User Manuals: Evinrude E-TEC 200 Outboard Boat Motor

Manuals and User Guides for Evinrude E-TEC 200 Outboard Boat Motor. We have 2 Evinrude E-TEC 200 Outboard Boat Motor manuals available for free PDF download: Service Manual, Original Instructions Manual

Evinrude E-TEC 200 Service Manual (416 pages)

Brand: Evinrude | Category: Outboard Motor | Size: 36 MB

S M Ervice Anual

4
- Table of Contents
  4
- Safety Notice
  
  6
- Abbreviations Used in this Manual
  
  8
- Units of Measurement
  
  8
- List of Abbreviations
  
  8
  - Reference Information
    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
- Index
  17
- Inspection and Maintenance Schedule
  
  18
- Outboard Rigging Connections
  
  19
  - Control Cable Installation
    19
    
    Routine Service
    20
  - Battery Cable Connections
    23
  - Systemcheck Harness Connections
    23
  - I-Command Network Connections
    24
  - Icon Network Connections
    25
  - Water Pressure Gauge
    26
- Lifting the Outboard
  
  19
- 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
  - Fuel System
    34
- Cooling System
  
  35
- Lubrication
  
  38
  - Steering System
    38
  - Tilt Tube
    38
  - Swivel Bracket and Trailering Bracket
    38
  - Throttle and Shift Linkage
    38
  - Propeller Shaft
    39
  - Gearcase Lubricant
    39
  - Trim and Tilt
    41
- Spark Plugs
  
  42
  - Indexing
    42
- Fuel and Oil Systems
  
  43
  - Fuel Filter
    43
  - Oil Filters and Oil Reservoir
    43
  - Air Silencer
    43
  - Hoses and Connections
    43
- Exhaust Pressure Fitting
  
  44
  - Operation Test
    44
  - Cleaning
    44
- Anti-Corrosion Protection
  
  45
  - Metallic Component Protection
    45
  - Exterior Finishes
    45
- Storage
  
  46
  - Fuel System Treatment
    46
  - Internal Engine Treatment
    46
  - Additional Recommendations
    47
- Pre-Season Service
  
  48
- Submerged Engines
  
  48
  - Power Trim and Tilt
    48
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
  - Engine Cover Service
    54
Table of Contents

55
- Description
  
  56
- Emm Inputs and Outputs Diagram
  
  57
- Internal Sensors
  
  58
  - Emm Temperature Sensor
    58
  - 55 V Circuit Sensor
    58
  - Engine Management Module (Emm)
    58
  - 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
  - Knock Sensor
    62
  - Neutral/Shift Interrupt Switch
    62
- Internal Emm Functions
  
  63
  - Start Assist Circuit (Sac)
    63
  - Rom Verification
    63
  - Idle Controller
    63
  - Rpm Limiter
    63
  - Neutral Rpm Limiter
    63
  - Engine Monitor and Warning Systems
    63
  - Fault Code Creation and Storage
    63
- Engine Monitor System
  
  64
- Warning System
  
  65
- Shutdown Mode
  
  65
- Diagnostic Software Functions
  
  66
  - Communication
    66
  - Static Information
    66
  - Dynamic Information
    67
  - Stored Service Codes (Faults)
    67
  - Hard Faults
    67
  - Persistent Faults
    67
  - Static Tests
    67
  - Dynamic Tests
    68
  - Oil Control Settings
    69
  - Ignition Timing
    70
  - Tps Calibration
    70
  - Fuel Injector Servicing
    70
  - Reports
    71
  - Emm Transfer Emm Servicing
    72
Engine Management Module (Emm) Notes Notes

75
- Diagnostic Procedures
  
  76
  - Visual Inspections
    76
  - Diagnostic Software Inspections
    76
  - Operational Inspections
    77
  - Troubleshooting
    78
  - System Analysis
    78
- Dynamic Tests
  
  79
  - Cylinder Drop 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
  - Ignition Control Circuit Tests
    86
  - Ignition Coil Tests
    86
  - Capacitor Test
    86
- Fuel Delivery Tests
  
  87
  - Fuel Pump Static Test
    87
  - Fuel Injector Static Test
    87
  - Running Fuel System Tests
    88
Table of Contents

