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DE300PXINR
BRP DE300PXINR Manuals
Manuals and User Guides for BRP DE300PXINR. We have
1
BRP DE300PXINR manual available for free PDF download: Service Manual
BRP DE300PXINR Service Manual (416 pages)
Brand:
BRP
| Category:
Outboard Motor
| Size: 50.13 MB
Table of Contents
Ervice Anual Contents
4
Table of Contents
4
Table of Contents
5
Safety Notice
6
Abbreviations Used in this Manual
8
Units of Measurement
8
List of Abbreviations
8
Emission-Related Installation Instructions
9
Manufacturer's Responsibility
9
Dealer's Responsibility
9
Owner's Responsibility
9
Epa Emission Regulations
9
Model Designation
10
Models Covered in this Manual
11
Service Specifications
12
Standard Torque Specifications
16
Product Reference and Illustrations
16
Table of Contents
17
Inspection and Maintenance Schedule
18
Control Cable Installation
19
Lifting the Outboard
19
Outboard Rigging Connections
19
Battery Cable Connections
23
Systemcheck Harness Connections
23
I-Command Network Connections
24
Icon Network Connections
25
Water Pressure Gauge
26
Battery and Battery Connections
27
Oetiker Clamp Servicing
28
Adjustments
30
Tilt Limit Switch Adjustment
30
Trim Sending Unit Adjustment
31
Trim Tab Adjustment
32
Dual-Outboard Alignment
33
Operational Checks
34
Cooling System
35
Engine Flushing
36
Running the Outboard Using a Hose and Flushing Adapter
37
Lubrication
38
Steering System
38
Swivel Bracket and Trailering Bracket
38
Throttle and Shift Linkage
38
Tilt Tube
38
Gearcase Lubricant
39
Propeller Shaft
39
Trim and Tilt
41
Indexing
42
Spark Plugs
42
Air Silencer
43
Fuel and Oil Systems
43
Fuel Filter
43
Hoses and Connections
43
Oil Filters and Oil Reservoir
43
Cleaning
44
Exhaust Pressure Fitting
44
Operation Test
44
Anti-Corrosion Protection
45
Storage
46
Pre-Season Service
48
Submerged Engines
48
Engine Cover Service
51
Latch Hook Installation
52
Upper Cover Cap Replacement
52
Upper Cover Service
52
Lower Cover Installation
53
Lower Cover Removal
53
Lower Cover Service
53
Latch Handle Installation
54
Trim Switch Installation
54
Engine Management Module (Emm)
55
Description
56
Emm Inputs and Outputs Diagram
57
55 V Circuit Sensor
58
Emm Temperature Sensor
58
Internal Sensors
58
Barometric Pressure Sensor
59
Circuit Sensor
59
Exhaust Pressure Sensor
59
Air Temperature Sensor
60
Engine Temperature Sensor
60
External Sensors
60
Oil Pressure Sensor
61
Throttle Position Sensor
61
Crankshaft Position Sensor
62
Knock Sensor
62
Neutral/Shift Interrupt Switch
62
Engine Monitor and Warning Systems
63
Fault Code Creation and Storage
63
Idle Controller
63
Internal Emm Functions
63
Neutral Rpm Limiter
63
Rom Verification
63
Rpm Limiter
63
Start Assist Circuit (Sac)
63
Engine Monitor System
64
Shutdown Mode
65
Warning System
65
Communication
66
Diagnostic Software Functions
66
Static Information
66
Dynamic Information
67
Hard Faults
67
Persistent Faults
67
Static Tests
67
Stored Service Codes (Faults)
67
Dynamic Tests
68
Oil Control Settings
69
Fuel Injector Servicing
70
Ignition Timing
70
Tps Calibration
70
Reports
71
Software Replacement
71
Emm Servicing
72
Emm Transfer
72
System Analysis
75
Diagnostic Procedures
76
Diagnostic Software Inspections
76
Visual Inspections
76
Operational Inspections
