Evinrude & Johnson E75DSLSCS Boat Engine Manuals

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Evinrude & Johnson E75DSLSCS Service Manual (349 pages)

75, 90 HP

Brand: Evinrude & Johnson | Category: Engine | Size: 14 MB

Able of

4
- Table of Contents
  4
  - Safety
    6
- Abbreviations Used in this Manual
  8
- Introduction
  8
Special Tools Special Tools 1

15
- Diagnostic Tools
  16
- Special Tools
  16
- Universal Tools
  16
- Electrical / Ignition Tools
  18
  - Special Tools
    18
- Fuel /Oil System Tools
  19
- Powerhead Tools
  19
- Gearcase Tools
  20
- Trim and Tilt Tools
  22
- Shop Aids
  23
- Notes
  26
Table of Contents

27
- Boat Rigging
  
  28
  - Remote Controls
    28
  - Battery Installation
    29
  - Battery Switches and Multiple Batteries
    30
    
    Installation and Predelivery
    30
  - Battery and Switch Wiring Diagrams
    32
  - Fuel System Requirements
    34
  - Fuel Filters
    35
  - Cable and Hose Installation
    36
  - Battery Cables
    37
- Outboard Installation
  
  40
  - Hull Preparation
    40
  - Transom Measuring and Drilling
    42
  - Lifting the Outboard
    45
  - Steering Systems
    45
  - Outboard Mounting
    47
- Outboard Rigging
  
  48
  - Cable, Hose, and Wire Routing
    48
  - Control Cable Adjustments
    48
  - Electrical Harness Connections
    50
  - Water Pressure Gauge
    50
  - Canbus Connections
    51
- Fuel and Oil Priming
  
  53
  - Fuel Requirements
    53
  - Fuel System Priming
    54
  - Oil Requirements
    54
  - Oil Injection Rate
    55
  - Break-In Oiling
    56
  - Oil Supply Priming
    56
- Before Start-Up
  
  57
  - Oil Level
    57
- Running Checks
  
  58
  - Engine Monitoring System
    58
  - Fuel System
    58
  - Emergency Stop / Key Switch
    58
  - Remote Control Operation
    58
  - Start-In-Gear Prevention
    58
  - Tachometer Pulse Setting
    58
  - Water Pump Overboard Indicator
    59
  - Operating Temperature
    59
- Propellers
  
  60
  - Propeller Selection
    60
  - Propeller Hardware Installation
    61
- Final Adjustments
  
  62
  - Tilt Limit Switch Adjustment
    62
  - Trim Sending Unit Adjustment
    63
  - Trim Tab Adjustment
    64
  - Dual-Outboard Alignment
    65
- Notes
  
  66
Maintenance Maintenance

67
- Inspection and Maintenance Schedule
  
  68
- Anti-Corrosion Protection
  
  69
  - Sacrificial Anodes
    69
  - Testing Procedure - Continuity
    69
  - Metallic Component Protection
    69
  - Exterior Finishes
    69
- Cooling System
  
  70
  - Flushing
    70
  - Maintenance
    70
  - Water Intake Screens
    71
  - Additional Maintenance
    71
- Lubrication
  
  71
  - Steering System
    71
  - Swivel Bracket and Trailering Bracket
    72
  - Tilt Tube
    72
  - Throttle and Shift Linkage
    72
  - Propeller Shaft
    73
  - Gearcase Lubricant
    73
  - Trim and Tilt
    75
- Battery and Battery Connections
  
  76
- Fuel and Oil Systems
  
  76
  - Fuel Filter
    76
  - Oil Filters and Oil Reservoir
    76
  - Air Silencer
    77
  - Hoses and Connections
    77
- Spark Plugs
  
  78
  - Removal
    78
  - Indexing
    78
- Storage
  
  79
  - Fuel System Treatment
    79
  - Internal Engine Treatment
    79
  - Additional Recommendations
    80
- Pre-Season Service
  
  80
  - Outboard Mounting Bolts
    80
  - Gearcase Lubricant
    80
  - Battery(S)
    80
  - Power Trim and Tilt
    80
  - Operational Checks
    80
- Submerged Engines
  
