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BRP E200HSLSEA Service Manual

Evinture e-tec. 200 hp,225 hp,250 hp,300 hp, 90 grd. v6
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Summary of Contents for BRP E200HSLSEA

  • Page 1 Main Menu...
  • Page 3 † Permatex is a registered trademark of Permatex. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: ® Nut Lock™...
  • Page 4 ABLE ONTENTS INTRODUCTION ........3 1 SPECIAL TOOLS ......15 2 INSTALLATION AND PREDELIVERY .
  • Page 5 INTRODUCTION INTRODUCTION CONTENTS ABBREVIATIONS USED IN THIS MANUAL ..........6 .

  • Page 6: Safety

    SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained Always follow common shop safety practices. If technicians who are already familiar with the use you have not had training related to common shop safety practices, you should do so to protect your- of Evinrude...
  • Page 7 DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 8: Introduction

    INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft. lbs. foot pounds barometric pressure sensor horsepower...

  • Page 9: Engine Emissions Information

    INTRODUCTION ENGINE EMISSIONS INFORMATION The owner/operator is not to, and should not allow ENGINE EMISSIONS anyone to, modify the outboard in any manner INFORMATION that would alter the horsepower or allow emis- sions levels to exceed their predetermined factory specifications. Maintenance, replacement, or repair of the emission control devices and systems may be Tampering with the fuel system to change horse-...

  • Page 10: Model Designation

    INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: LENGTH: J = Johnson = 15” Std. E = Evinrude L = 20” Long Y = 22.5” Special MODEL RUN X = 25” X-long HORSEPOWER PREFIX or SUFFIX Z = 30” XX-long E 200 DP X SE MODEL YR: DESIGN FEATURES: I = 1...

  • Page 11: Models Covered In This Manual

    This manual covers service information on all 200.1 and 210 cubic inch, 90° V Evinrude E-TEC ® models. Model Shaft Color Gearcase E200DHLSEB 3.3 L 20” .54 L2 E200HSLSEA 3.3 L 20” .54 L2 E200HVLSEC 3.3 L 20” .54 M2 E200DHXSEA 3.3 L 25”...
  • Page 12 INTRODUCTION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS Full Throttle 4500–5800 RPM Operating Range 200 HP 225 HP 250 HP (187 kw) Power (149 kw) (168 kw) @ 5150 RPM @ 5150 RPM @ 5150 RPM Idle RPM in Gear 500 ± 50 Standard Rotation Models: P/N 436080 or P/N 396277 Test Propeller Counter Rotation Models: P/N 436081 or P/N 398674...
  • Page 13 INTRODUCTION SERVICE SPECIFICATIONS 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation Tachometer Setting 6 pulse (12 pole) Charging Isolator Integral, Terminal on Engine Harness Engine Fuse...
  • Page 14 INTRODUCTION SERVICE SPECIFICATIONS 250 H Full Throttle 4500–6000 RPM 5000–6000 RPM Operating Range 250 HP 300 HP Power (187 kw) (234 kw) @ 5250 RPM @ 5500 RPM Idle RPM in Gear 500 ± 50 Standard Rotation Models: P/N 436080 or P/N 396277 Test Propeller Counter Rotation Models: P/N 436081 or P/N 398674 20 in.
  • Page 15 INTRODUCTION SERVICE SPECIFICATIONS 250 H 675 CCA (845 MCA); or Minimum Battery 750 CCA (940 MCA) below 32°F (0°C) Requirements (Use a 107 amp-hr battery for extreme applications.) Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation Tachometer Setting 6 pulse (12 pole) Charging Isolator Integral, Terminal on Engine Harness...

  • Page 16: Standard Torque Specifications

    INTRODUCTION STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE PRODUCT REFERENCE SPECIFICATIONS AND ILLUSTRATIONS BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and Size In. Lbs. Ft. Lbs. N·m models and also to discontinue models. The right No.
  • Page 17 SPECIAL TOOLS SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS ..............16 UNIVERSAL TOOLS .
  • Page 18 SPECIAL TOOLS DIAGNOSTIC TOOLS DIAGNOSTIC TOOLS 765011 002276 45583 Diagnostic Software P/N 765011 Bootstrap tool P/N 586551 Interface cable P/N 437955 UNIVERSAL TOOLS 32885 23701 000669 Universal Puller Set P/N 378103 Lifting eye P/N 321537 Lifting ring assembly P/N 396748 CO1577 15345 42938...
  • Page 19 SPECIAL TOOLS UNIVERSAL TOOLS 15356 23146 50243 Slide hammer adapter P/N 390898 Puller Bridge – 432127 Syringe P/N 346936 46879 33249 001081 † Tilt tube nut wrench P/N 342680 Tilt tube service kit P/N 434523 Oetiker pincers, P/N 787145 45240 50110 Temperature gun P/N 772018 Fresh water flusher P/N 500542...

