Evinrude E-Tec 40 HP Manuals

Manuals and User Guides for Evinrude E-Tec 40 HP. We have 1 Evinrude E-Tec 40 HP manual available for free PDF download: Service Manual

Evinrude E-Tec 40 HP Service Manual (426 pages)

Brand: Evinrude | Category: Engine | Size: 49 MB

S M Ervice Anual

4
Table of Contents

17
- Inspection and Maintenance Schedule
  
  18
- Lifting the Outboard
  
  19
- Outboard Rigging Connections
  
  19
- Battery and Battery Connections
  
  26
- Oetiker Clamp Servicing
  
  27
- Adjustments
  
  29
- Operational Checks
  
  35
- Cooling System
  
  36
  - Engine Flushing
    37
  - Running the Outboard Using a Hose and Flushing Adapter
    38
- Lubrication
  
  39
  - Steering System
    39
  - Tiller Handle
    39
  - Swivel Bracket and Trailering Bracket
    40
  - Tilt Tube
    40
  - Throttle and Shift Linkage
    40
  - Propeller Shaft
    41
  - Gearcase Lubricant
    41
  - Trim and Tilt
    43
- Spark Plugs
  
  44
  - Indexing
    44
- Fuel and Oil Systems
  
  45
  - Fuel Filter
    45
  - Oil Filters and Oil Reservoir
    45
  - Air Silencer
    45
  - Hoses and Connections
    45
- Anti-Corrosion Protection
  
  46
- Storage
  
  47
  - Fuel System Treatment
    47
  - Internal Engine Treatment
    47
  - Additional Recommendations
    48
- Pre-Season Service
  
  48
- Submerged Engines
  
  49
Engine Cover Service

51
- Lower Cover Service
  52
  - Lower Cover Removal
    52
  - Lower Cover Installation
    53
  - Latch Handle Installation
    54
  - Trim Switch Installation
    54
- Upper Cover Service
  52
  - Latch Hook Installation
    52
Table of Contents

55
- Description
  56
  - Emm Functions
    56
  - Emm Connections
    56
  - Led Indicators
    56
- Emm Inputs and Outputs Diagram
  57
- Internal Sensors
  58
  - Emm Temperature Sensor
    58
  - 55 V Circuit Sensor
    58
  - 5 V Circuit Sensor
    59
  - Barometric Pressure Sensor
    59
- External Sensors
  59
  - Air Temperature Sensor
    59
  - Engine Temperature Sensor
    59
  - Low Oil Switch
    60
  - Throttle Position Sensor
    61
  - Crankshaft Position Sensor
    61
  - Neutral Switch
    61
- Internal Emm Functions
  62
- Engine Monitor System
  63
- Shutdown Mode
  64
- Warning System
  64
- Diagnostic Software Functions
  65
  - Communication
    65
  - Static Information
    66
  - Dynamic Information
    66
  - Stored Service Codes (Faults)
    67
  - Hard Faults
    67
  - Persistent Faults
    67
  - Static Tests
    67
  - Dynamic Tests
    68
  - Oil Control Settings
    68
  - Tiller/Remote Programming
    69
  - Ignition Timing
    69
  - Tps Calibration
    70
  - Idle Speed Control
    70
  - Fuel Injector Servicing
    70
  - Reports
    71
  - Software Replacement
    71
  - Emm Transfer
    72
- Emm Servicing
  72
  - Removal
    72
  - Installation
    73
Engine Management Module (Emm) Notes Notes

75
- 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 Water Valve (60-65Hp)
  
  88
  - Exhaust Water Valve Static Test
    88
  - Exhaust Water Valve Dynamic Test
    88
Table of Contents