77
Troubleshooting
78
Cylinder Drop Tests
79
Dynamic Tests
79
Fuel Control Adjustment
79
Inductive Amp Meter Test
79
Emm Led Indicators
80
Key on
80
Starting
80
Running
81
Ignition Output Tests
82
Required Ignition Systems
82
Wiring Inspection
82
Crankshaft Position Sensor (Cps) Test
83
System Voltage Test
83
Static Ignition Test
84
Running Ignition Tests
85
Capacitor Test
86
Ignition Coil Tests
86
Ignition Control Circuit Tests
86
Fuel Delivery Tests
87
Fuel Injector Static Test
87
Fuel Pump Static Test
87
Running Fuel System Tests
88
Electrical and Ignition
89
Service Chart
90
Ignition System Circuit Diagram
92
Electrical Harness Connections
93
Fuse
95
Ground Circuits
95
Crankshaft Position Sensor (Cps) Test
96
Sensor Tests
96
Throttle Position Sensor (Tps) Test
96
Air Temperature Sensor (At) Test
97
Engine Temperature Sensor Test
97
Knock Sensor Test
97
Stator Resistance Tests
98
Stator Tests
98
Stator Voltage Output Test
98
12 V Charging Circuit
99
Charging System Tests
99
55 V Alternator Circuit
100
Auxiliary Battery Charge Wire
100
Electric Start Circuit
101
Electric Start Tests
103
Remote Control Switch Tests
105
Tilt/Trim Relay Test
107
Systemcheck Circuit Tests
108
Tachometer Circuit Tests
110
Flywheel and Stator Servicing
111
Flywheel Removal
111
Stator Service
111
Flywheel Installation
112
Ignition Coil Installation
113
Ignition Coil Removal
113
Ignition Coil Servicing
113
Timing Adjustments
114
Timing Pointer
114
Timing Verification
115
Tps Calibration
115
Electric Starter Servicing
117
Starter Disassembly
117
Starter Removal
117
Starter Cleaning and Inspection
120
Starter Assembly
121
Starter Installation
123
Connector Servicing
124
Fuel System
129
Service Chart
130
Fuel System Hose Routing
133
Fuel System Circuit Diagram
134
Fuel Flow Requirements
135
Fuel System Requirements
135
Portable Fuel Tanks
135
Regulations and Guidelines
135
Fuel Requirements
136
Components
137
Fuel Filter
137
Fuel Lift Pump
137
Vapor Separator
137
Fuel Circulation Pump
138
Fuel Injectors
139
Fuel Manifolds
139
Fuel System Priming
140
Priming the Fuel System
140
Vent Line Clamp
140
Fuel System Pressure Test
141
Fuel System Tests
141
Fuel Injector Pressure Test
142
Pressure Regulator Test
142
Vapor Separator Vent Check
142
Circulation Pump Resistance Test
143
Fuel Injector Resistance Test
143
Lift Pump Pressure Test
143
Lift Pump Diaphragm Test
144
Lift Pump Vacuum Test
144
Anti-Siphon Valve Test
145
Fuel Component Servicing
145
Relieving Fuel System Pressure
145
Fuel Filter Service
146
Fuel Lift Pump Service
147
Fuel Manifold Service
148
Vapor Separator Service
148
Fuel Injector Service
149
Intake Manifold Service
153
Oiling System
157
Service Chart
158
Oiling System Circuit Diagram
159
Oil Supply Diagrams
160
Oil Recirculation Diagrams
164
Components
166
Oil System Requirements
166
Oil Tank Assembly
166
Recommended Lubricants
166
Electrical Circuit (55 V)
167
Oil Injection Pump
167
Oil Pressure Sensor
167
Electrical Circuit (12 V)
168
Low Oil Warning
168
NO OIL Warning
168
Rear Oil Manifold (3.3 L Models)
168
Rear Oil Pump (3.4 L Models)
168
Cylinder and Crankcase
169
Oil Recirculation System
169
Oil Control Settings
170
Oil Injection Rate
170
Break-In Oiling
171
Oil Hose Priming
172
Oil Pump Priming
172
Oil Supply Priming
