BRP EVINRUDE Johnson E200DPLAA Manuals

Manuals and User Guides for BRP EVINRUDE Johnson E200DPLAA. We have 1 BRP EVINRUDE Johnson E200DPLAA manual available for free PDF download: Service Manual

BRP EVINRUDE Johnson E200DPLAA Service Manual (442 pages)

Brand: BRP | Category: Outboard Motor | Size: 39 MB

Table of Contents
2
Table of Contents
3
Safety Notice
4
Abbreviations Used in this Manual
6
Units of Measurement
6
List of Abbreviations
6
Emission-Related Installation Instructions
7
Manufacturer's Responsibility
7
Dealer's Responsibility
7
Owner's Responsibility
7
Epa Emission Regulations
7
Model Designation
8
Models Covered in this Manual
9
Service Specifications Aa Models
10
Service Specifications Ab Models
12
Standard Torque Specifications
14
Product Reference and Illustrations
14
Wire Size Table
15
Technician's Notes
16
Related Documents
16
Inspection and Maintenance Schedule
18
Lifting the Outboard
19
Outboard Rigging Connections
19
Common Practices - All Models
19
Cable, Hose, and Wire Routing
20
Control Cable Installation
21
Battery Cable Connections
23
Systemcheck Harness Connections
23
I-Command Network Connections
24
Icon Network Connections
26
Water Pressure Gauge
27
Battery and Battery Connections
28
Oetiker Clamp Servicing
29
Clamp Installation
30
Clamp Removal
30
Adjustments
31
Tilt Limit Switch Adjustment
31
Trim Sending Unit Adjustment
32
Trim Tab Adjustment
33
Dual-Outboard Alignment
34
Operational Checks
35
Cooling System
36
Engine Flushing
36
Running the Outboard Using a Hose and Flushing Adapter
37
Lubrication
38
Steering System
38
Tilt Tube
38
Swivel Bracket and Trailering Bracket
39
Throttle and Shift Linkage
39
Propeller Shaft
39
Gearcase Lubricant
40
Trim and Tilt
41
Spark Plugs
42
Indexing
42
Fuel and Oil Systems
43
Fuel Filter
43
Oil Filters and Oil Reservoir
44
Air Silencer
44
Hoses and Connections
44
Exhaust Pressure Fitting
45
Operation Test
45
Cleaning
45
Anti-Corrosion Protection
46
Storage
47
Additional Recommendations
48
Pre-Season Service
49
Submerged Engines
50
Engine Cover Service
51
Upper Cover Service
52
Latch Hook Installation
52
Upper Cover Cap Replacement
52
Lower Cover Service
53
Lower Cover Removal
53
Lower Cover Installation
53
Latch Handle Installation
54
Trim Switch Installation
54
Description
56
Emm Inputs and Outputs Diagram
57
Internal Sensors
58
Emm
58
55 V Circuit Sensor
58
5 V Circuit Sensor
59
Barometric Pressure Sensor
59
Exhaust Pressure Sensor
59
External Sensors
60
Air Temperature Sensor
60
Engine Temperature Sensor
60
Oil Pressure Sensor
61
Throttle Position Sensor
61
Crankshaft Position Sensor
62
Neutral Switch (V4 Models)
62
Internal Emm Functions
63
Start Assist Circuit (Sac)
63
Rom Verification
63
Idle Controller
63
Rpm Limiter
63
Exhaust Valve (V4 Models)
63
Engine Monitor and Warning Systems
63
Fault Code Creation and Storage
63
Engine Monitor System
64
Warning System
65
Shutdown Mode
66
Diagnostic Software Functions
66
Communication
66
Static Information
67
Dynamic Information
67
Occurred Service Codes (Faults)
67
Active Faults
68
Historical Faults
68
Static Tests
68
Dynamic Tests
69
Oil Control Settings
69
Tiller/Remote Programming
70
Ignition Timing
70
Tps Calibration
71
Fuel Injector Servicing
71
Reports
71
Software Replacement
72
Emm Transfer
72
Emm Servicing
73
Installation
73
Technician's Notes
74
Related Documents
74
Diagnostic Procedures
76
Visual Inspections
76
Operational Inspections
76
Troubleshooting
77
Dynamic Tests
78
Cylinder Drop Tests
78
Fuel Control Adjustment
78
Inductive Amp Meter Test
78
Emm Led Indicators
79
Key on
79
Starting
79
Running
80
Ignition Output Tests
81
Required Ignition Systems
81
Wiring Inspection
81
Crankshaft Position Sensor (Cps) Test
82
System Voltage Test
82