89
- Service Chart
  90
- Ignition System Circuit Diagram, 40 - 65 Hp
  92
- Ignition System Circuit Diagram, 75 - 90 Hp
  93
- Electrical Harness Connections
  94
- Fuse
  96
- Ground Circuits
  96
- Sensor Tests
  97
- Stator Tests
  99
  - Stator Resistance Tests
    99
  - Stator Voltage Output Test
    99
- Charging System Tests
  100
- Electric Start Circuit
  102
- Electric Start Tests
  104
- Remote Control Switch Tests
  106
- Exhaust Water Valve Test
  108
- Tilt/Trim Relay Test
  108
- Systemcheck Circuit Tests
  109
- Tachometer Circuit Tests
  111
- Flywheel and Stator Servicing
  112
  - Flywheel Removal
    112
  - Stator Service
    113
  - Flywheel Installation
    113
- Ignition Coil Servicing
  114
  - Ignition Coil Removal
    114
  - Ignition Coil Installation
    114
- Timing Adjustments
  115
  - Timing Pointer
    115
  - Timing Verification
    116
  - Tps Calibration
    116
- Electric Starter Servicing
  117
  - Starter Removal
    117
  - Starter Installation
    117
- Connector Servicing
  118
  - Deutsch Connectors
    118
  - Amp Connectors
    119
  - Packard Connectors
    121
Electrical and Ignition Notes Notes

123
- Service Chart
  
  124
- Fuel System Hose Routing
  
  128
- Fuel System Circuit Diagrams
  
  130
- Fuel System Requirements
  
  132
  - Regulations and Guidelines
    132
  - Portable Fuel Tanks
    132
  - Fuel Flow Requirements
    132
  - Fuel Requirements
    133
- Components
  
  134
  - Fuel Lift Pump
    134
  - Fuel Filter
    134
  - Vapor Separator
    134
  - Fuel Circulation Pump
    136
  - Fuel Manifolds
    136
  - Fuel Injectors
    136
- Fuel System Priming
  
  138
  - Vent Line Clamp
    138
  - Priming the Fuel System
    138
- Fuel System Tests
  
  139
  - Fuel System Pressure Test
    139
  - Pressure Regulator Test
    140
  - Vapor Separator Vent Check
    140
  - Fuel Injector Pressure Test
    140
  - Fuel Injector Resistance Test
    141
  - Circulation Pump Resistance Test
    141
  - Lift Pump Pressure Test
    141
  - Lift Pump Vacuum Test
    142
  - Lift Pump Diaphragm Test
    143
  - Anti-Siphon Valve Test
    143
- Fuel Component Servicing
  
  144
  - Relieving Fuel System Pressure
    144
  - Fuel Filter Service
    145
  - Fuel Lift Pump Service
    145
  - Vapor Separator Service
    146
  - Fuel Manifold Service
    147
  - Fuel Injector Service
    148
  - Intake Manifold Service
    151
Fuel System Notes Notes

155
- Service Chart
  156
- Oil Supply Diagrams
  158
- Oil Recirculation Diagrams
  160
- Oiling System Circuit Diagram
  161
- Components
  162
  - Oil Tank Assembly
    162
  - Oil Injection Pump
    163
  - Electrical Circuit (55 V)
    163
  - Low Oil Warning
    164
  - No Oil Warning
    164
  - Cylinder and Crankcase
    164
  - Oil Recirculation System
    165
- Oil System Requirements
  162
  - Recommended Lubricants
    162
- Oil Control Settings
  166
  - Oil Injection Rate
    166
  - Break-In Oiling
    167
  - Oil Supply Priming
    167
- Oiling System Tests
  168
  - Oil Injection Pump Voltage Tests
    168
  - Oil Injection Pump Resistance Test
    169
  - Oil Injection Pump Function Test
    170
  - Oil Injection Fittings Flow Test
    170
  - Low Oil Sending Unit Test
    170
- Oil Component Servicing
  171
  - Oil Distribution Hoses
    171
  - Oil Tank Assembly
    171
  - Oil Injection Pump
    173
Table of Contents

175
- Hose Routing and Water Flow Diagrams
  
  176
- Components
  
  178
  - Water Pump and Intakes
    178
  - Exhaust Housing
    178
  - Water Supply Tube
    178
  - Adapter/Inner Exhaust Housing
    179
  - Pressure Relief Valve
    179
  - Thermostat
    179
  - Block Venting
    180
  - Water Pressure Connection
    180
- Operation
  
  181
  - Cylinder Block / Cylinder Head Cooling
    181
  - Emm and Vapor Separator Cooling
    181
- Engine Temperature Check
  
  182
  - Software Method
    182
  - Pyrometer Method
    182
- Thermostat Servicing
  