  • Page 20: Special Tools

    SPECIAL TOOLS ELECTRICAL / IGNITION TOOLS ELECTRICAL / IGNITION TOOLS DRC7265 49799 45241 Digital multimeter Peak reading voltmeter Test probe kit P/N 342677 Ohms resolution 0.01 P/N 507972 Purchase through local supplier 30387 004222 49789 Crimping pliers P/N 322696 Stator Test Adapter P/N 5006211 Tachometer/timing light P/N 507980 42004 †...
  • Page 21 SPECIAL TOOLS FUEL /OIL SYSTEM TOOLS FUEL /OIL SYSTEM TOOLS 005339 004560 002465 Fuel pressure gauge (60 PSI) Fuel pressure gauge (15 PSI) Injector test fitting kit P/N 5007100 P/N 5006397 P/N 5005844 90° fitting, P/N 353322 90° fitting, P/N 353322 POWERHEAD TOOLS 45303 21596...
  • Page 22 SPECIAL TOOLS GEARCASE TOOLS 23668 23651 Wrist pin pressing tool DR1641 Seal installation tool P/N 325453 1. Wrist pin retaining ring driver P/N 396747 P/N 396747 2. Wrist pin cone P/N 331913 GEARCASE TOOLS 002601 002805 32872 Universal Driveshaft Shimming Tool Universal Pinion Bearing Remover Universal shift rod height gauge P/N 5005925...
  • Page 23 SPECIAL TOOLS GEARCASE TOOLS 006783 006784 006788 Prop shaft bearing housing Prop shaft bearing housing Prop shaft bearing housing installers P/N 354058 (L2) remover/puller P/N 354060 alignment pins P/N 354140 P/N 354057 (M2) 004315 006822 006823 Gearcase Alignment Gauge Kit Gauging Head, “M2”...
  • Page 24 SPECIAL TOOLS GEARCASE TOOLS 15356 23692 40371 Slide hammer adapter P/N 432398 Driveshaft seal protector 1. Pinion nut holder P/N 334455 P/N 318674 2. Wrench retainer P/N 341438 47257 32880 32924 Lower Driveshaft Puller P/N 342681 Prop shaft bearing installer Seal installation tool P/N 330268 P/N 339750 40372...
  • Page 25 SPECIAL TOOLS TRIM AND TILT TOOLS TRIM AND TILT TOOLS 33023 33013 23694 Gauge and collar assembly Trim/tilt service kit P/N 390010 Tilt cylinder seal protector P/N 983975 P/N 326005 23665 005340 32213 Hydraulic cylinder rod holder Tilt cylinder end cap remover Spanner wrench P/N 912084 P/N 983213 P/N 352932, for single-piston...
  • Page 26 SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 D.P.L. Spray P/N 777183 Oil - XD30™ P/N 764349 “6 in 1” Multi-Purpose Lubricant P/N 777192 Oil - XD50™ P/N 764354 HPF XR™ Gear Lube P/N 778749 Oil - XD100™ P/N 764357 Anti-Corrosion Spray P/N 777193 HPF PRO Gearcase Lube P/N 778755 Engine Tuner P/N 777185...
  • Page 27 SPECIAL TOOLS SHOP AIDS Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Electrical Grease P/N 503243 P/N 777186 P/N 775612 Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 2 + 4™ Fuel conditioner P/N 775613 Triple-Guard® Grease P/N 508298 Starter Bendix Lube P/N 337016 Gel-Seal and Gasket Remover P/N 771050 Needle Bearing Grease, P/N 378642...
  • Page 28 SPECIAL TOOLS SHOP AIDS RTV Silicone Sealant P/N 263753 Gasket Sealing Compound P/N 508235 Thermal Joint Compound P/N 322170 Fuel System Cleaner P/N 763681 Pipe Sealant with Teflon P/N 910048 Instant Bonding Adhesive P/N 509955 Gel·Seal II P/N 327361 Locquic Primer P/N 772032 1.
  • Page 29 INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............28 .

