Evinrude E-tec E90DPLSUM Manuals

Manuals and User Guides for Evinrude E-tec E90DPLSUM. We have 1 Evinrude E-tec E90DPLSUM manual available for free PDF download: Service Manual

Evinrude E-tec E90DPLSUM Service Manual (344 pages)

75, 90 HP

Brand: Evinrude | Category: Outboard Motor | Size: 29.07 MB

Safety Information

2
- Table of Contents
  2
  - Safety Information
    2
  - Table of Contents
    5
- Models Covered in this Manual
  6
- Identifying Model and Serial Numbers
  6
- Model Designation
  7
- Typical Page - a
  8
- Introduction
  8
- Typical Page - B
  9
- Typical Page - C
  10
- Oil Pressure Switch
  11
- Typical Page - D
  11
- Abbreviations Used in this Manual
  12
- Units of Measurement
  12
- List of Abbreviations
  12
- Engine Emissions Information
  13
- Manufacturer's Responsibility
  13
- Dealer's Responsibility
  13
- Owner's Responsibility
  13
- Epa Emission Regulations
  13
- Product Reference and Illustrations
  14
- Symbols
  14
- Electrical
  14
- Values
  15
- Notes
  16
Service Specifications and Special Tools 1

17
- Service Specifications and Special Tools
  18
- Technical Data
  18
  - Service Specifications and Special Tools
    19
- Standard Torque Specifications
  20
  - Service Specifications and Special Tools
    20
- Special Tools
  21
  - Electrical / Ignition
    21
  - Fuel System
    22
  - Gearcase
    22
  - Powerhead
    24
  - Universal
    25
- Shop Aids
  27
Table of Contents

31
- Boat Rigging
  
  32
  - Remote Controls
    32
  - Battery Installation
    34
    
    Installation and Predelivery
    34
  - Battery Switches and Multiple Batteries
    35
  - Battery and Switch Wiring Diagrams
    37
  - Fuel System Requirements
    39
  - Fuel Filters
    40
  - Cable and Hose Installation
    41
  - Oetiker Clamp Servicing
    43
- Outboard Installation
  
  46
  - Hull Preparation
    46
  - Transom Measuring and Drilling
    47
  - Lifting the Outboard
    51
  - Steering Systems
    51
  - Outboard Mounting
    53
- Outboard Rigging
  
  54
- Fuel and Oil Priming
  
  57
  - Fuel Requirements
    57
  - Fuel System Priming
    58
  - Oil Requirements
    59
  - Oil Injection Rate
    59
  - Systemcheck Low Oil Warning Test
    59
  - Oil Supply Priming
    60
  - Break-In Oiling
    60
- Before Start-Up
  
  61
  - Gearcase Lubricant
    61
  - Oil Level
    61
  - Trim and Tilt Fluid
    61
- Running Checks
  
  62
  - Systemcheck Operation
    62
  - Emergency Stop / Key Switch
    62
  - Start-In-Gear Prevention
    62
  - Break-In
    63
  - Operating Temperature
    63
- Propellers
  
  64
  - Propeller Selection
    64
  - Propeller Hardware Installation
    65
- Final Adjustments
  
  66
  - Tilt Limit Switch Adjustment
    66
  - Trim Sending Unit Adjustment
    67
  - Trim Tab Adjustment
    68
  - Dual-Outboard Alignment
    69
- Notes
  
  70
Maintenance Maintenance

71
- Inspection and Maintenance Schedule
  
  72
- Anti-Corrosion Protection
  
  73
  - Sacrificial Anodes
    73
  - Testing Procedure - Continuity
    73
  - Metallic Component Protection
    73
  - Exterior Finishes
    73
  - Cooling System
    74
  - Flushing
    74
- Maintenance
  
  74
  - Water Intake Screens
    75
  - Additional Maintenance
    75
- Lubrication
  
  75
  - Steering System
    75
  - Swivel Bracket and Trailering Bracket
    76
  - Tilt Tube
    76
  - Throttle and Shift Linkage
    76
  - Propeller Shaft
    77
  - Gearcase Lubricant
    77
  - Trim and Tilt
    78
- Battery and Battery Connections
  
  78
- Fuel and Oil Systems
  
  79
  - Fuel Filter
    79
  - Oil Reservoir
    79
  - Air Silencer
    79
  - Hoses and Connections
    79
- Spark Plugs
  