  184
  - Disassembly
    184
  - Inspection
    185
  - Assembly
    185
- Temperature Sender Servicing
  
  184
  - Removal
    184
  - Installation
    184
- Pressure Relief Valve Servicing
  
  185
  - Disassembly
    185
  - Inspection
    186
  - Assembly
    186
Powerhead

187
- Service Chart
  
  188
- Powerhead Removal
  
  192
  - 2-Cylinder Models
    192
  - 3-Cylinder Models
    194
- Compression Testing
  
  192
- Powerhead Disassembly
  
  195
  - Systems Removal
    195
  - Throttle Linkage Removal
    196
  - Shift Linkage Removal
    196
  - Crankcase Disassembly
    197
  - Cylinder Head Removal
    198
  - Connecting Rods and Pistons
    198
  - Crankshaft Removal
    199
- Powerhead
  
  195
- Cylinder Block Cleaning
  
  202
- Powerhead Inspection
  
  203
- Powerhead Assembly
  
  205
  - Crankshaft Assembly
    205
  - Pistons and Connecting Rods
    207
  - Cylinder Head Installation
    209
  - Crankshaft and Connecting Rod Installation
    210
  - Crankcase Assembly
    213
  - Shift Linkage Installation
    214
  - Throttle Linkage Installation
    215
  - Final Powerhead Assembly
    216
- Upper Mount Servicing (3-Cylinder)
  
  217
- Powerhead Installation
  
  218
  - Powerhead Mounting - 2-Cylinder Models
    218
  - Powerhead Mounting - 3-Cylinder Models
    220
  - Shift Linkage Adjustment
    222
  - Final Adjustments
    222
- Powerhead Views
  
  223
  - 2-Cylinder Models
    223
  - 3-Cylinder Models
    230
Midsection

235
- Service Charts
  
  236
- Tilt Tube, 75 - 90 Hp
  
  243
- Exhaust Housing, 40 - 65 Hp
  
  245
  - Exhaust Housing Removal
    245
  - Exhaust Water Valve (60-65 Hp)
    246
  - Exhaust Relief Muffler
    246
  - Exhaust Housing Installation
    247
- Exhaust Housing, 75 - 90 Hp
  
  248
  - Exhaust Housing Removal
    248
  - Lower Mount Service
    248
  - Exhaust Housing Installation
    249
  - Exhaust Housing Disassembly
    250
  - Cleaning and Inspection
    251
  - Exhaust Housing Assembly
    251
- Stern Bracket, 40 - 60 Hp Power Tilt
  
  253
  - Stern Bracket Disassembly
    253
  - Stern Bracket Assembly
    254
- Stern Bracket, 75 - 90 Hp Power Tilt
  
  255
  - Stern Bracket Disassembly
    255
  - Stern Bracket Assembly
    258
- Stern Bracket, 40 - 60 Hp Manual Tilt
  
  260
  - Clamp Screw Service
    260
  - Stern Bracket Disassembly
    260
  - Stern Bracket Assembly
    263
  - Tilt Assist Cylinder
    266
- Stern Bracket, 90 Hp Manual Tilt
  
  267
  - Stern Bracket Disassembly
    267
  - Stern Bracket Assembly
    270
- Tiller Handle Service - Standard
  
  273
  - Removal
    273
  - Disassembly
    274
  - Inspection
    275
  - Assembly
    275
  - Installation
    277
  - Throttle Cable Adjustment
    278
- Tiller Handle Service - Long Handle
  
  279
  - Removal
    279
  - Disassembly
    280
  - Inspection
    283
  - Assembly
    283
  - Installation
    287
  - Control Cable Installation
    288
Midsection Notes Notes

291
- Service Charts
  
  292
- Propeller Service
  
  295
- Gearcase Types, 75 - 90 Hp
  
  295
- Gearcase Leak Test
  
  297
- Gearcase Service, 40 - 65 Hp Models
  
  298
- Gearcase Removal and Installation
  
  298
  - Gearcase Service, 40 - 65 Hp Models
    299
  - Gearcase Service, 75 - 90 Hp Models
    299
- Water Pump Service
  