  • Page 30: Remote Controls

    INSTALLATION AND PREDELIVERY BOAT RIGGING Dual-outboard controls require separate key BOAT RIGGING • switches with a single emergency stop switch. Remote Controls Control Selection WARNING The remote control used must have start- in-gear prevention. This feature can pre- vent injuries resulting from unexpected boat movement when the outboard starts.
  • Page 31 INSTALLATION AND PREDELIVERY BOAT RIGGING Control Installation Battery Installation Plan the installation of remote controls carefully, Each outboard requires its own starting battery. following all instructions provided with the remote Select a battery that meets or exceeds the mini- control. mum requirements.

  • Page 32: Installation And Predelivery

    INSTALLATION AND PREDELIVERY BOAT RIGGING Connections Battery Cable Requirements Evinrude outboards are shipped with stranded Connect the battery positive (+) IMPORTANT: copper battery cables for typical installations in cable to the battery positive (+) post FIRST. Con- which the starting battery is positioned close to nect the battery negative (–) cable to the battery the transom.
  • Page 33 INSTALLATION AND PREDELIVERY BOAT RIGGING Typical battery functions Battery Switch Requirements Battery switches must meet the following require- Never connect an external bat- IMPORTANT: ments. tery isolator to the stator of an Evinrude E-TEC. The switch must be approved for marine use. •...
  • Page 34 INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Switch Operation Auxiliary Battery Charging Select the primary battery for normal operation. • Evinrude E-TEC V4–V6 outboards are equipped Secondary batteries should only be selected for • with isolated battery charging capability. The iso- emergency starting.

  • Page 35: Battery And Switch Wiring Diagrams

    INSTALLATION AND PREDELIVERY BOAT RIGGING Battery and Switch Wiring Diagrams One outboard: Battery disconnect One outboard: One primary starting battery; one secondary battery BOTH PRIMARY PRIMARY SECONDARY 000135rev1 Two outboards: Two starting batteries for each outboard BOTH BOTH PRIMARY SECONDARY SECONDARY PRIMARY Positive (+) Battery cables...
  • Page 36 INSTALLATION AND PREDELIVERY BOAT RIGGING Two outboards: One primary starting battery for each outboard; one isolated accessory battery BOTH BOTH PRIMARY PRIMARY ACCESSORY Two outboards: One primary starting battery for each outboard; two isolated accessory batteries BOTH BOTH PRIMARY PRIMARY ACCESSORY ACCESSORY Positive (+) Battery cables...

  • Page 37: Fuel System Requirements

    INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements Fuel System Primer Outboards require a priming system capable of Overview refilling the fuel system after periods of non-use. Boat fuel systems must meet minimum specifica- Primer bulbs that meet the outboard's minimum tions to insure the proper delivery of fuel to the inside diameter fuel line requirements are used on outboard.
  • Page 38 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.
  • Page 39 INSTALLATION AND PREDELIVERY BOAT RIGGING Replacement hose must be designated for fuel Oiling System Set-Up • or oil use and approved for marine use. Location Extend wiring harness with 16 gauge AWG • wire. Consider the installation location IMPORTANT: Protect connections with heat shrink tube. •...
  • Page 40 INSTALLATION AND PREDELIVERY BOAT RIGGING Place floor bracket on center line between end 1.8 G ALLON lines. Use the inner bracket holes as guides to drill Place rods into floor bracket and secure floor two 5/32 in. (4 mm) pilot holes. bracket with lag bolts.
  • Page 41 INSTALLATION AND PREDELIVERY BOAT RIGGING Oil Tank Profiles 1.8 Gallon Tank 3 Gallon Tank P/N 176995 P/N 176996 Remote Oil Fill Kit (Optional) The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly.

  • Page 42: Cable And Hose Installation

    INSTALLATION AND PREDELIVERY BOAT RIGGING Cable and Hose Installation Cable and Wire Harness Routing Before installation, identify all required wiring, WARNING cables, and hoses: Throttle and shift cables Improper installation and routing of out- • Instrument harnesses • board controls could wear, bind, and dam- Battery cables and switches age components, causing loss of control.
  • Page 43 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Hose The fuel hose may be routed outside of the pro- tective sleeve or conduit. Electric primers or man- ual primers may not require this consideration. Route fuel hoses with enough slack to allow the primer bulb arrow to point “up”...
  • Page 44 INSTALLATION AND PREDELIVERY BOAT RIGGING Oetiker † Clamp Servicing Use Oetiker clamps for making hose connec- † tions. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging com- ponents, and provide solid, permanent connec- tions. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
  • Page 45 INSTALLATION AND PREDELIVERY BOAT RIGGING Clamp Installation Clamp Removal A constant stress should be applied to close the Method 1: Position Oetiker pincers across clamp ear clamps. This method ensures a positive stress ear and cut clamp. on the hose and does not result in excessive com- pression or expansion of the band material.