  81
- Notes
  
  82
  - Engine Cover Service
    86
Table of Contents

87
- Description
  88
  - Emm Functions
    88
  - Emm Connections
    88
  - Led Indicators
    88
- Emm Inputs and Outputs Diagram
  89
- Internal Sensors
  90
  - Emm Temperature Sensor
    90
  - 55 V Circuit Sensor
    90
  - Engine Management Module (Emm)
    90
  - Barometric Pressure Sensor
    91
- External Sensors
  91
  - Air Temperature Sensor
    91
  - Engine Temperature Sensor
    92
  - Low Oil Switch
    92
  - Throttle Position Sensor
    92
  - Crankshaft Position Sensor
    93
  - Neutral Switch
    93
- Internal Emm Functions
  94
- Engine Monitoring System
  95
  - Engine Running
    95
  - Service Mode
    95
- Shutdown Mode
  96
- Warning System
  96
- Diagnostic Software Functions
  97
  - Communication
    97
  - Static Information
    97
  - Dynamic Information
    98
  - Stored Service Codes (Faults)
    98
  - Hard Faults
    98
  - Persistent Faults
    98
  - Static Tests
    98
  - Dynamic Tests
    99
  - Oil Control Settings
    100
  - Tiller/Remote Programming
    100
  - Ignition Timing
    101
  - Tps Calibration
    101
  - Idle Speed Control
    101
  - Fuel Injector Servicing
    102
  - Reports
    102
  - Software Replacement
    103
  - Emm Transfer
    103
- Emm Servicing
  104
System Analysis System Analysis

105
- Diagnostic Procedures
  
  106
  - Visual Inspections
    106
  - Operational Inspections
    106
  - Troubleshooting
    107
- Dynamic Tests
  
  108
  - Cylinder Drop Tests
    108
  - Fuel Control Adjustment
    108
  - Inductive Amp Meter Test
    108
  - System Analysis
    108
- Emm Led Indicators
  
  109
  - Key on
    109
  - Starting
    109
  - Running
    110
- Ignition Output Tests
  
  111
  - Ignition System Requirements
    111
  - Wiring Inspection
    111
  - Crankshaft Position Sensor (Cps) Test
    112
  - System Voltage Test
    112
  - Static Ignition Test
    113
  - Running Ignition Tests
    114
  - Ignition Control Circuit Tests
    115
  - Ignition Coil Tests
    115
  - Capacitor Test
    115
- Fuel Delivery Tests
  
  116
  - Fuel Pump Static Test
    116
  - Fuel Injector Static Test
    116
  - Running Fuel System Tests
    117
- Notes
  
  118
Electrical and Ignition Electrical and Ignition

119
- Electrical and Ignition
  120
- Service Chart
  120
- Dash Connections, Instrument Harness
  122
  - Electrical and Ignition
    122
- Electrical Harness Connections
  123
- Fuse
  125
- Ground Circuits
  125
- Sensor Tests
  126
- Stator Tests
  128
- Charging System Tests
  129
- V Alternator Circuit
  130
- Electric Start Circuit
  131
- Electric Start Tests
  133
- No Load Current Draw Test
  134
- Remote Control Switch Tests
  135
  - Key Switch Test
    135
  - Neutral Start Circuit Test
    135
  - Neutral Start Switch Test
    136
  - Emergency Stop Switch Test
    136
- Tilt/Trim Relay Test
  137
- Systemcheck Circuit Tests
  138
  - Gauge Self-Test Check
    138
  - Check Engine Circuit Test
    139
  - Water Temp/ Hot Circuit Test
    139
  - Low Oil Circuit Test
    140
  - No Oil Circuit
    140
- Tachometer Circuit Tests
  140
- Flywheel and Stator Servicing
  141
  - Flywheel Removal
    141
  - Stator Service
    143
  - Flywheel Installation
    143
- Timing Adjustments
  144
  - Timing Pointer
    144
  - Timing Verification
    145
  - Tps Calibration
    145
- Electric Starter Servicing
  146
  - Starter Removal
    146
  - Starter Disassembly
    146
  - Starter Cleaning and Inspection
    147
  - Starter Assembly
    148
  - Starter Installation
    149
- Connector Servicing
  150
Table of Contents

155
- Service Chart
  
  156
- Fuel System Hose Routing
  
  158
- Fuel System Circuit Diagram
  
  159
- Components
  
  160
  - Fuel Lift Pump
    160
  - Fuel Filter
    160
  - Vapor Separator
    160
  - Fuel Circulation Pump
    161
  - Fuel Manifolds
    162
  - Fuel Injectors
    162
- Fuel System Tests
  
  163
  - Fuel System Pressure Test
    163
  - Pressure Regulator Test
    164
  - Vapor Separator Vent Check
    164
  - Fuel Injector Pressure Test
    164
  - Fuel Injector Resistance Test
    165
  - Circulation Pump Resistance Test
    165
  - Lift Pump Pressure Test
    165
  - Lift Pump Vacuum Test
    166
  - Lift Pump Diaphragm Test
    167
  - Anti-Siphon Valve Test
    167
- Fuel Component Servicing
  