89
- Service Chart
  90
- Ignition System Circuit Diagram
  92
  - Electrical and Ignition
    92
- Diagrams
  93
- Electrical Harness Connections
  93
- Diagrams
  95
- Fuse
  95
- Ground Circuits
  95
- Sensor Tests
  96
- Stator Tests
  98
  - Stator Resistance Tests
    98
  - Stator Voltage Output Test
    98
- Charging System Tests
  99
  - 12 V Charging Circuit
    99
  - Auxiliary Battery Charge Wire
    100
  - 55 V Alternator Circuit
    100
- Electric Start Circuit
  101
- Electric Start Tests
  103
- Diagrams
  105
- 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 Servicing
  113
  - Ignition Coil Removal
    113
  - Ignition Coil Installation
    113
- Timing Adjustments
  114
  - Timing Pointer
    114
  - Timing Verification
    115
  - Tps Calibration
    115
- Electric Starter Servicing
  117
  - Starter Removal
    117
  - Starter Disassembly
    117
  - Starter Cleaning and Inspection
    120
  - Starter Assembly
    121
  - Starter Installation
    123
- Connector Servicing
  124
Electrical and Ignition Notes Notes

129
- Service Chart
  
  130
  - Fuel System
    132
- Fuel System Hose Routing
  
  133
- Fuel System Circuit Diagram
  
  134
- Fuel System Requirements
  
  135
  - Regulations and Guidelines
    135
  - Portable Fuel Tanks
    135
  - Fuel Flow Requirements
    135
  - Fuel Requirements
    136
- Components
  
  137
  - Fuel Lift Pump
    137
  - Fuel Filter
    137
  - Vapor Separator
    137
  - Fuel Circulation Pump
    138
  - Fuel Manifolds
    139
  - Fuel Injectors
    139
- Fuel System Priming
  
  140
  - Vent Line Clamp
    140
  - Priming the Fuel System
    140
- Fuel System Tests
  
  141
  - Fuel System Pressure Test
    141
  - Pressure Regulator Test
    142
  - Vapor Separator Vent Check
    142
  - Fuel Injector Pressure Test
    142
  - Fuel Injector Resistance Test
    143
  - Circulation Pump Resistance Test
    143
  - Lift Pump Pressure Test
    143
  - Lift Pump Vacuum Test
    144
  - Lift Pump Diaphragm 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
  - Vapor Separator Service
    148
  - Fuel Manifold Service
    148
  - Fuel Injector Service
    149
  - Intake Manifold Service
    153
Fuel System Notes Notes

157
- Diagrams
  157
- Service Chart
  158
- Oiling System Circuit Diagram
  159
- Oil Supply Diagrams
  160
  - Oiling System
    160
  - Diagrams
    161
  - Diagrams
    162
  - Diagrams
    163
- Oil Recirculation Diagrams
  164
  - Diagrams
    165
- Components
  166
  - Oil Tank Assembly
    166
  - Oil Injection Pump
    167
  - Electrical Circuit (55 V)
    167
  - Oil Pressure Sensor
    167
  - Rear Oil Manifold (3.3 L Models)
    168
  - Rear Oil Pump (3.4 L Models)
    168
  - Electrical Circuit (12 V)
    168
  - Low Oil Warning
    168
  - No Oil Warning
    168
  - Cylinder and Crankcase
    169
  - Oil Recirculation System
    169
- Oil System Requirements
  166
  - Recommended Lubricants
    166
- Oil Control Settings
  170
  - Oil Injection Rate
    170
  - Break-In Oiling
    171
- Oil Supply Priming
  172
  - Oil Hose Priming
    172
  - Oil Pump Priming
    172
  - Hp (3.4 L) Models
    172
  - Hp (3.3 L) Models
    174
- Oiling System Tests
  175
  - Oil Injection Pump Static Test
    175
  - Oil Injection Pump Voltage Test
    175
  - Oil Injection Pump Circuit Resistance Test
    176
  - Cylinder Oil Pump Voltage Test
    176
  - Cylinder Oil Pump Circuit Resistance Test
    177
  - Oil Supply Vacuum Test
    177
  - Oil Injection Pump Function Test
    178
  - Oil Injection Fittings Flow Test
    178
  - Low Oil Sending Unit Test
    178
  - Oil Distribution Hoses
    179
- Oil Component Servicing
  180
  - Oil Injection Pump
    181
  - Cylinder Oil Pump
    181
    
