. Pull shifter detent back up to NEU- peller shaft. Install the clutch dog on the shaft with TRAL position to hold the cradle and shaft in “PROP END”...
Page 316: Driveshaft Bearing Housing Service
GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear- Service ing housing’s bottom groove. The bottom groove is an oil passage. Gearcase damage The driveshaft bearing is not serviceable. Replace could result.
Page 317: Propeller Shaft Bearing Housing Service
GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Propeller Shaft Bearing Housing Inspect the bearing housing anode. Replace anode if it is reduced to two-thirds of original size. Service Tighten screws to a torque of 108 to 132 in. lbs. (12 to 15 N·m).
Page 318 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Bearing Installation OUNTER OTATION HOUSING Oil, then install new bearings in bearing housing. Bearing Installation Tool: • P/N 432401 – front bearing “O” and “M2” type Place the lettered end of the bearing case on the •...
Page 319: Driveshaft Shimming
GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing. NOTICE If a new pinion gear is needed, replace gear set before shimming. Use Seal Installation Tool to install new seals back to back in bearing housing.
Page 320 GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING “O”, “L2”, “M2” T Insert the assembled driveshaft into the tool base EARCASES and tighten preload screw against the driveshaft IMPORTANT: Clean pinion driveshaft until groove on the spring-loaded plunger is flush before assembly. Replace any damaged parts. with end of threads.
Page 321: Gearcase Assembly
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Check squareness of the pinion to the driveshaft. Hold the shim gauge bar against the bearing housing (between the screw holes) while rotating Water Intake Screens just the driveshaft and pinion assembly. Mea- Install water intake screens.
Page 322: Shift Rod Housing Installation
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Shift Rod Housing Installation Install the shift rod spacer on the shift rod (25 in. models). Lubricate a new shift rod cover O-ring with Triple- Guard grease. Install the O-ring into the shift rod Place the shift rod grommet on the shift rod.
Page 323: Pinion Gear And Driveshaft Installation - "S2" Type
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY “M2” T Pinion Gear and Driveshaft EARCASES Apply Adhesive 847 to seal groove of shift rod Installation – “S2” Type cover. Place a new shift rod cover seal in groove. Refer to DRIVESHAFT SHIMMING on p. 319. Place the driveshaft thrust bearing, thrust washer, and correct shim(s) on the driveshaft as shown.
Page 324 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install pinion gear in gearcase housing IMPORTANT: Temporarily install bearing hous- ing for support during pinion tightening procedure. 005420 005426 Install driveshaft with thrust bearing, thrust washer, and correct shim(s) in gearcase housing. Insert Lower Driveshaft Spline Tool, P/N 5007052, Position pinion on lower driveshaft.
Page 325 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY IMPORTANT: To install upper driveshaft into lower driveshaft, Make sure Lower Driveshaft position new retainers (circlip type) on upper Wrench is fully seated in head of pinion screw. driveshaft as shown. Use a long 3/4 in. combination wrench to hold Driveshaft Spline Tool and a 1/2”...
Page 326 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing Service on p. 316. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft. 1. Seal protector COA3130 Apply Gasket Sealing Compound to the threads of the driveshaft bearing housing screws.
Page 327: Pinion Gear And Driveshaft Installation - "O", "L2", And "M2" Type
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Pinion Gear and Driveshaft Adjust shift rod to move clutch dog as far forward as possible. Be sure excess grease is removed Installation – “O”, “L2”, and “M2” from the pinion bearing. Type Washer must be snapped into recess of pinion Refer to DRIVESHAFT SHIMMING on p.
Page 328: Propeller Shaft Bearing Housing And Gear Installation - "S2" And "O" Type
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Apply Gasket Sealing Compound to the threads of Propeller Shaft Bearing Housing the driveshaft bearing housing screws. Tighten and Gear Installation – “S2” and screws in stages to a torque of 120 to 144 in. lbs. “O”...