  168
  - Relieving Fuel System Pressure
    168
  - Fuel Filter Service
    169
  - Fuel Lift Pump Service
    169
  - Vapor Separator Service
    170
  - Fuel Manifold Service
    170
  - Fuel Injector Service
    171
  - Intake Manifold Service
    174
Oiling System Oiling System

177
- Service Chart
  178
  - Oiling System
    178
- Oil Supply Diagrams
  179
- Oil Recirculation Diagram
  180
- Oiling System
  180
- Oiling System Circuit Diagram
  181
- Components
  182
  - Oil Tank Assembly
    182
  - Oil Injection Pump
    182
  - Electrical Circuit (55 V)
    182
  - Low Oil Warning
    183
  - No Oil Warning
    183
  - Cylinder and Crankcase
    183
  - Oil Recirculation System
    184
- Oil Control Settings
  184
  - Oil Priming
    184
  - Oiling Rates
    184
  - Break-In Oiling
    184
- Oiling System Tests
  185
  - Oil Injection Pump Static Test
    185
  - Oil Injection Pump Voltage Test
    185
  - Oil Injection Pump Circuit Resistance Test
    186
  - Oil Injection Pump Function Test
    186
  - Oil Injection Fittings Flow Test
    187
  - Low Oil Sending Unit Test
    187
- Oil Component Servicing
  188
  - Oil Distribution Hoses
    188
  - Oil Tank Assembly
    189
- Notes
  190
Cooling System Cooling System

191
- Hose Routing and Water Flow Diagram
  
  192
- Components
  
  193
  - Water Pump and Intakes
    193
  - Water Supply Tube
    193
  - Adapter/Inner Exhaust Housing
    193
  - Pressure Relief Valve
    194
  - Thermostat
    194
  - Block Venting
    194
  - Water Pressure Connection
    194
  - Cooling System
    194
- Operation
  
  195
  - Cylinder Block / Cylinder Head Cooling
    195
  - Emm and Vapor Separator Cooling
    195
- Engine Temperature Check
  
  196
  - Software Method
    196
  - Pyrometer Method
    196
  - Idle Operating Temperature Troubleshooting (below Range)
    197
  - Thermostat Inspection
    197
- Thermostat Servicing
  
  198
  - Disassembly
    198
  - Inspection
    198
  - Assembly
    198
- Pressure Relief Valve Servicing
  
  199
  - Disassembly
    199
  - Inspection
    199
  - Assembly
    199
- Notes
  
  200
Powerhead Powerhead

201
- Service Chart
  
  202
- Powerhead Removal
  
  204
- Powerhead Disassembly
  
  206
  - General
    206
  - Throttle Linkage Removal
    206
  - Shift Linkage Removal
    206
  - Crankcase Disassembly
    207
  - Cylinder Head Removal
    208
  - Connecting Rods and Pistons
    208
  - Crankshaft Removal
    209
- Cylinder Block Cleaning
  
  212
- Powerhead Inspection
  
  213
  - Cylinder Head
    213
  - Crankshaft
    213
  - Cylinder Bore
    213
  - Pistons
    214
  - Piston Rings
    214
  - Bearings
    215
- Powerhead Assembly
  
  215
  - Crankshaft Assembly
    215
  - Pistons and Connecting Rods
    217
  - Cylinder Head Installation
    219
  - Crankshaft and Connecting Rod Installation
    220
  - Crankcase Assembly
    223
  - Shift Linkage Installation
    225
  - Throttle Linkage Installation
    225
  - Final Powerhead Assembly
    226
- Upper Mount Servicing
  
  227
  - Removal
    227
  - Installation
    227
- Powerhead Installation
  
  228
  - Powerhead Mounting
    228
  - Shift Linkage Adjustment
    230
- Powerhead Views
  
  231
  - Port Short Block
    231
  - Starboard Short Block
    231
  - Port Dressed Powerhead
    232
  - Starboard Dressed Powerhead
    232
  - Front
    233
  - Rear
    234
  - Top
    235
- Notes
  
  236
Midsection Midsection

237
- Service Chart
  
  238
- Tilt Tube
  
  240
  - Removal
    240
- Midsection
  
  240
  - Installation
    241
- 10 Cooling System
  
  240
- 11 Powerhead
  
  240
- Exhaust Housing
  
  242
  - Exhaust Housing Removal
    242
  - Exhaust Housing Disassembly
    243
  - Cleaning and Inspection
    244
  - Exhaust Housing Assembly
    244
  - Exhaust Housing Installation
    247
- Stern Bracket
  