  300
- Shift Rod Adjustment
  
  302
- Gearcase Disassembly
  
  303
- Shifter, Bearing and Seal Service
  
  307
- Driveshaft Shimming
  
  314
- Gearcase Assembly
  
  315
- Gearcase Service, 75 - 90 Hp Models
  
  320
- Gearcase Removal and Installation
  
  320
- Water Pump Service
  
  322
- Shift Rod Adjustment
  
  325
- Gearcase Disassembly
  
  326
  - Pre-Disassembly Inspection
    326
  - Propeller Shaft Bearing Housing Removal
    327
  - Pinion Gear and Driveshaft Removal
    327
  - Driveshaft Service
    329
  - Shift Housing, Gear and Propeller Shaft Removal
    330
  - Water Intake Screens
    330
- Gearcase Housing Inspection
  
  330
- Shifter, Bearing and Seal Service
  
  331
- Driveshaft Shimming
  
  339
- Gearcase Assembly
  
  340
Table of Contents

345
- Service Chart
  
  346
- System Description
  
  348
  - Manual Adjustment
    348
  - Trailering Bracket and Tilt Support
    348
- Routine Inspections
  
  350
  - General
    350
  - Reservoir Fluid
    350
  - Manual Release Valve
    350
  - Stern Brackets
    350
- Troubleshooting
  
  350
- Electrical Circuit Tests
  
  351
  - Relay Testing
    351
  - Trim and Tilt Motor Current Draw Tests
    351
  - Trim and Tilt Motor no Load Test
    352
  - Trim Gauge Test
    353
  - Trim Sender Test
    353
- Trim and Tilt Replacement
  
  354
  - Removal
    354
  - Installation
    356
- Trim and Tilt Service
  
  358
  - Disassembly
    358
  - Assembly
    360
Manual Starter

363
- Service Chart
  364
- Recoil Starter Disassembly
  365
- Recoil Starter Removal
  365
- Recoil Starter Assembly
  367
- Recoil Starter Cleaning and Inspection
  367
- Recoil Starter Installation
  371
Manual Starter Notes Notes

373
- Marine Products and the Safety of People Who Use Them
  375
- Safety
  
  379
  - Outboard Fuel, Electrical System, and Safety
    380
  - Outboard Mounting System and Safety
    383
  - Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety
    385
  - Outboard Emergency Stop System and Safety
    386
  - Summing up
    388
  - Marine Products and the Safety of People Who Fix Them
    389
    
    Handling Outboards
    389
    
    Handling Lead/Acid Batteries
    393
    
    Gasoline - Handle with Care
    394
    
    Hazardous Products
    395
    
    Safety Awareness Test
    396
- Index
  
  397
- Trouble Check Chart
  
  405

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Evinrude E-Tec 40 HP Manuals

Evinrude E-Tec 40 HP Service Manual (426 pages)

Table of Contents

S M Ervice Anual

Table of Contents

Inspection and Maintenance Schedule

Lifting the Outboard

Outboard Rigging Connections

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Table of Contents

Engine Management Module (Emm) Notes Notes

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Exhaust Water Valve (60-65Hp)

Table of Contents

Electrical and Ignition Notes Notes

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagrams

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Fuel System Notes Notes

Table of Contents

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat Servicing

Temperature Sender Servicing

Pressure Relief Valve Servicing

Powerhead

Service Chart

Powerhead Removal

Compression Testing

Powerhead Disassembly

Powerhead

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Upper Mount Servicing (3-Cylinder)

Powerhead Installation

Powerhead Views

Midsection

Service Charts

Tilt Tube, 75 - 90 Hp

Exhaust Housing, 40 - 65 Hp

Exhaust Housing, 75 - 90 Hp

Stern Bracket, 40 - 60 Hp Power Tilt

Stern Bracket, 75 - 90 Hp Power Tilt

Stern Bracket, 40 - 60 Hp Manual Tilt

Stern Bracket, 90 Hp Manual Tilt

Tiller Handle Service - Standard

Tiller Handle Service - Long Handle

Midsection Notes Notes

Service Charts

Propeller Service

Gearcase Types, 75 - 90 Hp

Gearcase Leak Test

Gearcase Service, 40 - 65 Hp Models

Gearcase Removal and Installation

Water Pump Service

Shift Rod Adjustment