BRP EVINRUDE E-TEC BE225HGXABA Manuals

Manuals and User Guides for BRP EVINRUDE E-TEC BE225HGXABA. We have 1 BRP EVINRUDE E-TEC BE225HGXABA manual available for free PDF download: Manual

BRP EVINRUDE E-TEC BE225HGXABA Manual

BRP EVINRUDE E-TEC BE225HGXABA Manual (356 pages)

Brand: BRP | Category: Engine | Size: 41 MB

Table of Contents

Reference Information

3
Routine Service

17
- Inspection and Maintenance Schedule
  18
- Lifting the Outboard
  19
- Outboard Rigging Connections
  20
- Cable, Hose, and Wire Routing
  21
- Control Cable Installation
  22
- 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
  29
- Adjustments
  30
- Tilt Limit Switch Adjustment
  30
- Trim Sending Unit Adjustment
  31
- Dual-Outboard Alignment
  32
- Trim Tab Adjustment
  32
- Operational Checks
  34
- Cooling System
  35
- Engine Flushing
  35
- Running the Outboard Using a Hose and Flushing Adapter
  36
- 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
  40
- Indexing
  41
- Spark Plugs
  41
- Fuel and Oil Systems
  42
- Fuel Filter
  42
- Oil Filters and Oil Reservoir
  42
- Exhaust Pressure Fitting
  43
- Hoses and Connections
  43
- Operation Test
  43
- Anti-Corrosion Protection
  44
- Cleaning
  44
- Gearcase Removal and Installation
  45
- Storage
  48
- Pre-Season Service
  50
- Submerged Engines
  51
Engine Cover Service

53
- Latch Hook Installation
  54
- Upper Cover Cap Replacement
  54
- Upper Cover Service
  54
- Lower Cover Installation
  55
- Lower Cover Removal
  55
- Lower Cover Service
  55
- Latch Handle Installation
  56
- Trim Switch Installation
  56
Engine Management Module (Emm)

57
- Description
  58
- 55 V Circuit Sensor
  59
- EMM Temperature Sensor
  59
- Internal Sensors
  59
- Barometric Pressure Sensor
  60
- Circuit Sensor
  60
- Exhaust Pressure Sensor
  60
- Air Temperature Sensor
  61
- Engine Temperature Sensor
  61
- External Sensors
  61
- Oil Pressure Sensor
  62
- Throttle Position Sensor
  62
- Crankshaft Position Sensor
  63
- Knock Sensor
  63
- Neutral/Shift Interrupt Switch
  63
- Engine Monitor and Warning Systems
  64
- Fault Code Creation and Storage
  64
- Idle Controller
  64
- Internal EMM Functions
  64
- Neutral RPM Limiter
  64
- ROM Verification
  64
- RPM Limiter
  64
- Start Assist Circuit (SAC)
  64
- Engine Monitor System
  65
- Warning System
  66
- Communication
  67
- Diagnostic Software Functions
  67
- Shutdown Mode
  67
- Dynamic Information
  68
- Occurred Faults
  68
- Static Information
  68
- Active Faults
  69
- Historical Faults
  69
- Static Tests
  69
- Dynamic Tests
  70
- Oil Control Settings
  70
- Fuel Injector Servicing
  71
- Ignition Timing
  71
- TPS Calibration
  71
- Reports
  72
- EMM Transfer
  73
- Software Replacement
  73
- EMM Servicing
  74
System Analysis

75
- Diagnostic Inspections
  76
- Diagnostic Procedures
  76
- Visual Inspections
  76
- Operational Inspections
  77
- Troubleshooting
  77
- EMM LED Indicators
  78
- Running
  78
- Cylinder Drop Tests
  79
- Dynamic Tests
  79
- Fuel Control Adjustment
  79
- Inductive Amp Meter Test
  79
- Key on
  80
- Starting
  80
- Running Fuel System Tests
  81
- Fuel Delivery Tests
  82
- Fuel Injector Static Test
  82
- Fuel Pump Static Test
  82
- System Voltage Test
  83
- Crankshaft Position Sensor (CPS) Test
  84
- Ignition Output Tests
  84
- Required Ignition Systems
  84
- Running Ignition Tests
  84
- Wiring Inspection
  84
- Ignition Coil Tests
  85
- Ignition Control Circuit Tests
  85
- Static Ignition Test
  85
- Capacitor Test
  87
Electrical and Ignition