  80
  - Indexing
    80
- Storage
  
  81
  - Fuel System Treatment
    81
  - Internal Engine Treatment
    81
  - Additional Recommendations
    82
- Pre-Season Service
  
  82
  - Outboard Mounting Bolts
    82
  - Gearcase Lubricant
    82
  - Battery(S)
    82
  - Power Trim and Tilt
    82
  - Operational Checks
    82
- Submerged Engines
  
  83
- Notes
  
  84
Engine Management Module (Emm) Engine Management Module (Emm)

85
- Description
  
  86
  - Emm Functions
    86
  - Emm Connections
    86
- Sensors and Functions
  
  87
  - Internal Sensors
    87
  - External Sensors
    88
- Engine Management Module (Emm)
  
  88
  - Engine Temperature Sensor
    88
  - Air Temperature Sensor
    88
  - Internal Functions
    90
- Emm Inputs and Outputs Diagram
  
  91
- Shutdown Mode
  
  92
- Warning System
  
  92
  - Activation
    92
  - Recovery
    92
- Emm Diagnostics
  
  93
  - Led Indicators
    93
  - Diagnostic Software Programs
    94
  - Communication
    94
  - Program Information
    95
  - Service Codes (Faults)
    95
  - Static Tests
    96
  - Dynamic Tests
    97
  - Oil Control
    98
  - Starter Mode (Tiller/Remote Programming)
    98
  - Timing Verification
    98
  - Tps Calibration
    99
  - Idle Speed
    99
  - Fuel Injector Servicing
    99
  - Fuel Control Adjustment
    100
  - Reports
    100
  - Software Replacement
    101
  - Emm Transfer
    101
- Systemcheck Engine Monitor
  
  101
  - System Self-Test
    102
  - Service Mode
    102
  - Engine Running
    102
System Analysis System Analysis

103
- Electrical Connections
  
  104
- Ground Circuits
  
  106
- System Analysis
  
  106
- Fuse
  
  106
- Emm Diagnostics
  
  107
  - Led Indicators
    107
  - Software Programs
    107
- Diagnostic Procedures
  
  108
  - Symptoms
    109
- Specialized Test Procedures
  
  110
  - Dynamic Tests
    110
  - Testing with Timing Light
    110
  - Inductive Amp Meter Test
    111
  - Engine Monitoring Information
    111
  - Voltage Testing
    112
- Start Circuit
  
  112
  - Electric Starter Operation
    112
  - Starter Solenoid Activation
    113
- Ignition and Electrical Circuits
  
  114
  - Ignition Coil
    114
- Ignition Output
  
  115
  - Wiring Inspection
    115
  - Ignition Voltage
    115
  - System Voltage
    116
  - Static Spark Test
    116
  - Running Ignition Tests
    117
  - Ignition Primary Circuit Resistance Test
    118
  - Crankshaft Position Sensor (Cps) Test
    118
- Fuel Delivery
  
  119
  - Manifold Pressure Test
    119
  - Vapor Separator Checks
    120
  - Fuel Delivery to Lift Pump
    120
- Fuel Injector Operation
  
  120
  - Neutral Switch
    120
  - Static Tests
    120
  - Dynamic Tests
    121
- Notes
  
  122
Electrical and Ignition Electrical and Ignition

123
- Service Chart
  
  124
  - Electrical and Ignition
    124
- Dash Connections, Instrument Harness
  
  126
- Ignition System Tests
  
  127
  - Sensor Resistance Tests
    127
  - Ignition Coil Tests
    128
  - Stator Tests
    129
  - Capacitor Test
    130
- Charging System Tests
  
  130
  - 12 V Charging Circuit
    130
  - 55 V Alternator Circuit
    131
- Systemcheck Circuit Tests
  
  132
  - Gauge Self-Test Check
    132
  - Check Engine Circuit Test
    133
  - Water Temp/ Hot Circuit Test
    133
  - Low Oil Circuit Test
    134
  - No Oil Circuit
    134
- Remote Control Switch Tests
  
  134
- Electric Starter Tests
  
  136
  - Starter Solenoid Test
    136
  - No Load Current Draw Test
    137
- Tilt/Trim Relay Test
  