    Diagrams
    181
    
    Diagrams
    183
Idle Operating Temperature Troubleshooting (below Range)

185
- Hose Routing and Water Flow Diagram
  
  186
- Components
  
  187
  - Water Pump and Intakes
    187
  - Water Supply Tube
    187
  - Adapter Housing
    187
  - Pressure Relief Valve
    188
  - Thermostats
    188
  - Block Venting
    188
  - Cooling System
    188
- Operation
  
  189
  - Cylinder Block / Cylinder Head Cooling
    189
  - Emm and Vapor Separator Cooling
    190
- Engine Temperature Check
  
  190
  - Software Method
    191
  - Pyrometer Method
    191
  - Idle Operating Temperature Troubleshooting (below Range)
    191
- Thermostat Servicing
  
  193
  - Disassembly
    193
  - Inspection
    193
  - Assembly
    193
- Temperature Sender Servicing
  
  193
  - Removal
    193
  - Installation
    193
- Pressure Relief Valve Servicing
  
  194
  - Disassembly
    194
  - Inspection
    194
  - Assembly
    194
Evinrude Icon Remote Control System

195
- Service Chart
  
  196
- Components
  
  197
  - Electronic Servo Module (Esm)
    197
  - Shift Actuator
    197
  - Throttle Actuator
    198
  - Icon System Failsafe Mode
    198
  - Evinrude Icon Remote Control System
    198
- Icon Component Servicing
  
  199
  - Electronic Servo Module (Esm)
    199
  - Shift Actuator
    202
  - Throttle Actuator
    204
- Icon System Settings
  
  207
  - Set Engine Identity (Instance)
    207
  - Calibrate Actuator Stroke
    207
- Icon Remote Control System Troubleshooting Chart
  
  210
- Icon Remote Control System Fault Messages
  
  212
Table of Contents

215
- Service Chart
  216
- Compression Testing
  218
- Powerhead
  218
- Taper Pin Tool
  218
- Powerhead Removal
  219
- Powerhead Disassembly
  221
  - Systems Removal
    221
  - Throttle Linkage Removal
    221
  - Shift Linkage Removal
    221
  - Crankcase Disassembly
    222
  - Cylinder Head Removal
    223
  - Connecting Rods and Pistons
    223
  - Crankshaft Removal
    224
- Cylinder Block Cleaning
  227
- Powerhead Inspection
  228
  - Cylinder Head
    228
  - Crankshaft
    228
  - Cylinder Bore
    229
  - Pistons
    229
  - Piston Rings
    229
  - Bearings
    230
- Powerhead Assembly
  230
  - Crankshaft Assembly
    230
  - Pistons and Connecting Rods
    233
  - Cylinder Head Installation
    234
  - Crankshaft and Connecting Rods
    235
  - Crankcase Assembly
    238
  - Shift Linkage Installation
    239
  - Throttle Linkage Installation
    240
  - Final Powerhead Assembly
    240
- Diagrams
  240
- Powerhead Installation
  241
  - Pre-Service Adjustments
    243
- Powerhead Views
  244
  - Hose Routings - 3.3 L Models
    244
  - Hose Routings - 3.4 L Models
    246
  - Port - 3.3 L Models
    248
  - Starboard - 3.3 L Models
    249
  - Port - 3.4 L Models
    250
  - Starboard - 3.4 L Models
    251
  - Front - 3.3 L Models
    252
  - Front - 3.4 L Models
    253
  - Rear - 3.3 L Models
    254
  - Rear - 3.4 L Models
    255
  - Top
    256
  - Starboard - Icon Models
    257
Powerhead Notes Notes

259
- Service Chart
  
  260
  - Stern Bracket
    260
  - Exhaust Housing - 3.3 L Models
    261
  - Exhaust Housing - 3.4 L Models
    262
  - Midsection
    262
    