Static Ignition Test
83
Running Ignition Tests
84
Ignition Control Circuit Tests
85
Ignition Coil Tests
85
Capacitor Test
85
Fuel Delivery Tests
86
Fuel Pump Static Test
86
Fuel Injector Static Test
86
Running Fuel System Tests
87
Exhaust Valve (V4 Models)
88
Exhaust Valve Static Test
88
Service Chart
90
Ignition System Circuit Diagram S
92
Electrical Harness Connections
94
Ground Circuits
96
Additional Ground Tests
96
Fuse
96
Sensor Tests
97
Crankshaft Position Sensor (Cps) Test
97
Throttle Position Sensor (Tps) Test
97
Engine Temperature Sensor Test
98
Air Temperature Sensor (At) Test
98
Stator Tests
99
Stator Resistance Tests
99
Stator Voltage Output Test
99
Charging System Tests
100
12 V Charging Circuit
100
Auxiliary Battery Charge Wire
101
55 V Alternator Circuit
101
Electric Start Circuit
102
Start Circuit Diagram
102
Start Circuit Operation
103
Electric Start Tests
104
Starter Solenoid Test
104
No Load Current Draw Test
105
Remote Control Switch Tests
106
Neutral Start Switch Test
107
Emergency Stop Switch Test
107
Tilt/Trim Relay Test
108
Test Procedure
108
Exhaust Valve Relay Tests
109
Systemcheck CIRCUIT TESTS
111
Gauge Self-Test Check
111
WATER TEMP/ HOT Circuit Test
112
CHECK ENGINE Circuit Test
112
LOW OIL Circuit Test
113
NO OIL Circuit
113
Tachometer Circuit Tests
113
Flywheel and Stator Servicing
114
Flywheel Removal
114
Stator Service
115
Flywheel Installation
115
Ignition Coil Servicing
117
Ignition Coil Removal
117
Ignition Coil Installation
117
Timing Adjustments
118
Timing Pointer
118
Timing Verification
119
Tps Calibration
120
Electric Starter Servicing
120
Starter Removal
120
Starter Disassembly
121
Starter Cleaning and Inspection
123
Starter Assembly
124
Starter Installation
127
Connector Servicing
127
Technician's Notes
132
Related Documents
132
Service Chart
134
Fuel System Hose Routing
137
Fuel System Circuit Diagram - V4
138
Fuel System Circuit Diagram - V6
139
Fuel System Requirements
140
Regulations and Guidelines
140
Portable Fuel Tanks
140
Fuel Flow Requirements
140
Fuel Requirements
141
Components
142
Fuel Lift Pump
142
Fuel Filter
142
Vapor Separator
142
Flow Diagrams
143
Fuel Circulation Pump
143
Fuel System Components
144
Fuel Manifolds
144
Fuel Injectors
144
Fuel System Priming
145
Vent Line Clamp
145
Priming the Fuel System
145
Fuel System Tests
146
Fuel System Pressure Test
146
Pressure Regulator Test
147
Vapor Separator Vent Check
147
Fuel Injector Pressure Test
147
Fuel Injector Resistance Test
148
Circulation Pump Resistance Test
148
Lift Pump Pressure Test
148
Lift Pump Vacuum Test
149
Lift Pump Diaphragm Test
149
Anti-Siphon Valve Test
150
Fuel Component Servicing
150
Relieving Fuel System Pressure
150
Fuel Filter Service
151
Fuel Lift Pump Service
152
Vapor Separator Service
152
Fuel Manifold Service
153
Fuel Injector Service
154
Intake Manifold Service
158
Service Chart
162
Oiling System Circuit Diagram
163
Oil Supply Diagrams - V4
164
Oil Supply Diagrams - V6
166
Oil Recirculation Diagrams - V4
168
Oil Recirculation Diagrams - V6
170
Oil System Requirements
172
Recommended Lubricants
172
Components
172
Oil Tank Assembly
172
Oil Injection Pump
173
Oil Pressure Sensor
173
Rear Oil Manifold
173
Electrical Circuit (55 V)
174
Low Oil Warning
174
NO OIL Warning
174
Cylinder and Crankcase
174
Oil Recirculation System
175
Oil Control Settings
176
Oil Injection Rate
176
Break-In Oiling
177
Oil Supply Priming
177
Oiling System Tests
179
Oil Injection Pump Static Test
179
Oil Injection Pump Voltage Tests
179
Oil Injection Pump Circuit Resistance Test
180
Oil Supply Vacuum Test
181
Oil Injection Pump Function Test
182
Oil Injection Fittings Flow Test
182
Low Oil Sending Unit Test
182
Oil Component Servicing
183
Oil Distribution Hoses
183