89
- Service Charts
  90
- Ignition System Circuit Diagram
  92
- Electrical Harness Connections
  93
- Ground Circuits
  95
- Crankshaft Position Sensor (CPS) Test
  96
- Fuse
  96
- Sensor Tests
  96
- Air Temperature Sensor (AT) Test
  97
- Engine Temperature Sensor Test
  97
- Throttle Position Sensor (TPS) Test
  97
- Knock Sensor Test
  98
- Stator Tests
  98
- 12 V Charging Circuit
  99
- Charging System Tests
  99
- Auxiliary Battery Charge Wire
  100
- 55 V Alternator Circuit
  101
- Electric Start Circuit
  102
- Electric Start Tests
  104
- Remote Control Switch Tests
  106
- Tilt/Trim Relay Test
  108
- Systemcheck Circuit Tests
  109
- Tachometer Circuit Tests
  111
- Flywheel and Stator Servicing
  112
- Flywheel Installation
  112
- Flywheel Removal
  112
- Stator Service
  112
- Ignition Coil Bracket Installation
  114
- Ignition Coil Bracket Removal
  114
- Ignition Coil Installation
  114
- Ignition Coil Removal
  114
- Ignition Coil Servicing
  114
- Timing Adjustments
  115
- Timing Pointer
  115
- Timing Verification
  116
- TPS Calibration
  116
- Electric Starter Servicing
  118
- Connector Servicing
  125
- Deutsch Connectors
  125
- AMP Connectors
  126
- Packard Connectors
  129
Fuel System

131
- Service Charts
  132
- Fuel System Hose Routing
  135
- Fuel System Circuit Diagram
  136
- Fuel Flow Requirements
  137
- Fuel System Requirements
  137
- Portable Fuel Tanks
  137
- Regulations and Guidelines
  137
- Fuel Requirements
  138
- Components
  139
- Fuel Filter
  139
- Fuel Lift Pump
  139
- Vapor Separator
  139
- Fuel Circulation Pump
  140
- Fuel Manifolds
  140
- Fuel Injectors
  141
- Fuel System Priming
  142
- Priming the Fuel System
  142
- Vent Line Clamp
  142
- Fuel System Pressure Test
  143
- Fuel System Tests
  143
- Pressure Regulator Test
  143
- Fuel Injector Pressure Test
  144
- Fuel Injector Resistance Test
  144
- Vapor Separator Vent Check
  144
- Circulation Pump Resistance Test
  145
- Lift Pump Pressure Test
  145
- Anti-Siphon Valve Test
  146
- Lift Pump Diaphragm Test
  146
- Lift Pump Vacuum Test
  146
- Fuel Component Servicing
  147
- Fuel Filter Service
  147
- Relieving Fuel System Pressure
  147
- Fuel Lift Pump Service
  148
- Fuel Manifold Service
  149
- Vapor Separator Service
  149
- Fuel Injector Service
  151
- Intake Manifold Service
  154
Oiling System

159
- Service Chart
  160
- Oiling System Circuit Diagram
  161
- Oil Supply Diagrams
  162
- Oil Recirculation Diagrams
  166
- Components
  168
- Oil Injection Pump
  168
- Oil System Requirements
  168
- Oil Tank Assembly
  168
- Recommended Lubricants
  168
- Electrical Circuit (55 V)
  169
- Oil Pressure Sensor
  169
- Cylinder and Crankcase
  170
- Electrical Circuit (12 V)
  170
- LOW OIL Warning
  170
- NO OIL Warning
  170
- Rear Oil Manifold (3.3 L Models)
  170
- Rear Oil Pump (3.4 L Models)
  170
- Oil Recirculation System
  171
- Oil Control Settings
  173
- Oil Injection Rate
  173
- Break-In Oiling
  174
- Oil Supply Priming
  175
- Oil Injection Pump Static Test
  178
- Oil Injection Pump Voltage Tests
  178
- Oiling System Tests
  178
- Oil Injection Pump Circuit Resistance Test
  179
- Cylinder Oil Pump Voltage Tests
  180
- Cylinder Oil Pump Resistance Test
  181
- Oil Supply Vacuum Test
  181
- Oil Injection Fittings Flow Test
  182
- Oil Injection Pump Function Test
  182
- LOW OIL Sending Unit Test
  183
- Oil Component Servicing
  183
- Oil Distribution Hoses
  183
- Oil Injection Pump
  184
- Rear Oil Pump
  185
Cooling System

189
- Hose Routing and Water Flow Diagram 3.3 L
  190
- Hose Routing and Water Flow Diagram 3.4 L
  191
- Adapter Housing
  192
- Components
  192
- Water Pump and Intakes
  192
- Water Supply Tube
  192
- Block Venting
  193
- Pressure Relief Valve
  193
- Thermostats
  193
- Cylinder Block / Cylinder Head Cooling
  194
- Operation
  194
- EMM and Vapor Separator Cooling
  195
- Engine Temperature Check
  195
- Idle Operating Temperature Troubleshooting (below Range)
  196
- Pyrometer Method
  196
- Software Method
  196
- Installation
  198
- Removal
  198
- Temperature Sensor Servicing
  198
- Assembly
  199
- Disassembly
  199
- Inspection
  199
- Pressure Relief Valve Servicing
  199
- Thermostat Servicing
  199
- Assembly
  200
Evinrude Icon Remote Control System