    Muffler
    263
- Tilt Tube
  
  264
  - Removal
    264
  - Installation
    265
- Exhaust Housing Service
  
  266
  - Exhaust Housing Removal
    266
  - Lower Mount Service
    266
  - Exhaust Housing Installation
    267
  - Exhaust Housing Disassembly - 3.3 L Models
    268
  - Exhaust Housing Disassembly - 3.4 L Models
    269
  - Cleaning and Inspection
    270
  - Exhaust Housing Assembly - 3.3 L Models
    271
  - Exhaust Housing Assembly - 3.4 L Models
    273
- Stern Bracket
  
  275
  - Stern Bracket Disassembly
    275
  - Stern Bracket Assembly
    277
- Exhaust Relief Muffler Assembly
  
  280
Gearcase - Standard Rotation/Gearcase - Counter Rotation

281
- Service Chart
  282
- Gearcase
  284
  - Gearcase Types
    285
  - Propeller Selection
    286
  - Propeller Service
    286
  - Propeller Hardware Installation
    287
  - Gearcase Leak Test
    288
  - Gearcase Removal and Installation
    289
  - Water Pump Service
    292
  - Shift Rod Adjustment
    295
- Gearcase - Standard Rotation
  
  296
  - Gearcase Disassembly
    296
    
    Propeller Shaft Bearing Housing Removal
    297
    
    Pinion Gear and Driveshaft Removal
    298
    
    Gearcase – Standard Rotation
    299
    
    Driveshaft Service
    300
    
    Shift Housing, Gear, and Propeller Shaft Removal
    300
  - Gearcase Housing Inspection
    301
  - Shifter, Bearing and Seal Servicing
    302
    
    Pinion Bearing
    302
    
    Shift Housing
    303
    
    Driveshaft Bearing Housing
    307
    
    Propeller Shaft Bearing Housing Service
    308
  - Driveshaft Shimming
    310
  - Gearcase Assembly
    312
    
    Shift Housing, Gear, and Propeller Shaft Installation
    312
    
    Pinion Gear and Driveshaftinstallation
    313
- Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
  
  315
  - Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
    316
    
    Final Assembly and Adjustment
    318
- Gearcase - Counter Rotation
  
  319
Table of Contents

331
- Service Chart
  
  332
- System Description
  
  333
- Modes of Operation
  
  334
  - Trim-Out / Tilt-Up Mode
    334
  - Trim and Tilt
    334
  - Tilt-Down / Trim-In Mode
    335
  - Impact Relief
    336
  - Shallow Water Drive Tilt Relief
    337
  - Thermal Expansion Relief
    337
  - Manual Release - up
    338
  - Manual Release - down
    339
- Routine Inspections
  
  340
  - General
    340
  - Reservoir Fluid
    340
  - Manual Release Valve
    340
  - Stern Brackets
    340
- Troubleshooting
  
  340
  - Symptoms Chart
    341
  - Service Procedures
    341
  - Pressure Leakdown Test
    341
- Electrical Circuit Tests
  
  344
  - Relay Testing
    344
  - Trim and Tilt Motor Current Draw Tests
    344
  - Trim and Tilt Motor no Load Test
    345
  - Trim Gauge Test
    346
  - Trim Sender Test
    346
- Trim and Tilt Replacement
  
  347
  - Removal
    347
  - Installation
    348
- Trim and Tilt Service
  
  349
  - Disassembly
    349
  - Tilt Piston Removal
    352
  - Tilt Piston Identification
    353
  - Tilt Piston Assembly
    353
  - Tilt Rod Assembly
    354
  - Trim Rod Removal
    355
  - Trim Rod Assembly
    356
  - Manifold and Reservoir Installation
    357
  - Trim Rod Installation
    358
  - Tilt Rod Installation
    359
  - Motor Installation
    359
Trim and Tilt Notes Notes

363
- Marine Products and the Safety of People Who Use Them
  365
- Marine Products and the Safety of People Who Fix Them
  379
  - Handling Outboards
    379
  - Handling Lead/Acid Batteries
    383
  - Gasoline - Handle with Care
    384
  - Hazardous Products
    385
  - Safety Awareness Test
    386
  - Trouble Check Chart
    397

Evinrude E-TEC 200 Original Instructions Manual (90 pages)