  • Page 46: Outboard Installation

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Control Cable Identification OUTBOARD Control cable function must be IMPORTANT: INSTALLATION identified before rigging outboard. Hull Preparation Identify each control cable: Put the control handle into NEUTRAL position. • Maximum Capacity The throttle cable casing guide will retract com- pletely and the shift cable casing guide will go to WARNING the midpoint of its travel.
  • Page 47 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Brackets and Jack Plates WARNING When mounting an outboard on boats equipped with transom brackets or jack plates, refer to the DO NOT install an outboard on a curved or manufacturer's recommendations. irregular surface. Doing so can wear, bind, Confirm maximum weight and horsepower •...

  • Page 48: Transom Measuring And Drilling

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Some steering systems Transom Measuring and Drilling IMPORTANT: require additional spacing. Refer to steering sys- Hull Centerline tem manufacturer for recommendations. Use the chines of the boat as reference points to The top edge of the transom should be more than locate the centerline of the boat transom.
  • Page 49 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Position drill fixture on top of transom or bracket Transom Height and align indicator points with centerline. Make sure the transom height matches the length of the outboard to be installed. A 19 to 21 in. (48.3 to 53.3 cm) transom height •...
  • Page 50 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagrams This is not a template. IMPORTANT: 6 7/16" 6 7/16" (136.5mm) (136.5mm) 2" (50.8mm) (50.8mm) 90˚ 10 11 12 8" 8" (203.2mm) (203.2mm) 90˚ 4 15/16" 4 15/16" (125.4mm) (125.4mm) 000133m Quantity 1.

  • Page 51: Lifting The Outboard

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Lifting the Outboard Steering Systems Lifting Fixtures Mechanical Cables All Evinrude outboards equipped with tilt tubes are WARNING compatible with mechanical steering systems that meet ABYC Standard P-17. Single-cable mechan- To avoid personal injury, make sure the ical steering systems can be used on single or lifting capacity of the hoist is at least twice dual-outboard installations if an ABYC-approved...
  • Page 52 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Manual Hydraulic Steering Drag Links Manual hydraulic steering systems use hydraulic Use the correct drag link to allow full steering fluid to transfer motion and load from the helm to travel: the outboard. Model Drag Link Use only a hydraulic steering system designed for 90°...
  • Page 53 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Assemble transom mounting plates on mounting Outboard Mounting bolts. Some rigging components, such IMPORTANT: Install the mounting bolts through the transom as steering cables, must be fitted to the outboard from the inside of the boat. before the outboard is mounted to the transom.
  • Page 54 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Refer to the following diagram to ensure proper OUTBOARD RIGGING positioning of rigging components in grommet. CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.
  • Page 55 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING board side of the powerhead. Secure all cables Use long nose pliers to insert straight section of • with clamps. clip into linkage pin hole. DP0818 003974 1. Straight section DP0817 2. Angled section After installation, make sure...
  • Page 56 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Install trunnion cover and screw. Tighten retaining Place throttle cable on throttle lever pin and install screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). washer and retainer clip. 005038 003968 1.
  • Page 57 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Install battery cables on starter solenoid and main Electrical Harness Connections ground stud. Remove harness connector cover. 003975 1. Positive (+) battery connection 003972 2. Ground (–) connection Before installing electrical connectors, check that BE SURE all harnesses and IMPORTANT: the seal is in place.
  • Page 58 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING If installing a Deutsch-style I-Command network, CANbus Connections connect the purple wire from the CANbus Ignition If the outboard will be used with I-Command, or Harness to the CANbus network harness. This other NMEA 2000 compliant CANbus instruments, connection supplies power to the network when the following connections will supply information the key switch is on.
  • Page 59 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING If a CANbus water pressure gauge is used, install Use Evinrude Diagnostics software to activate Water Pressure Transducer Kit, P/N 5006214, in CANbus control functions in the EMM. From the the cylinder block. Settings screen, select Engine Options. 005036 1.

  • Page 60: Fuel Requirements

    INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING When using alcohol-extended fuels, be aware of FUEL AND OIL PRIMING the following: The boat’s fuel system may have different • Fuel Requirements requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. WARNING Alcohol attracts and holds moisture that can •...