Page 329: Propeller Shaft Bearing Housing And Gear Installation - "L2" Type
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install two retainers, washers and screws. Apply Propeller Shaft Bearing Housing Ultra Lock to threads and tighten screws to a and Gear Installation – “L2” Type torque of 18 to 20 ft. lbs. (24 to 27 N·m). IMPORTANT: The propeller shaft bearing hous- ing on the “L2”...
Page 330 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install housing into gearcase. Align screw holes Housing must be completely seated in gearcase with retainer slots in gearcase. to install retainer tabs. Depth to retainer tab sur- face bearing housing approximately 1 in. (25.4 mm). 006836 Use Installer Handle, P/N 345822, Propeller Shaft 006845...
Page 331: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Propeller Shaft Bearing Housing Align retaining holes in bearing housing with screw holes in gearcase. Thread Alignment Pins, and Gear Installation – “M2” Type P/N 354140, into gearcase. IMPORTANT: The propeller shaft bearing hous- ing on the “M2”...
Page 332: Final Assembly And Adjustment
GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Housing must be completely seated in gearcase Final Assembly and Adjustment to install retainer screws. Bearing housing is To complete gearcase assembly, refer to: approximately level with gearcase. • GEARCASE LEAK TEST on p. 293 •...
Page 333: Gearcase Disassembly
GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY GEARCASE – COUNTER ROTATION GEARCASE To remove the propeller shaft, bearing housing and forward gear from gearcase, thread Propeller DISASSEMBLY Shaft Adapter, P/N 432398, onto Slide Hammer, P/N 432128, until it seats. Thread adapter com- pletely onto propeller shaft and pull propeller IMPORTANT: Counter rotation (CR) gearcases...
Page 334: Pinion Gear Removal And Driveshaft Servicing
GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY DO NOT use tools designed to push on the pro- Pull propeller shaft and bearing housing far peller shaft. Pushing against the propeller shaft enough to loosen the PRESSED bearing housing could damage the forward gear thrust bearing or from the gearcase housing.
Page 335: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE – COUNTER ROTATION GEARCASE HOUSING INSPECTION Shift Housing, Gear and Water Intake Screens Propeller Shaft Removal Remove and clean water intake screens. Replace if damaged. Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out.
Page 336: Shifter, Bearing And Seal Servicing
GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING SHIFTER, BEARING AND Remove the gear, thrust bearing, and thrust washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. IMPORTANT: The shift housing and bearing are serviced as an assembly.
Page 337: Shift Housing Assembly
GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a shop cloth to catch ball able tool. Once the detent is past the ball, remove and spring. Pull the shifter detent straight out of the tool and position detent to engage NEUTRAL. the housing.
Page 338 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Install arms of shift lever into detent slots. Align Coat thrust bearing and thrust washer with Needle the pivot holes and insert the retaining pin. Push Bearing grease. Place the bearing on the back of shifter detent down.
Page 339: Pinion Bearing
GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Slide the propeller shaft onto the shift shaft, align Remove gear housing retaining ring. the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring.
Page 340 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the thrust bearing. Remove the forward gear bearing only if it needs to be replaced. If removal of the bearing is neces- sary, use Large Puller Jaws, P/N 432129, and Puller Bridge, P/N 432127, with an appropriate base.
Page 341 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING For seal and bearing service refer to Propeller Place the bearing housing on the forward gear. Shaft Bearing Housing Service on p. 317. Assembly If removed, install a new forward gear bearing. Apply Needle Bearing grease to 25 new rollers.
Page 342 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Place the gear assembly so the indicator needle Apply Needle Bearing grease to the thrust washer. makes contact with the flange on the housing. The Place washer in recess of bearing housing. indicator needle must be parallel with the side of the gear housing and perpendicular to the table surface.
Page 343: Propeller Shaft Bearing Housing And Forward Gear - "M2" Type
GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING IMPORTANT: Clamp the propeller shaft bearing housing by the To prevent damage to threads, anode bosses in a vise, as shown. Remove the install forward gear bearing housing assembly by forward gear bearing housing assembly from pro- hand until fully seated against propeller shaft peller shaft bearing housing.