172
Oil Injection Pump Static Test
175
Oil Injection Pump Voltage Tests
175
Oiling System Tests
175
Oil Injection Pump Circuit Resistance Test
176
Cylinder Oil Pump Voltage Tests
177
Cylinder Oil Pump Resistance Test
178
Oil Supply Vacuum Test
178
Low Oil Sending Unit Test
179
Oil Injection Fittings Flow Test
179
Oil Injection Pump Function Test
179
Oil Component Servicing
180
Oil Distribution Hoses
180
Oil Injection Pump
181
Rear Oil Pump
182
Cooling System
185
Hose Routing and Water Flow Diagram 3.3 L
186
Hose Routing and Water Flow Diagram 3.4 L
187
Adapter Housing
188
Components
188
Water Pump and Intakes
188
Water Supply Tube
188
Block Venting
189
Pressure Relief Valve
189
Thermostats
189
Cylinder Block / Cylinder Head Cooling
190
Operation
190
Emm and Vapor Separator Cooling
191
Engine Temperature Check
191
Idle Operating Temperature Troubleshooting (below Range)
192
Pyrometer Method
192
Software Method
192
Assembly
194
Disassembly
194
Inspection
194
Installation
194
Removal
194
Temperature Sender Servicing
194
Thermostat Servicing
194
Assembly
195
Disassembly
195
Inspection
195
Pressure Relief Valve Servicing
195
Evinrude Icon Remote Control System
197
Service Chart
198
Components
199
Electronic Servo Module (Esm)
199
Shift Actuator
199
Icon System Failsafe Mode
200
Throttle Actuator
200
Electronic Servo Module (Esm)
201
Icon Component Servicing
201
Shift Actuator
204
Throttle Actuator
206
Calibrate Actuator Stroke
209
Icon System Settings
209
Set Engine Identity (Instance)
209
Icon Remote Control System Troubleshooting Chart
212
Icon Remote Control System Fault Messages
214
Powerhead
217
Service Chart
218
Compression Testing
220
Powerhead Removal
221
Powerhead Disassembly
223
Shift Linkage Removal
223
Systems Removal
223
Throttle Linkage Removal
223
Crankcase Disassembly
224
Connecting Rods and Pistons
225
Cylinder Head Removal
225
Crankshaft Removal
226
Cylinder Block Cleaning
229
Crankshaft
230
Cylinder Head
230
Powerhead Inspection
230
Cylinder Bore
231
Piston Rings
231
Pistons
231
Bearings
232
Crankshaft Assembly
232
Powerhead Assembly
232
Pistons and Connecting Rods
235
Cylinder Head Installation
236
Crankshaft and Connecting Rods
237
Crankcase Assembly
240
Shift Linkage Installation
241
Final Powerhead Assembly
242
Throttle Linkage Installation
242
Powerhead Installation
243
Pre-Service Adjustments
245
Port Hose Routings - 3.3 L Models
246
Powerhead Views
246
Starboard Hose Routings - 3.3 L Models
247
Port Hose Routings - 3.4 L Models
248
Starboard Hose Routings - 3.4 L Models
249
Port - 3.3 L Models
250
Starboard - 3.3 L Models
251
Port - 3.4 L Models
252
Starboard - 3.4 L Models
253
Front - 3.3 L Models
254
Front - 3.4 L Models
255
Rear - 3.3 L Models
256
Rear - 3.4 L Models
257
Top
258
Starboard - Icon Models
259
Midsection
261
Service Chart
262
Stern Bracket
262
Exhaust Housing - 3.3 L Models
263
Exhaust Housing - 3.4 L Models
264
Muffler
265
Removal
266
Tilt Tube
266
Installation
267
Exhaust Housing Removal
268
Exhaust Housing Service
268
Lower Mount Service
268
Exhaust Housing Installation
269
Exhaust Housing Disassembly - 3.3 L Models
270
Exhaust Housing Disassembly - 3.4 L Models
271
Cleaning and Inspection
272
Exhaust Housing Assembly - 3.3 L Models
273
Exhaust Housing Assembly - 3.4 L Models