Brand: Evinrude | Category: Outboard Motor | Size: 6 MB

Table of Contents

6
Starboard 13 12

17
- 200, 225, 250, 300 Hp 90°V6
  18
- Air Silencer
  19
- Description
  19
- Flywheel Cover
  19
- Item Description Item
  19
- Port
  19
- Spark Plugs
  19
- Water Pump Indicator, Flushing Port
  19
- Oil and Fuel
  20
  - Oil Requirements
    20
  - Oiling System Information
    20
  - Priming the Oil System
    21
  - Fueling Procedure
    23
  - Fuel Requirements
    24
  - Fuel Additives
    25
  - Fuel System Information
    25
- Operation
  27
  - Safety Information
    27
  - Engine Starting / Stopping
    27
  - Engine Stopping
    29
  - Remote Controls - Evinrude ICON Control System
    30
  - Remote Controls - Evinrude/Johnson (Brp) Controls
    32
  - Speed Control
    33
  - Fuel Economy
    33
- Tilting and Trim
  34
- Engine Monitoring
  38
  - Engine Overheating
    40
- Special Operating Conditions
  41
  - Cold and Freezing Weather
    41
  - Dual Outboard Operation
    41
  - High Altitude
    41
  - Salt Water
    41
  - Shallow Water
    42
  - Under Tow
    42
  - Weedy Water
    42
- Transporting the Outboard
  43
  - Trailering
    43
  - Transporting / Storage
    44
- Pre-Ride Inspection
  45
  - Maintenance
    47
- Engine Emissions Information
  48
  - Owner Responsibility
    48
- Maintenance Schedule
  49
- Service
  50
  - Anti-Corrosion Anodes
    50
  - Flushing
    50
  - Fuse
    51
  - Fuse Replacement
    51
  - Hull Finish
    52
  - Outboard External Finish
    52
  - Scratch Repair
    52
  - Spark Plugs
    52
  - Submerged Outboard
    52
- Storage
  53
- Troubleshooting
  58
  - Product Information
    59
- Installation
  60
  - Transom Height
    60
  - Installing the Outboard
    61
  - Boat-Mounted Fuel Filters
    61
  - Battery
    61
  - Accessory Battery Connection
    62
  - Water Pressure
    62
  - Propeller
    63
- Adjustments
  65
- Specifications
  66
- Product Warranty Information
  73
- California Emission Control Warranty Statement
  76
- EMM (Engine Management Module)
  77
  - Electrical System
    77
  - Oil System
    77
  - Exhaust System
    77
- Readiness Test
  83
- Frequently Asked Questions
  85
- Change of Address / Change of Ownership
  87
- Confirmation of Receipt
  89

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User Manuals: Evinrude E-TEC 200 Outboard Boat Motor

Evinrude E-TEC 200 Service Manual (416 pages)

Table of Contents

S M Ervice Anual

Safety Notice

Abbreviations Used in this Manual

Units of Measurement

List of Abbreviations

Emission-Related Installation Instructions

Manufacturer's Responsibility

Dealer's Responsibility

Owner's Responsibility

Epa Emission Regulations

Model Designation

Models Covered in this Manual

Service Specifications

Standard Torque Specifications

Product Reference and Illustrations

Table of Contents

Inspection and Maintenance Schedule

Outboard Rigging Connections

Lifting the Outboard

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Exhaust Pressure Fitting

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Table of Contents

Description

Emm Inputs and Outputs Diagram

Internal Sensors

External Sensors

Internal Emm Functions

Engine Monitor System

Warning System

Shutdown Mode

Diagnostic Software Functions

Engine Management Module (Emm) Notes Notes

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Table of Contents

Electrical and Ignition Notes Notes

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Fuel System Notes Notes

Idle Operating Temperature Troubleshooting (below Range)

Hose Routing and Water Flow Diagram

Components

Operation

Engine Temperature Check

Thermostat Servicing

Temperature Sender Servicing

Pressure Relief Valve Servicing

Evinrude Icon Remote Control System

Service Chart

Components

Icon Component Servicing

Icon System Settings

Icon Remote Control System Troubleshooting Chart

Icon Remote Control System Fault Messages

Table of Contents

Powerhead Notes Notes