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E250DHXSCS
BRP E250DHXSCS Manuals
Manuals and User Guides for BRP E250DHXSCS. We have
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BRP E250DHXSCS manual available for free PDF download: Service Manual
BRP E250DHXSCS Service Manual (396 pages)
Evinrude E-TEC series 250, 300 HP 90 V6 (3.4L)
Brand:
BRP
| Category:
Outboard Motor
| Size: 21.13 MB
Table of Contents
Table of Contents
4
Table of Contents
5
Abbreviations Used in this Manual
8
List of Abbreviations
8
Units of Measurement
8
Dealer's Responsibility
9
Engine Emissions Information
9
Epa Emission Regulations
9
Manufacturer's Responsibility
9
Owner's Responsibility
9
Model Designation
10
Identifying Model and Serial Numbers
11
Models Covered in this Manual
11
Service Specifications
12
Product Reference and Illustrations
14
Standard Torque Specifications
14
Special Tools 1
15
Diagnostic Tools
16
Special Tools
16
Universal Tools
16
Electrical / Ignition Tools
18
Fuel /Oil System Tools
19
Powerhead Tools
19
Gearcase Tools
20
Trim and Tilt Tools
23
Shop Aids
24
Installation and Predelivery
27
Boat Rigging
28
Remote Controls
28
Battery Installation
29
Battery Switches and Multiple Batteries
30
Auxiliary Battery Charging
32
Fuel System Requirements
35
Oiling System Set-Up
37
Cable and Hose Installation
40
Outboard Installation
44
Hull Preparation
44
Transom Measuring and Drilling
46
Lifting the Outboard
49
Steering Systems
49
Outboard Mounting
51
Outboard Rigging
52
Cable, Hose, and Wire Routing
52
Control Cable Installation
53
Electrical Harness Connections
55
Water Pressure Gauge
55
Canbus Connections
56
Fuel and Oil Priming
58
Fuel Requirements
58
Fuel System Priming
59
Oil Requirements
59
Oil Injection Rate
60
Break-In Oiling
61
Oil Supply Priming
61
Before Start-Up
63
Running Checks
64
Engine Monitoring System
64
Fuel System
64
Emergency Stop / Key Switch
64
Start-In-Gear Prevention
64
Tachometer Pulse Setting
65
Water Pump Overboard Indicator
65
Break-In
65
Propellers
66
Propeller Selection
66
Propeller Hardware Installation
67
Final Adjustments
68
Tilt Limit Switch Adjustment
68
Trim Sending Unit Adjustment
69
Trim Tab Adjustment
70
Dual-Outboard Alignment
71
Notes
72
Maintenance
73
Inspection and Maintenance Schedule
74
Anti-Corrosion Protection
75
Sacrificial Anodes
75
Testing Procedure - Continuity
75
Metallic Component Protection
75
Exterior Finishes
75
Cooling System
76
Flushing
76
Water Intake Screens
77
Additional Maintenance
77
Lubrication
78
Steering System
78
Swivel Bracket and Trailering Bracket
78
Tilt Tube
78
Throttle and Shift Linkage
79
Propeller Shaft
79
Gearcase Lubricant
79
Trim and Tilt
81
Battery and Battery Connections
82
Fuel and Oil Systems
82
Fuel Filter
82
Oil Filters and Oil Reservoir
83
Air Silencer
83
Hoses and Connections
83
Spark Plugs
84
Indexing
84
Exhaust Pressure Fitting
85
Operation Test
85
Cleaning
85
Storage
86
Fuel System Treatment
86
Internal Engine Treatment
86
Additional Recommendations
87
Pre-Season Service
87
Outboard Mounting Bolts
87
Gearcase Lubricant
87
Battery(S)
87
Power Trim and Tilt
87
Operational Checks
87
Submerged Engines
88
Engine Dropped Overboard (Not Running)
88
Engine Dropped Overboard (Running)
88
Engine Dropped Overboard (in Salt Water)
88
Prolonged Submersion (Fresh or Salt Water)
88
Engine Cover Service
89
Upper Cover Service
90
Latch Hook Installation
90
Upper Cover Cap Replacement
90
Lower Cover Service
91
Lower Cover Removal
91
Lower Cover Installation
91
Latch Handle Installation
92
Trim Switch Installation
92
Engine Management Module (Emm)
93
Description
94
Emm Inputs and Outputs Diagram
95
Internal Sensors
96
Emm Temperature Sensor
96
55 V Circuit Sensor
96
Barometric Pressure Sensor
97
Exhaust Pressure Sensor
97
External Sensors
97
Air Temperature Sensor
97
Oil Pressure Sensor
98
Throttle Position Sensor
99
Crankshaft Position Sensor
99
Internal Emm Functions
100
Start Assist Circuit (Sac)
100
Rom Verification
100
Idle Controller
100
Rpm Limiter
100
Shift Interrupt
100
Engine Monitor and Warning Systems
100
Fault Code Creation and Storage
100
Engine Monitoring System
101
Warning System
102
Shutdown Mode
102
Diagnostic Software Functions
103
Communication
103
Static Information
103
Dynamic Information
104