Oil Injection Pump
184
Technician's Notes
186
Related Documents
186
Hose Routing and Water Flow Diagrams
188
Components
190
Water Pump and Intakes
190
Water Supply Tube
190
Adapter/Inner Exhaust Housing
190
Pressure Relief Valve
191
Thermostats
191
Block Venting 1
191
Cooling System Components
191
Cooling System Operation
192
Operation
192
Cylinder Block / Cylinder Head Cooling
192
Emm and Vapor Separator Cooling
192
Engine Temperature Check
193
Software Method
193
Pyrometer Method
193
Idle Operating Temperature Troubleshooting (below Range)
194
Temperature Sender Servicing
195
Removal
195
Installation
195
Thermostat Servicing
195
Disassembly
195
Inspection
196
Assembly
196
Pressure Relief Valve Servicing
196
Disassembly
196
Service Chart
198
Components
199
Electronic Servo Module (Esm)
199
Shift Actuator
199
Throttle Actuator
200
Icon System Failsafe Mode
200
Icon Component Servicing
201
Electronic Servo Module (Esm)
201
Shift Actuator
204
Throttle Actuator
205
Icon System Settings
207
Set Engine Identity (Instance)
207
Calibrate Actuator Stroke
208
Icon System Faults
211
Recoverable Faults
211
Non-Recoverable Faults
212
Icon System Fault Code Chart
213
Technician's Notes
216
Related Documents
216
Service Chart
218
Compression Testing
220
Powerhead Removal
220
Powerhead Disassembly
222
Systems Removal
222
Throttle Linkage Removal
223
Shift Linkage Removal
223
Crankcase Disassembly
223
Cylinder Head Removal
224
Connecting Rods and Pistons
224
Crankshaft Removal
225
Cylinder Block Cleaning
228
Powerhead Inspection
229
Cylinder Head
229
Cylinder Bore
230
Piston Rings
230
Powerhead Assembly
231
Crankshaft Assembly
231
Pistons and Connecting Rods
233
Cylinder Head Installation
235
Crankshaft and Connecting Rods
236
Crankcase Assembly
239
Shift Linkage Installation
240
Throttle Linkage Installation
241
Final Powerhead Assembly
241
Upper Mount Servicing
242
Powerhead Installation
243
Final Adjustments
246
Powerhead Views
247
V4 Starboard - Hose Routings
247
V4 Port - Hose Routings
247
V4 Starboard
248
V4 Port
248
V4 Front
249
V4 Rear
250
V4 - V6 Top - Hose Routings
251
V4 - V6 Top
252
V6 Starboard - Hose Routings
253
V6 Port - Hose Routings
254
V6 Port
255
V6 Starboard
256
V6 Starboard Icon Models
257
V6 Front
258
V6 Rear
259
Technician's Notes
260
Related Documents
260
Service Chart
262
Tilt Tube
266
Removal
266
Installation
267
Exhaust Housing Service
268
Exhaust Housing Removal
268
Lower Mount Service
268
Exhaust Housing Installation
269
Removal and Installation
269
Exhaust Housing Disassembly - V6 Models
270
Exhaust Housing Disassembly - V4 Models
270
Cleaning and Inspection
271
Exhaust Housing Assembly - V6 Models
271
Exhaust Housing Assembly - V4 Models
272
Extension Service - V4 Models
274
Removal
274
Installation
274
Stern Bracket
274
Stern Bracket Disassembly
274
Stern Bracket Assembly
277
Exhaust Relief Muffler Assembly
280
Service Charts
283
Gearcase Types
289
Propeller Service
291
Propeller Hardware Installation
292
Gearcase Leak Test
293
Gearcase Removal and Installation
294
Gearcase Installation
295
Water Pump Service
297
Disassembly
297
Inspection
297
Assembly
298
Shift Rod Adjustment
300
Gearcase - Standard Rotation
301
Gearcase Disassembly
301
Pre-Disassembly Inspection
301
Propeller Shaft Bearing Housing Removal - "S2" and "O" Type
302
Propeller Shaft Bearing Housing Removal - "L2" and "M2" Type
303
Pinion Gear and Driveshaft Removal - "S2" Type
304
Pinion Gear and Driveshaft Removal - "O", "L2", and "M2" Type
307
Driveshaft Service
308
Shift Housing, Gear and Propeller Shaft Removal
309
Water Intake Screens
309
Gearcase Housing Inspection
310
Shifter, Bearing and Seal Service
311
Pinion Bearing Removal
311
Pinion Bearing Installation
311
Shift Housing Disassembly
312