Page 344 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Inspect the forward gear and bearing housing Assembly assembly for excessive wear or damage. Position the forward gear bearing housing assem- bly on a flat, level surface. (Mirror or glass can be used.) Use depth gauge to measure distance from flange of housing to flat surface as shown.
Page 345 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Coat bearing surfaces of propeller shaft with Use Spanner Wrench, P/N 432400, to tighten the gearcase lubricant. Slide the propeller housing gear assembly to a torque of 100 ft. lbs. (136 onto the propeller shaft.
Page 346: Driveshaft Shimming
GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar: • “M2”: Shim gauge bar, P/N 349957 • “O”: Shim gauge bar, P/N 328367 NOTICE If a new pinion gear is needed, replace gear set before shimming. Slide the collar onto the driveshaft with large end in contact with the bearing housing.
Page 347: Gearcase Assembly
GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Check squareness of the bearing housing mount- ing surface by holding the shim gauge bar against the pinion while rotating just the bearing hous- Water Intake Screens ing. Use a feeler gauge to measure clearance Install water intake screens.
Page 348: Shift Rod Cover
GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Shift Rod Cover Housing must be completely seated to install retainer tabs. Refer to Shift Rod Housing Installation on p. 322. Pinion Gear and Driveshaft Installation Refer to Pinion Gear and Driveshaft Installation – “O”, “L2”, and “M2” Type on p. 327. Propeller Shaft Bearing Housing and Gear Installation –...
Page 349: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type
GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Re-tighten two retainer screws to 18 to 20 ft. lbs. IMPORTANT: To align pinion, clutch dog and (24 to 27 N·m). forward gears turn driveshaft clockwise while installing propeller shaft bearing housing. Gears Confirm that torque on the wedge screw is 15 to MUST align for bearing housing to seat com- 20 in.
Page 350: Final Assembly And Adjustment
GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Housing must be completely seated in gearcase to install retainer screws. Bearing housing is approximately level with gearcase. 006928 Apply Ultra Lock to threads and install two retain- ing screws. Tighten screws to a torque of 18 to 20 ft.
Page 351 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............352 SYSTEM DESCRIPTION .
Page 352: Service Chart
TRIM AND TILT SERVICE CHART SERVICE CHART 20” 115 HP M ODELS INGLE ISTON YSTEM 30 to 50 In. lbs. (4 to 5.6 N·m) 60 to 85 ft. lbs. (82 to 115 N·m) 45 to 55 In. lbs. (5 to 6 N·m) 60 to 85 ft.
Page 353 TRIM AND TILT SERVICE CHART 25” M ODELS HREE ISTON YSTEM 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 84-108 In. lbs. 58-87 Ft. lbs. (9.5-12 N·m) (79-118 N·m) 60-84 In. lbs. 60-70 Ft. lbs. (7-9.5 N·m) (81-95 N·m) DO NOT OVER TIGHTEN 58-87 Ft.
Page 354: System Description
TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket And Tilt Support The power trim/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in the tilted position. This bracket The system consists of: protects the hydraulic system from damage.
Page 355: Modes Of Operation (Three Piston System)
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) 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 356: Tilt-Down / Trim-In Mode
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) 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 357: Impact Relief
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) 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 358: Shallow Water Drive Tilt Relief
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) 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 359: Manual Release - Up
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve. Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring.
Page 360: Manual Release - Down
TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) 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 361: Routine Inspections
TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General Single Piston System Check for external signs of fluid leakage. Correct Use the following guidelines to check a single pis- causes as necessary. ton trim/tilt unit that is not working correctly. Check the battery to be sure it is in good operating Cylinder Leakdown: condition.
Page 362: Three Piston System
TRIM AND TILT TROUBLESHOOTING Three Piston System If the outboard does not tilt as high as it should, and the tilt motor TURNS OFF at maximum tilt If the power trim/tilt system has malfunctioned and (does not sound like it is stalled at the maximum the cause has not been determined, the Symp- tilt position), adjust the tilt limit switch higher and toms Chart on p.