275
Stern Bracket
277
Stern Bracket Disassembly
277
Stern Bracket Assembly
279
Exhaust Relief Muffler Assembly
282
Gearcase
283
Service Chart
284
Gearcase Types
287
Propeller Service
288
Gearcase Leak Test
290
Gearcase Removal and Installation
291
Water Pump Service
294
Shift Rod Adjustment
297
Gearcase - Standard Rotation
298
Gearcase Disassembly
298
Propeller Shaft Bearing Housing Removal
299
Pinion Gear and Driveshaft Removal
300
Driveshaft Service
302
Shift Housing, Gear, and Propeller Shaft Removal
302
Gearcase Housing Inspection
303
Pinion Bearing
304
Shifter, Bearing and Seal Servicing
304
Shift Housing
305
Driveshaft Bearing Housing
309
Propeller Shaft Bearing Housing Service
310
Driveshaft Shimming
312
Gearcase Assembly
314
Shift Housing, Gear, and Propeller Shaft Installation
314
Pinion Gear and Driveshaft Installation
315
Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
317
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
318
Final Assembly and Adjustment
320
Gearcase - Counter Rotation
321
Gearcase Disassembly
321
Propeller Shaft Bearing Housing Removal - "M2" Type
321
Gearcase Housing Inspection
322
Pinion Gear Removal and Driveshaft Servicing
322
Shift Housing, Gear and Propeller Shaft Removal
322
Shift Housing
323
Shifter, Bearing and Seal Servicing
323
Pinion Bearing
326
Propeller Shaft Bearing Housing and Forward Gear
326
Driveshaft Shimming
329
Gearcase Assembly
331
Pinion Gear and Driveshaft Installation
331
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
331
Shift Housing, Gear, and Propeller Shaft Installation
331
Final Assembly and Adjustment
332
Trim and Tilt
333
Service Chart
334
System Description
335
Modes of Operation
336
Trim-Out / Tilt-Up Mode
336
Tilt-Down / Trim-In Mode
337
Impact Relief
338
Shallow Water Drive Tilt Relief
339
Thermal Expansion Relief
339
Manual Release - up
340
Manual Release - down
341
General
342
Manual Release Valve
342
Reservoir Fluid
342
Routine Inspections
342
Stern Brackets
342
Troubleshooting
342
Pressure Leakdown Test
343
Service Procedures
343
Symptoms Chart
343
Electrical Circuit Tests
346
Relay Testing
346
Trim and Tilt Motor Current Draw Tests
346
Trim and Tilt Motor no Load Test
347
Trim Gauge Test
348
Trim Sender Test
348
Removal
349
Trim and Tilt Replacement
349
Installation
350
Disassembly
351
Trim and Tilt Service
351
Tilt Piston Removal
354
Tilt Piston Assembly
355
Tilt Piston Identification
355
Tilt Rod Assembly
356
Trim Rod Removal
357
Trim Rod Assembly
358
Manifold and Reservoir Installation
359
Trim Rod Installation
360
Motor Installation
361
Tilt Rod Installation
361
Safety
365
Marine Products and the Safety of People Who Use Them
367
Outboard Shift Systems and Safety
368
Outboard Speed Control System and Safety
369
Outboard Steering Control System and Safety
370
Outboard Fuel, Electrical System, and Safety
372
Outboard Mounting System and Safety
375
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
377
Outboard Emergency Stop System and Safety
378
Summing up
380
Handling Outboards
381
Marine Products and the Safety of People Who Fix Them
381
Handling Lead/Acid Batteries
385
Gasoline - Handle with Care
386
Hazardous Products
387
Safety Awareness Test
388
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