Shift Housing Assembly
314
Driveshaft Bearing Housing Service
316
Propeller Shaft Bearing Housing Service
317
Driveshaft Shimming
319
Gearcase Assembly
321
Water Intake Screens
321
Shift Housing, Gear, and Propeller Shaft Installation
321
Shift Rod Housing Installation
322
Pinion Gear and Driveshaft Installation - "S2" Type
323
Pinion Gear and Driveshaft Installation - "O", "L2", and "M2" Type
327
Propeller Shaft Bearing Housing and Gear Installation - "S2" and "O" Type
328
Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
329
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
331
Final Assembly and Adjustment
332
Gearcase Disassembly
333
Pre-Disassembly Inspection
333
Propeller Shaft Bearing Housing Removal - "O" Type
333
Propeller Shaft Bearing Housing Removal - "M2" Type
333
Pinion Gear Removal and Driveshaft Servicing
334
Shift Housing, Gear and Propeller Shaft Removal
335
Water Intake Screens
335
Gearcase Housing Inspection
335
Shifter, Bearing and Seal Servicing
336
Shift Housing Disassembly
336
Shift Housing Assembly
337
Pinion Bearing
339
Propeller Shaft Bearing Housing and Forward Gear - "O" Type
339
Propeller Shaft Bearing Housing and Forward Gear - "M2" Type
343
Driveshaft Shimming
346
Gearcase Assembly
347
Water Intake Screens
347
Shift Housing, Gear, and Propeller Shaft Installation
347
Shift Rod Cover
348
Pinion Gear and Driveshaft Installation
348
Propeller Shaft Bearing Housing and Gear Installation - "O" Type
348
Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
349
Final Assembly and Adjustment
350
Service Chart
352
System Description
354
Modes of Operation (Three Piston System)
355
Trim-OUT / Tilt-UP Mode
355
Tilt-DOWN / Trim-IN Mode
356
Impact Relief
357
Shallow Water Drive Tilt Relief
358
Thermal Expansion Relief
358
Manual Release - up
359
Manual Release - down
360
Routine Inspections
361
General
361
Reservoir Fluid
361
Manual Release Valve
361
Stern Brackets
361
Troubleshooting
361
Single Piston System
361
Three Piston System
362
Electrical Circuit Tests
365
Relay Testing
365
Trim and Tilt Motor Current Draw Tests
365
Trim and Tilt Motor no Load Test
366
Trim Gauge Test
367
Trim Sender Test
368
Trim and Tilt Replacement
368
Removal
368
Installation
370
Servicing-Single Piston System
371
Manual Release Valve
371
Piston Seal and End Cap
372
Trim Motor
378
Servicing - Three Piston System
379
Disassembly
379
Tilt Piston Removal
382
Tilt Piston Identification
383
Tilt Piston Assembly
383
Tilt Rod Assembly
384
Trim Rod Removal
385
Trim Rod Assembly
386
Manifold and Reservoir Installation
387
Trim Rod Installation
388
Tilt Rod Installation
389
Motor Installation
389
Technician's Notes
392
Related Documents
392
Marine Products and the Safety of People Who Use Them
395
Outboard Shift Systems and Safety
396
Outboard Speed Control System and Safety
397
Outboard Steering Control System and Safety
398
Outboard Fuel, Electrical System, and Safety
400
Outboard Mounting System and Safety
403
If Weakened, Parts Could Fail Later on the Water, When Not Expected
404
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
405
Outboard Emergency Stop System and Safety
406
Summing up
408
Marine Products and the Safety of People Who Fix Them
409
Handling Outboards
409
Handling Lead/Acid Batteries
413
Gasoline - Handle with Care
414
Hazardous Products
415
Safety Awareness Test
416
Trouble Check Chart
427
Outboard will Not Start
428
Outboard Hard to Start
429
Outboard will Not Shut off
430
Outboard Starts and Stalls
430
Outboard Starts, Low Maximum Rpm
431
Excessive Smoking
431
Outboard Surges, Runs Rough
432

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BRP EVINRUDE Johnson E200DPLAA Service Manual (442 pages)

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