Page 363 TRIM AND TILT TROUBLESHOOTING STEP 3 • The “B” adapter, P/N 336659, checks operation of the DOWN circuit. Go to TILT/TRIM RELAY TEST on p. 108 to determine if problem is power supply. STEP 4 Remove trim motor and check condition of drive coupling.
Page 364 TRIM AND TILT TROUBLESHOOTING bypass the reservoir cap. These steps will relieve all rods must be completely extended to check the pressure in the unit. fluid level. 1. Manual release valve 41739 41757 2. Reservoir cap Starting with the tilt cylinder fully retracted, run the Remove the manual release valve retaining ring unit UP.
Page 365: Electrical Circuit Tests
TRIM AND TILT ELECTRICAL CIRCUIT TESTS ELECTRICAL CIRCUIT Remove the manual release valve. Install pres- sure gauge and adapter “B” to check problems in TESTS the DOWN circuit. Cycle the unit down and up several times to purge air. With all rods fully Relay Testing extended, run the unit down momentarily to reduce pressure.
Page 366: Trim And Tilt Motor No Load Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Connect a 0 to 100 A DC ammeter in series Test results include three basic possibilities: between the battery side of the starter solenoid A. Low current draw – Check for: and the red lead to the trim/tilt relay module. •...
Page 367: Trim Gauge Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Monitor motor RPM and current draw. Trim Gauge Test STEP 1 Turn key switch ON. Using a voltmeter, check for voltage between the trim gauge “I” and “G” termi- nals. • If no voltage, check condition of instrument har- ness, key switch, and engine 20 A fuse.
Page 368: Trim Sender Test
TRIM AND TILT TRIM AND TILT REPLACEMENT Trim Sender Test TRIM AND TILT REPLACEMENT IMPORTANT: To avoid immediate meter dam- age, never apply a multimeter to an electrical cir- Removal cuit where voltage is present. Raise the outboard and engage the tilt support. Disconnect the 3-pin connector between the instrument harness and engine trim harness.
Page 369 TRIM AND TILT TRIM AND TILT REPLACEMENT Separate the trim/tilt unit wires in the braided tube Use a punch to remove the upper pin. to permit removal through the hole in the stern bracket. 25065 Retract the tilt cylinder rod. 25078 Remove the external snap rings from the lower pin.
Page 370: Installation
TRIM AND TILT TRIM AND TILT REPLACEMENT Installation Place trim/tilt wires in braided tube and install through hole in the stern bracket. Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. Install external snap rings on lower pin with sharp edge of ring facing out.
Page 371: Servicing-Single Piston System
TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM SERVICING–SINGLE Slowly remove the manual release valve. There may be pressure behind the valve—wear safety PISTON SYSTEM glasses. Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from con- taminating internal parts.
Page 372: Piston Seal And End Cap
TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Install new retaining ring in groove. Use end cap spanner wrench, P/N 352932, to remove the end cap from the trim and tilt assem- bly. 1. Retaining ring 004283 Piston Seal and End Cap 1.
Page 373 TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Remove springs, valves and check balls from the Inspection piston assembly. Remove ALL debris. Thoroughly clean and dry all parts before continuing. Remove ALL old thread locking compound from threaded parts. Inspect the piston, rod and cylinder bore for scratches or damage which could allow seals to leak.
Page 374 TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Apply trim/tilt fluid to the piston o-ring. Install the Assemble the piston as shown in the SERVICE piston o-ring on the piston. Make sure the o-ring is CHART on p. 352. NOT damaged or twisted. Remove and reinstall Apply red Ultra Lock to the threaded portion of the the o-ring correctly if necessary.
Page 375 TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM chart. Part number is stamped on the bottom of Place the loading mandrel, on the piston. Make the housing of trim and tilt assemblies. sure the edge of the loading mandrel is flush with the top edge of the seal groove in the piston.
Page 376 TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Place the seal on the loading mandrel. Lift the resizing fixture up over the piston as shown. 1. Seal 008833 1. Resizing fixture 008835 Slowly move the seal pusher down the mandrel. Use the seal pusher to slide the seal into the Lift resizing fixture over the seal while observing groove of the piston.