  138
  - Operation
    138
  - Test Procedure
    138
- Tachometer Circuit Tests
  
  139
- Flywheel Servicing
  
  140
  - Removal
    140
  - Installation
    141
- Timing Adjustments
  
  142
  - Timing Pointer
    142
  - Timing Verification
    143
  - Tps Calibration
    143
- Spark Plugs
  
  144
  - Inspection
    144
  - Indexing
    144
- Electric Starter Servicing
  
  145
  - Removal
    145
  - Disassembly
    145
  - Cleaning and Inspection
    146
  - Assembly
    147
  - Installation
    148
- Connector Servicing
  
  149
- Notes
  
  154
Fuel System Fuel System

155
- Service Chart
  
  156
- Components
  
  158
  - Fuel Lift Pump
    158
  - Fuel Filter
    158
  - Vapor Separator
    158
- Fuel System
  
  158
  - Fuel Circulation Pump
    160
  - Fuel Manifolds
    160
  - Fuel Injectors
    161
- Fuel System Hose Routing
  
  162
- Direct Injection Electrical Circuits
  
  163
  - Injector / Circulation Pump Circuits Diagram
    163
- Fuel Component Tests
  
  164
  - Injectors
    164
  - Fuel Supply
    165
- Fuel Component Servicing
  
  168
  - Relieving Fuel System Pressure
    168
  - Fuel Filter
    169
  - Fuel Lift Pump
    169
  - Vapor Separator
    170
  - Fuel Injectors
    170
  - Fuel Manifolds
    174
- Intake Manifold
  
  174
  - Removal
    174
  - Disassembly
    174
  - Inspection
    175
  - Assembly
    175
  - Installation
    176
Oiling System Oiling System

177
- Service Chart
  
  178
  - Oiling System
    178
- Components
  
  179
  - Oil Tank Assembly
    179
  - Service Codes
    179
  - Electrical Circuit (55 V)
    180
  - Systemcheck Low and no Oil Warning Signals
    180
  - Oiling System Electrical Diagram
    181
  - Cylinder and Crankcase
    182
  - Oil Supply and Distribution Diagram
    182
  - Oil Recirculation System
    183
  - Recirculation Hose Diagram
    183
- Priming
  
  184
- Oiling Rates
  
  184
  - Oil Injection Rate
    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 Flow Tests
    186
  - Oil-To-Fuel Check Valve Test
    188
  - Low Oil Sending Unit Test
    188
  - No Oil Warning Test
    188
- Oil Component Servicing
  
  189
  - Oil Distribution Hoses
    189
  - Oil Tank Assembly
    190
Cooling System Cooling System

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

201
- Service Chart
  
  202
- General
  
  204
  - Cylinder Compression Testing
    204
  - Retaining Ring Pliers
    204
  - Powerhead
    204
- Removal
  
  205
- Disassembly
  
  207
  - General
    207
  - Shift Linkage
    207
  - Throttle Linkage
    207
  - Crankcase
    208
  - Cylinder Head
    209
  - Connecting Rods and Pistons
    209
  - Crankshaft
    210
- Cleaning
  
  212
- Inspection
  
  213
  - Cylinder Head
    213
  - Crankshaft
    214
  - Cylinder Bore
    214
  - Pistons
    214
  - Piston Rings
    214
  - Bearings
    215
- Assembly
  
  216
  - Crankshaft
    216
  - Pistons and Connecting Rods
    218
  - Cylinder Head
    220
  - Crankshaft and Connecting Rods
    221
  - Crankcase
    224
  - Shift Linkage
    226
  - Throttle Linkage
    227
  - General
    227
- Upper Mount Servicing
  
  228
  - Removal
    228
  - Installation
    228
- Installation
  
  229
- Powerhead Views
  
  233
  - Port Short Block
    233
  - Starboard Short Block
    233
  - Port Dressed Powerhead
    234
  - Starboard Dressed Powerhead
    234
  - Front
    235
  - Rear
    236
  - Top
    237
- Notes
  
  238
Midsection Midsection

239
- Service Chart
  
  240
- Tilt Tube
  
  242
  - Removal
    242
  - Midsection
    242
  - Installation
    243
- Exhaust Housing
  
  244
  - Removal
    244
  - Disassembly
    244
  - Cleaning and Inspection
    246
  - Assembly
    246
  - Installation
    249
- Stern Bracket
  
  249
  - Removal
    249
  - Disassembly
    249
  - Assembly
    252
Gearcase Gearcase