Stored Service Codes (Faults)
104
Hard Faults
104
Persistent Faults
104
Static Tests
104
Dynamic Tests
105
Oil Control Settings
106
Ignition Timing
107
Tps Calibration
107
Fuel Injector Servicing
108
Reports
108
Software Replacement
109
Emm Transfer
109
Emm Servicing
110
Removal
110
Installation
110
System Analysis
111
Diagnostic Procedures
112
Visual Inspections
112
Operational Inspections
112
Troubleshooting
113
Dynamic Tests
114
Cylinder Drop Tests
114
Fuel Control Adjustment
114
Inductive Amp Meter Test
114
Emm Led Indicators
115
Key on
115
Starting
115
Running
116
Ignition Output Tests
117
Required Ignition Systems
117
Wiring Inspection
117
Crankshaft Position Sensor (Cps) Test
118
System Voltage Test
118
Ignition Voltage Test
119
Static Ignition Test
119
Running Ignition Tests
120
Ignition Primary Circuit Resistance Test
121
Ignition Coil Tests
121
Capacitor Test
122
Fuel Delivery Tests
122
Fuel Pump Static Test
122
Fuel Injector Static Test
123
Running Fuel System Tests
123
Electrical and Ignition
125
Service Chart
126
Dash Connections, Instrument Harness
128
Electrical Harness Connections
129
Fuse
131
Ground Circuits
131
Sensor Tests
132
Crankshaft Position Sensor (Cps) Test
132
Throttle Position Sensor (Tps) Test
132
Engine Temperature Sensor Test
133
Air Temperature Sensor (At) Test
133
Stator Tests
134
Stator Resistance Tests
134
Stator Voltage Output Test
134
Charging System Tests
135
12 V Charging Circuit
135
Auxiliary Battery - Charge Wire
136
55 V Alternator Circuit
136
Electric Start Circuit
137
Electric Start Tests
139
Remote Control Switch Tests
141
Tilt/Trim Relay Test
143
Systemcheck Circuit Tests
144
Tachometer Circuit Tests
146
Flywheel and Stator Servicing
147
Flywheel Removal
147
Stator Service
147
Flywheel Installation
148
Timing Adjustments
149
Timing Pointer
149
Timing Verification
150
Tps Calibration
150
Electric Starter Servicing
151
Starter Removal
151
Starter Disassembly
151
Starter Cleaning and Inspection
154
Starter Assembly
155
Starter Installation
157
Connector Servicing
158
Fuel System
163
Service Chart
164
Fuel System Hose Routing
167
Fuel System Circuit Diagram
168
Components
169
Fuel Lift Pump
169
Fuel Filter
169
Vapor Separator
169
Fuel Circulation Pump
170
Fuel Manifolds
171
Fuel Injectors
171
Fuel System Tests
172
Fuel System Pressure Test
172
Pressure Regulator Test
173
Vapor Separator Vent Check
173
Fuel Injector Pressure Test
173
Fuel Injector Resistance Test
174
Circulation Pump Resistance Test
174
Lift Pump Pressure Test
174
Lift Pump Vacuum Test
175
Lift Pump Diaphragm Test
175
Anti-Siphon Valve Test
176
Fuel Component Servicing
176
Relieving Fuel System Pressure
176
Fuel Filter Service
177
Fuel Lift Pump Service
178
Vapor Separator Service
179
Fuel Manifold Service
179
Fuel Injector Service
180
Intake Manifold Service
183
Installation
184
Notes
186
Oiling System
187
Service Chart
188
Oiling System Circuit Diagram
189
Oil Supply Diagrams - V6
190
Oil Recirculation Diagrams - V6
192
Components
193
Oil Tank Assembly
193
Oil Injection Pump
193
Oil Pressure Sensor
193
Electrical Circuit (55 V)
194
Low Oil Warning
194
NO OIL Warning
194
Cylinder and Crankcase
194
Oil Recirculation System
195
Oil Control Settings
196
Oil Priming
196
Oiling Rates
196
Break-In Oiling
196
Oiling System Tests
197
Oil Injection Pump Static Test
197
Oil Injection Pump Voltage Test
197
Oil Injection Pump Circuit Resistance Test
198
Oil Supply Vacuum Test
198
Oil Injection Pump Function Test
199
Oil Injection Fittings Flow Test
199
Low Oil Sending Unit Test
199
Oil Component Servicing
200
Oil Distribution Hoses
200
Oil Injection Pump
201
Cooling System
203
Hose Routing and Water Flow Diagram
204
Components
205
Water Pump and Intakes
205
Water Supply Tube
205
Adapter Housing
205
Pressure Relief Valve
205
Thermostats
206
Block Venting
206
Operation
206
Cylinder Block / Cylinder Head Cooling
206
Emm and Vapor Separator Cooling
207
Engine Temperature Check
208
Software Method
208
Pyrometer Method
208
Idle Operating Temperature Troubleshooting (below Range)
209
Thermostat Servicing
210
Disassembly
210
Inspection
210
Assembly
210
Pressure Relief Valve Servicing
211
Disassembly
211
Inspection
211
Assembly
211
Notes
212
Powerhead
213
Service Chart
214
Taper Pin Tool
216
Powerhead Removal
217
Powerhead Disassembly