Page 377 TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Leave the resizing fixture in place for at least five Fill the cylinder with Power Trim/Tilt & Steering minutes. Fluid. Failure to fill the cylinder could cause diffi- culty purging air from the trim and tilt assembly. 1.
Page 378: Trim Motor
TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Trim Motor Install a new motor O-ring. Refer to Removal on p. 368 for trim and tilt assembly removal procedure. Removal Remove the four large motor flange retaining screws. Remove the motor and discard O-ring, screws, and washers.
Page 379: Servicing - Three Piston System
TRIM AND TILT SERVICING – THREE PISTON SYSTEM SERVICING – THREE Run the motor, then recheck oil level. Cycle the unit several times and check the oil level when the PISTON SYSTEM cylinder is fully extended. Oil should be level with bottom of fill port.
Page 380 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Screw the manual release valve in. Remove the Remove the three Pozidriv screws securing the retaining ring using retaining ring pliers. Remove reservoir to cylinder body. Remove reservoir. the manual release valve. 41753 41739 Remove the reservoir O-ring from the cylinder...
Page 381 TRIM AND TILT SERVICING – THREE PISTON SYSTEM 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 382: Tilt Piston Removal
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the manifold. Remove five O-rings from Slowly pull the piston out with a rag wrapped cylinder body. Check machined surfaces for nicks around the rod and the top of the cylinder. Drain and scratches.
Page 383: Tilt Piston Identification
TRIM AND TILT SERVICING – THREE PISTON SYSTEM 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 384: Tilt Rod Assembly
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Use a screwdriver to carefully pry the scraper out Use a wire brush to clean all thread-locking mate- of the end cap. Discard the scraper. Remove and rial from the threads on the tilt rod. discard the large outer O-ring.
Page 385: Trim Rod Removal
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Clean any thread-locking material from the Trim Rod Removal threads on the inside of the nut. Spray threads of Unscrew trim cylinder end caps using Trim Cylin- with Locquic Primer and let dry. Apply a small der End Cap Remover/Installer, P/N 436710, or amount of Nut Lock to the threads.
Page 386: Trim Rod Assembly
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Drain the remaining fluid from the cylinders. Remove the rod from the vise. Use a small screw- Inspect both bores of the trim cylinders for exces- driver to carefully pry the scraper out of the end sive scoring.
Page 387: Manifold And Reservoir Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Lubricate and install a new O-ring and two new Manifold and Reservoir back-up rings on the trim rod piston. Place one Installation back-up ring on each side of the O-ring. Position Lubricate five new manifold body O-rings. Place the open end of the back-up rings 180°...
Page 388: Trim Rod Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM on p. 363. Attach the reservoir to the cylinder body with three Pozidriv screws. Torque the screws to 35 to 52 in. lbs. (4.0 to 5.9 N·m). 41851 Install the reservoir filter screen in the cylinder 41866 body.
Page 389: Tilt Rod Installation
TRIM AND TILT SERVICING – THREE PISTON SYSTEM Spanner Wrench, P/N 912084. Tighten caps to a P/N 912084. Torque cap to 58 to 87 ft. lbs. (79 to torque of 60 to 70 ft. lbs. (81 to 95 N·m). 118 N·m). 41868 41870 Tilt Rod Installation...
Page 390 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Install the filter screen. Fill the reservoir to the bottom of the fill hole with Power Trim/Tilt & Steering Fluid. Install and tighten the reservoir cap. Turn the manual release valve in until it seats. Cycle the unit up and down several times to purge air.
Page 391 TRIM AND TILT SERVICING – THREE PISTON SYSTEM 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 392: Technician's Notes
TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 393 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... .S–3 OUTBOARD SHIFT SYSTEMS AND SAFETY ............S–4 OUTBOARD SPEED CONTROL SYSTEM AND SAFETY .
Page 394 S–2...
Page 395: Marine Products And The Safety Of People Who Use Them
SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.
Page 396: Outboard Shift Systems And Safety
SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...