255
- Service Chart
  
  256
- Gearcase Types
  
  258
- Lubricant
  
  258
  - Draining
    258
  - Inspection
    259
  - Filling
    259
- Propeller
  
  258
  - Inspection
    258
- Leak Test
  
  259
- Removal and Installation
  
  260
  - Removal
    260
  - Installation
    261
- Water Pump
  
  262
  - Disassembly
    262
  - Inspection
    262
  - Assembly
    263
- Shift Rod Adjustment
  
  265
- Disassembly
  
  266
  - Pre-Disassembly Inspection
    266
  - Propeller Shaft Bearing Housing Removal
    267
  - Pinion Gear and Driveshaft Removal
    267
  - Driveshaft Service
    269
  - Shift Housing, Gear and Propeller Shaft Removal
    270
  - Water Intake Screens
    270
- Gearcase Housing Inspection
  
  270
- Bearing and Seal Removal
  
  271
  - Shift Housing
    271
  - Pinion Gear Bearing
    272
  - Driveshaft Bearing Housing
    273
  - Propeller Shaft Bearing Housing
    273
- Bearing and Seal Installation
  
  274
  - Shift Housing
    274
  - Pinion Gear Bearing
    276
  - Driveshaft Bearing Housing
    277
  - Propeller Shaft Bearing Housing
    278
  - Bearing Installation
    278
- Driveshaft Shimming
  
  279
- Assembly
  
  280
Table of Contents

285
- System Description
  
  286
  - Manual Adjustment
    286
  - Trailering Bracket and Tilt Support
    286
- Routine Inspections
  
  287
  - General
    287
  - Reservoir Fluid
    287
  - Manual Release Valve
    287
  - Stern Brackets
    287
- Troubleshooting
  
  288
- Electrical Circuit Tests
  
  288
  - Relay Testing
    288
  - Trim and Tilt Motor Current Draw Tests
    288
  - Trim and Tilt Motor no Load Test
    289
  - Trim Gauge Test
    290
  - Trim Sender Test
    291
- Removal and Installation
  
  291
  - Removal
    291
  - Installation
    293
- Servicing
  
  294
  - Disassembly
    294
  - Assembly
    295
- Adjustments
  
  296
Safety Safety

297
- Marine Products and the Safety of People Who Use Them
  299
- Marine Products and the Safety of People Who Fix Them
  313
  - Handling Outboards
    313
  - Handling Lead/Acid Batteries
    317
  - Gasoline - Handle with Care
    318
  - Hazardous Products
    319
  - Safety Awareness Test
    320
  - Trouble Check Chart
    329

Evinrude Categories

Outboard Motor Engine Offroad Vehicle

Monitor Water Pump

More Evinrude Manuals

Evinrude E-tec E90DPLSUM Manuals

Evinrude E-tec E90DPLSUM Service Manual (344 pages)

Table of Contents

Safety Information

Service Specifications and 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

Maintenance

Lubrication

Battery and Battery Connections

Fuel and Oil Systems

Spark Plugs

Storage

Pre-Season Service

Submerged Engines

Notes

Engine Management Module (Emm) Engine Management Module (Emm)

Description

Sensors and Functions

Engine Management Module (Emm)

Emm Inputs and Outputs Diagram

Shutdown Mode

Warning System

Emm Diagnostics

Systemcheck Engine Monitor

System Analysis System Analysis

Electrical Connections

Ground Circuits

System Analysis

Fuse

Emm Diagnostics

Diagnostic Procedures

Specialized Test Procedures

Start Circuit

Ignition and Electrical Circuits

Ignition Output

Fuel Delivery

Fuel Injector Operation

Notes

Electrical and Ignition Electrical and Ignition

Service Chart

Dash Connections, Instrument Harness

Ignition System Tests

Charging System Tests

Systemcheck Circuit Tests

Remote Control Switch Tests

Electric Starter Tests

Tilt/Trim Relay Test

Tachometer Circuit Tests

Flywheel Servicing

Timing Adjustments

Spark Plugs

Electric Starter Servicing

Connector Servicing

Notes

Fuel System Fuel System

Service Chart

Components

Fuel System

Fuel System Hose Routing

Direct Injection Electrical Circuits

Fuel Component Tests

Fuel Component Servicing

Intake Manifold

Oiling System Oiling System

Service Chart

Components

Priming

Oiling Rates