219
General
219
Throttle Linkage Removal
219
Shift Linkage Removal
219
Crankcase Disassembly
220
Cylinder Head Removal
221
Connecting Rods and Pistons
221
Crankshaft Removal
222
Cylinder Block Cleaning
225
Powerhead Inspection
226
Cylinder Head
226
Crankshaft
226
Cylinder Bore
227
Pistons
227
Piston Rings
227
Bearings
228
Powerhead Assembly
228
Crankshaft
228
Pistons and Connecting Rods
231
Cylinder Head Installation
232
Crankshaft and Connecting Rods
233
Crankcase Assembly
236
Shift Linkage Installation
237
Throttle Linkage Installation
238
Final Powerhead Assembly
238
Powerhead Installation
239
Powerhead Views
242
Port Hose Routings
242
Starboard Hose Routings
243
Port
244
Starboard
245
Front
246
Rear
247
Top
248
Midsection
249
Service Chart
250
Tilt Tube
253
Removal
253
Installation
254
Exhaust Housing
255
Exhaust Housing Removal
255
Exhaust Housing Disassembly
256
Cleaning and Inspection
257
Exhaust Housing Assembly
257
Exhaust Housing Installation
260
Stern Bracket
261
Removal
261
Stern Bracket Disassembly
261
Stern Bracket Assembly
263
Exhaust Relief Muffler Assembly
266
Gearcase
267
Service Chart
268
Gearcase Types
271
Propeller Service
272
Gearcase Leak Test
272
Gearcase Removal and Installation
273
Water Pump Service
276
Shift Rod Adjustment
279
Gearcase - Standard Rotation
280
Gearcase Disassembly
280
Propeller Shaft Bearing Housing Removal
281
Pinion Gear and Driveshaft Removal
282
Driveshaft Service
284
Shift Housing, Gear, and Propeller Shaft Removal
284
Gearcase Housing Inspection
285
Shifter, Bearing and Seal Servicing
286
Shift Housing
286
Pinion Bearing
289
Driveshaft Bearing Housing Service
290
Propeller Shaft Bearing Housing Service
291
Driveshaft Shimming
294
Gearcase Assembly
295
Shift Housing, Gear, and Propeller Shaft Installation
295
Shift Rod Cover
296
Pinion Gear and Driveshaft Installation
297
Propeller Shaft Bearing Housing and Gear Installation
298
Final Assembly and Adjustment
301
Gearcase - Counter Rotation
302
Gearcase Disassembly
302
Propeller Shaft Bearing Housing Removal
302
Pinion Gear Removal and Driveshaft Servicing
303
Shift Housing, Gear and Propeller Shaft Removal
303
Gearcase Housing Inspection
303
Shifter, Bearing and Seal Servicing
304
Shift Housing
304
Pinion Bearing
307
Propeller Shaft Bearing Housing and Forward Gear
307
Driveshaft Shimming
310
Gearcase Assembly
312
Shift Housing, Gear, and Propeller Shaft Installation
312
Shift Rod Cover
312
Pinion Gear and Driveshaft Installation
312
Propeller Shaft Bearing Housing and Gear Installation
312
Final Assembly and Adjustment
313
Trim and Tilt
315
Service Chart
316
System Description
317
Manual Adjustment
317
Trailering Bracket and Tilt Support
317
Modes of Operation
318
Trim-Out / Tilt-Up Mode
318
Tilt-Down / Trim-In Mode
319
Impact Relief
320
Shallow Water Drive Tilt Relief
321
Thermal Expansion Relief
321
Manual Release - up
322
Manual Release - down
323
Routine Inspections
324
General
324
Reservoir Fluid
324
Manual Release Valve
324
Stern Brackets
324
Troubleshooting
324
Symptoms Chart
325
Service Procedures
325
Pressure Leakdown Test
325
Electrical Circuit Tests
328
Relay Testing
328
Trim and Tilt Motor Current Draw Tests
328
Trim and Tilt Motor no Load Test
329
Trim Gauge Test
330
Trim Sender Test
330
Trim and Tilt Service
331
Removal
331
Installation
332
Disassembly
334
Tilt Piston Removal
336
Tilt Piston Identification
337
Tilt Piston Assembly
338
Tilt Rod Assembly
338
Trim Rod Removal
340
Trim Rod Assembly
341
Manifold and Reservoir Installation
342
Trim Rod Installation
343
Tilt Rod Installation
343
Motor Installation
344
Adjustments
345
Notes
346
Safety
347
Marine Products and the Safety of People Who Use Them
349
Outboard Shift Systems and Safety
350
Outboard Speed Control System and Safety
351
Outboard Steering Control System and Safety
352
Outboard Fuel, Electrical System, and Safety
354
Outboard Mounting System and Safety
357
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
359
Outboard Emergency Stop System and Safety
360
Summing up
362
Marine Products and the Safety of People Who Fix Them
363
Handling Outboards
363
Handling Lead/Acid Batteries
367
Gasoline - Handle with Care
368
Hazardous Products
369
Safety Awareness Test
370
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