Page 397: Outboard Speed Control System And Safety
SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...
Page 398: Outboard Steering Control System And Safety
SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: • Must not come apart; • Must not jam;...
Page 399 SAFETY How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When • Follow warnings marked “ ” closely. rigging •...
Page 400: Outboard Fuel, Electrical System, And Safety
SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? •...
Page 401 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields •...
Page 402 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard Check for leaks under engine cover Whenever possible, remove hose from outboard and from tank.
Page 403: Outboard Mounting System And Safety
SAFETY Outboard Mounting System and Safety The mounting system includes: • outboard parts • bolts, nuts, and washers • boat’s transom What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
Page 404: If Weakened, Parts Could Fail Later On The Water, When Not Expected
SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.
Page 405: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety
SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? • Shock absorption system must always be ready to absorb some blows to the lower parts of the outboard. • Outboard must not trim in too far suddenly. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.
Page 406: Outboard Emergency Stop System And Safety
SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
Page 407 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.
Page 408: Summing Up
SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! • Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...
Page 409: Marine Products And The Safety Of People Who Fix Them
SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: •...
Page 410 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
Page 411 SAFETY Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
Page 412 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.
Page 413: Handling Lead/Acid Batteries
SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.
Page 414: Gasoline - Handle With Care
SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...
Page 415: Hazardous Products
SAFETY Hazardous Products Know how items in the shop can hurt people... READ • “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an emergency arise • “How to dispose of can” It’s all on the back of the can or bottle label.
Page 416: Safety Awareness Test
SAFETY Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations...
Page 417 INDEX INDEX Crankshaft 227, 231, 232 Pinion Gear 311 Abbreviations 6 Wrist Pin 225, 233 Accessories Break-In I-Command Water Pressure Transducer EMM Programming 177, 246 Kit, P/N 765353 27 Gearcase 297, 332, 350 XD100 Outboard Oil Decal, P/N 352369 Oiling 177 Procedure 70 Adapter Housing 190 Adjustments...
Page 418 INDEX Steering Cable 38 Service Codes 67 Counter Rotation Gearcase Service 333 Static Ignition Test 83 Cover Service 52 Timing Verification 70, 119 Crankcase TPS Calibration 71, 120 Assembly 239 Driveshaft Disassembly 223 Installation 323, 327 Crankshaft Removal 304, 307, 334 Assembly 231 Service 308 Bearings 231...
Page 419 INDEX Software Replacement 72 Additives 141 Timing Verification 119 Components 142 TPS Calibration 71 Filter 142 Transfer 72 Fuel Circulation Pump 143 Engine Monitor Fuel Filter 43 Description 64 Fuel Lift Pump 142, 149, 152 Low Oil Warning 182 Fuel Manifolds 153 No Oil Warning 174 Fuel Requirements 141 Operation Check 35...
Page 420 INDEX I-Command LED Indicators 79 Outboard connections 24 Lower Cover System settings 25 Installation 53 Water Pressure Gauge 27 Removal 53 ICON Component Servicing Lubrication Electronic Servo Module (ESM) 201 Engine Oil 172 Shift Actuator 204 Gearcase 40, 293 Throttle Actuator 205 Propeller Shaft 39 ICON Network Swivel Bracket 39...
Page 421 INDEX Oiling Rate 69, 176 Priming Oiling System Fuel System 145 Components 172 Oiling System 177 Engine Lubricant 172 Propeller New Engine Set-Up 172 Inspection 291 Oil Distribution Hose Replacement 183 Installation 292 Oil Filters 44 Selection 291 Oil Injector Electrical Circuits 172 Propeller Shaft Oil Pressure Sensor 61 Counter Rotation 335...
Page 422 INDEX Crankshaft Position Sensor 62, 82, 97 Voltage Drop Test 105 EMM 58 Start-In-Gear Protection 35, 106 Engine Temperature Sensor 60, 98, 195 Stator Exhaust Pressure Sensor 45, 59 Resistance Test 99 Oil Pressure 61, 173 Servicing 114 Tests 97 Voltage Output Test 99 Throttle Position Sensor 61, 97, 120 Steering System...