  248
  - Stern Bracket Removal
    248
  - Stern Bracket Disassembly
    248
  - Stern Bracket Assembly
    250
  - Swivel Bracket Disassembly (Manual Tilt)
    253
  - Swivel Bracket Assembly (Manual Tilt)
    255
- Notes
  
  258
Gearcase Gearcase

259
- Service Chart
  
  260
- Gearcase Leak Test
  
  262
- Propeller Service
  
  262
  - Inspection
    262
- Gearcase Types
  
  262
- Gearcase Removal and Installation
  
  263
  - Gearcase Removal
    263
  - Gearcase Installation
    264
- Water Pump
  
  265
  - Disassembly
    265
  - Inspection
    265
  - Assembly
    266
- Shift Rod Adjustment
  
  268
- Gearcase Disassembly
  
  269
  - Pre-Disassembly Inspection
    269
  - Propeller Shaft Bearing Housing Removal
    270
  - Pinion Gear and Driveshaft Removal
    270
  - Driveshaft Service
    272
  - Shift Housing, Gear and Propeller Shaft Removal
    273
  - Water Intake Screens
    273
- Gearcase Housing Inspection
  
  273
- Internal Gearcase Service
  
  274
  - Pinion Bearing Removal
    274
  - Pinion Bearing Installation
    274
  - Shift Housing Disassembly
    275
  - Shift Housing Assembly
    277
  - Driveshaft Bearing Housing Service
    279
  - Propeller Shaft Bearing Housing Service
    280
- Driveshaft Shimming
  
  282
- Gearcase Assembly
  
  283
- Notes
  
  288
Gearcase Notes Notes

289
- System Description
  
  290
  - Manual Adjustment
    290
  - Trailering Bracket and Tilt Support
    290
- Routine Inspections
  
  291
  - General
    291
  - Reservoir Fluid
    291
  - Manual Release Valve
    291
  - Stern Brackets
    291
- Troubleshooting
  
  291
- Electrical Circuit Tests
  
  292
  - Relay Testing
    292
  - Trim and Tilt Motor Current Draw Tests
    292
  - Trim and Tilt Motor no Load Test
    293
  - Trim Gauge Test
    293
  - Trim Sender Test
    294
- Servicing
  
  294
  - Removal
    294
  - Disassembly
    296
  - Assembly
    297
  - Installation
    298
- Adjustments
  
  299
- Notes
  
  300
Safety Safety

301
- Marine Products and the Safety of People Who Use Them
  303
- Marine Products and the Safety of People Who Fix Them
  317
  - Handling Outboards
    317
  - Handling Lead/Acid Batteries
    321
  - Gasoline - Handle with Care
    322
  - Hazardous Products
    323
  - Safety Awareness Test
    324
  - Trouble Check Chart
    333

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Evinrude & Johnson E75DSLSCS Service Manual (349 pages)

Table of Contents

Able of

Special Tools Special Tools 1

Table of Contents

Boat Rigging

Outboard Installation

Outboard Rigging

Fuel and Oil Priming

Before Start-Up

Running Checks

Propellers

Final Adjustments

Notes

Maintenance Maintenance

Inspection and Maintenance Schedule

Anti-Corrosion Protection

Cooling System

Lubrication

Battery and Battery Connections

Fuel and Oil Systems

Spark Plugs

Storage

Pre-Season Service

Submerged Engines

Notes

Table of Contents

System Analysis System Analysis

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Notes

Electrical and Ignition Electrical and Ignition

Table of Contents

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Components

Fuel System Tests

Fuel Component Servicing

Oiling System Oiling System

Cooling System Cooling System

Hose Routing and Water Flow Diagram

Components

Operation

Engine Temperature Check

Thermostat Servicing

Pressure Relief Valve Servicing

Notes

Powerhead Powerhead

Service Chart

Powerhead Removal

Powerhead Disassembly

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Upper Mount Servicing

Powerhead Installation

Powerhead Views

Notes

Midsection Midsection

Service Chart

Tilt Tube

Midsection

10 Cooling System

11 Powerhead

Exhaust Housing

Stern Bracket

Notes

Gearcase Gearcase

Service Chart

Gearcase Leak Test

Propeller Service

Gearcase Types

Gearcase Removal and Installation

Water Pump

Shift Rod Adjustment