201
- Service Chart
  202
- Components
  203
- Electronic Servo Module (ESM)
  203
- Shift Actuator
  203
- ICON System Failsafe Mode
  204
- Throttle Actuator
  204
- Electronic Servo Module (ESM)
  205
- ICON Component Servicing
  205
- Shift Actuator
  208
- Throttle Actuator
  210
- ICON System Settings
  212
- Set Engine Identity (Instance)
  212
- Calibrate Actuator Stroke
  213
- ICON System Faults
  216
- Recoverable Faults
  216
- Non-Recoverable Faults
  217
- ICON System Fault Code Chart
  218
Powerhead

221
- Service Charts
  222
- Piston Pin Retainer Tool
  224
- Taper Pin Tool
  224
- Compression Testing
  225
- Powerhead Removal
  225
- Powerhead Disassembly
  227
- Systems Removal
  227
- Crankcase Disassembly
  228
- Shift Linkage Removal
  228
- Throttle Linkage Removal
  228
- Cylinder Head Removal
  229
- Connecting Rods and Pistons
  230
- Crankshaft Removal
  231
- Cylinder Block Cleaning
  233
- Powerhead Inspection
  234
- Crankshaft Assembly
  237
- Powerhead Assembly
  237
- Pistons and Connecting Rods
  239
- Crankshaft and Connecting Rods
  241
- Cylinder Head Installation
  241
- Crankcase Assembly
  244
- Shift Linkage Installation
  245
- Final Powerhead Assembly
  246
- Throttle Linkage Installation
  246
- Powerhead Installation
  247
- Pre-Service Adjustments
  250
- Port Hose Routings - 3.3 L Models
  251
- Powerhead Views
  251
- Starboard Hose Routings - 3.3 L Models
  252
- Port Hose Routings - 3.4 L Models
  253
- Starboard Hose Routings - 3.4 L Models
  254
- Port - 3.3 L Models
  255
- Starboard - 3.3 L Models
  256
- Port - 3.4 L Models
  257
- Starboard - 3.4 L Models
  258
- Front - 3.3 L Models
  259
- Front - 3.4 L Models
  260
- Rear - 3.3 L Models
  261
- Rear - 3.4 L Models
  262
- Top
  263
- Starboard - ICON Models
  264
Midsection

265
- Exhaust Housing - 3.3 L Models
  266
- Service Charts
  266
- Exhaust Housing - 3.4 L Models
  267
- Stern Bracket
  268
- Muffler
  269
- Removal
  270
- Tilt Tube
  270
- Installation
  271
- Exhaust Housing Removal
  272
- Exhaust Housing Service
  272
- Lower Mount Service
  272
- Exhaust Housing Installation
  273
- Exhaust Housing Disassembly - 3.3 L Models
  274
- Cleaning and Inspection
  275
- Exhaust Housing Disassembly - 3.4 L Models
  275
- Exhaust Housing Assembly - 3.3 L Models
  276
- Exhaust Housing Assembly - 3.4 L Models
  279
- Stern Bracket
  281
- Stern Bracket Disassembly
  281
- Stern Bracket Assembly
  283
- Exhaust Relief Muffler Assembly
  286
Trim and Tilt

287
- Service Charts
  288
- System Description
  289
- Modes of Operation
  290
- Trim-OUT / Tilt-UP Mode
  290
- Tilt-DOWN / Trim-IN Mode
  291
- Impact Relief
  292
- Shallow Water Drive Tilt Relief
  293
- Thermal Expansion Relief
  293
- Manual Release - up
  294
- Manual Release - down
  295
- General
  296
- Manual Release Valve
  296
- Reservoir Fluid
  296
- Routine Inspections
  296
- Stern Brackets
  296
- Troubleshooting
  296
- Electrical Circuit Tests
  300
- Relay Testing
  300
- Trim and Tilt Motor Current Draw Tests
  300
- Trim and Tilt Motor no Load Test
  301
- Trim Gauge Test
  301
- Trim Sender Test
  302
- Trim and Tilt Replacement
  303
- Disassembly
  305
- Trim and Tilt Servicing
  305
- Tilt Piston Removal
  308
- Tilt Piston Assembly
  309
- Tilt Piston Identification
  309
- Tilt Rod Assembly
  310
- Trim Rod Removal
  312
- Trim Rod Assembly
  313
- Manifold and Reservoir Installation
  314
- Trim Rod Installation
  315
- Motor Installation
  316
- Tilt Rod Installation
  316
Safety

319

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