Page 423 INDEX Disassembly 195 321, 326, 327, 346, 347 Inspection 196 Driveshaft Shimming Tool, P/N 5005925 Temperature 11, 13 319, 346 Throttle Actuator Removal 205 Electrical Test Probe Kit, P/N 342677 101 Throttle Linkage Flywheel Holder, P/N 771311 114 Installation 241 Flywheel Service Kit, P/N 434649 114, 116 Lubrication 39 Flywheel Service Kit, P/N 5007181 114, 116...
Page 424 INDEX Propeller Shaft Bearing Housing Installer, Torque Charts P/N 354058 330 see Service Charts Propeller Shaft Bearing Housing Puller Kit, TPS Calibration 71, 120 P/N 354060 303, 333 Trailering Bracket 354 Puller Bridge, P/N 432127 316, 317, 340 Lubrication 39 Rod Cap Alignment Fixture, P/N 396749 Trim and Tilt Assembly 383, 386...
Page 425 INDEX Strategy 77 Timing Light Test 78 Trim and Tilt 361, 365 Trouble Check Chart 1 Upper Mount Installation 243 Removal 242 Vapor Separator Description 142 Installation 152 Removal 152 Voltage Drop Test 105 Water Intake Screens 36 Inspection 36 Installation 321, 347 Removal 309 Water Pressure Gauge 27...
Page 426 INDEX NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other I–10...
Page 427: Trouble Check Chart
TROUBLE CHECK CHART OUTBOARD WILL NOT START TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Battery switch not ON Check battery switch operation Discharged battery Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit.
Page 428: Outboard Will Not Start
TROUBLE CHECK CHART OUTBOARD WILL NOT START OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Check wiring and emergency stop switch. Check Stop circuit grounded the safety lanyard is installed and stop circuit is not grounded. In gear–Tiller models Make sure outboard is in neutral No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return...
Page 429: Outboard Hard To Start
TROUBLE CHECK CHART OUTBOARD HARD TO START OUTBOARD HARD TO START OBSERVATION POSSIBLE CAUSE PROCEDURE Weak battery Check battery, recharge or replace Clean and tighten connections, check voltage Battery cables and connections drop on high amperage circuit Starter or bendix/drive gears Check starter, inspect bendix/drive gears Check water separator/fuel filter, sample fuel from Water in fuel system...
Page 430: Outboard Will Not Shut Off
TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OBSERVATION POSSIBLE CAUSE PROCEDURE Check key switch and ground to key switch, refer Key switch or wire harness to SYSTEM ANALYSIS and ELECTRICAL AND ground IGNITION Outboard starts and Check EMM LED indicators.
Page 431: Outboard Starts, Low Maximum Rpm
TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM service codes and check System- SystemCheck light Outboard is in S.A.F.E. Check warning Refer to specifications, check recommended WOT Incorrect propeller RPM;...
Page 432: Outboard Surges, Runs Rough
TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSERVATION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F.E. Access EMM fault codes Incorrect, fouled, or worn spark Replace spark plugs plugs Check water separator/fuel filter, sample fuel from Water in fuel system fuel return manifold test port Contaminated or poor fuel...
Page 438 Evinrude E-TEC EMM LED Diagnostic Indicators V Models In-line Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS in the Service Manual. KEY ON : LED’s illuminate to indicate circuit function Start assist circuit (SAC) OK (V models only) Sensors / 5V Circuits OK FLASHING LED –...
Page 439 J1-B 60°V4 115 - 130 HP J1-A 1. Oil Injector 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11.
Page 440 J1-B J1-A 60°V6 150-200 HP 1. Oil Injector 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12.
Page 441 EVINRUDE 115 – 300 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied. 1-6 Excessive knock detected CHECK ENGINE Immediate...
Page 442 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Last digit indicates affected cylinder. 51-6 Fuel injector circuit OPEN LED 2: ON (Running) 10 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C). CHECK ENGINE TPS <...

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