  • Page 61: Oil Requirements

    INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe all fuel lines, both in the boat and on the Fuel System Priming outboard. Repair any fuel leaks. Vent Line Clamp In compliance with Federal Regulations, all out- WARNING boards with a fuel vapor separator must be Failure to check for fuel leaks could allow a shipped with a vent line clamp installed.
  • Page 62 INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Powerhead oil programming labels are provided Oil Injection Rate to identify EMM oil programming. Install the cor- The Engine Management Module (EMM) controls rect label to alert user to specific oil requirements. the oil injection rate based on engine RPM. This rate can be adjusted for the type of oil being used, and also for powerhead break-in.

  • Page 63: Oil Supply Priming

    INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Break-In Oiling Oil Distribution Manifold Priming Squeeze the oil primer bulb to flow oil from the DO NOT add oil in the fuel tank IMPORTANT: hose connection, through the filter, to the oil on Evinrude E-TEC models.
  • Page 64 INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe oil flow through the oil distribution hoses. Small bubbles are acceptable. Large bubbles must be eliminated through continued priming. 004398 1. Oil distribution hose 2. Small bubbles 3. Large bubbles All clear “blue” oil distribution IMPORTANT: 004224 1.

  • Page 65: Oil Level

    INSTALLATION AND PREDELIVERY BEFORE START-UP BEFORE START-UP Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run- Gearcase Lubricant ning outboard: Tilt the motor up and engage the tilt support. With outboard in vertical position, check the gear- •...

  • Page 66: Running Checks

    INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS Fuel System Perform running checks of the fuel system by fol- lowing these steps: WARNING Squeeze fuel primer bulb until hard or activate • DO NOT run outboard without a water sup- electric primer. Observe all fuel hoses and con- nections.

  • Page 67: Operating Temperature

    INSTALLATION AND PREDELIVERY RUNNING CHECKS Tachometer Pulse Setting Operating Temperature Confirm accuracy of tachometer reading. An outboard run at idle speed should achieve a temperature based on the engine’s thermostatic Adjust dial on back of tachometer to required • setting (the outboard should not be running). control.

  • Page 68: Propeller Selection

    INSTALLATION AND PREDELIVERY PROPELLERS When selecting a propeller, consider the follow- PROPELLERS ing: Use an accurate tachometer to determine the • Propeller Selection engine’s full-throttle RPM. The outboard should be trimmed for top speed. • CAUTION Select a propeller that suits the customer’s •...

  • Page 69: Propeller Hardware Installation

    INSTALLATION AND PREDELIVERY PROPELLERS Propeller Hardware Installation WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.

  • Page 70: Final Adjustments

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Place the outboard in normal operating position. FINAL ADJUSTMENTS Rotate the LOWER adjustment tab UP to reduce Tilt Limit Switch Adjustment the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side,...

  • Page 71: Trim Sending Unit Adjustment

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Observe the trim gauge. If the needle does not Trim Sending Unit Adjustment show center position, tilt the outboard up and Tilt the outboard and engage the tilt support. adjust the sending unit by pivoting it up or down. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

  • Page 72: Trim Tab Adjustment

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Trim Tab Adjustment WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to com- pensate for this steering torque.
  • Page 73 INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.
  • Page 74 INSTALLATION AND PREDELIVERY NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 75 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 74 ANTI-CORROSION PROTECTION .

  • Page 76: Inspection And Maintenance Schedule

    MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides guidelines for inspection and maintenance to be performed by an authorized Dealer. Outboards used in rental, commercial, or other high hour applications require more fre- IMPORTANT: quent inspections and maintenance.

  • Page 77: Sacrificial Anodes

    MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.

  • Page 78: Maintenance

    MAINTENANCE COOLING SYSTEM Remove plug and nozzle (overboard indicator) COOLING SYSTEM from the flushing port. Check the condition of cooling system compo- nents regularly: water intake screens • water pump • all internal water passages • thermostats • all external water hoses and fittings •...
  • Page 79 MAINTENANCE COOLING SYSTEM Flushing — Outboard Not Running Water Intake Screens Outboard can be in VERTICAL (DOWN) or Inspect condition of water intake screens. Clean TILTED (UP) position. or replace as needed. Remove plug and nozzle (overboard indicator) Confirm function of overboard water pressure indi- from the flushing port.
  • Page 80 MAINTENANCE LUBRICATION LUBRICATION Swivel Bracket and Trailering Bracket Steering System Lubricate the swivel bracket with Triple-Guard grease. WARNING Apply grease until the grease begins to flow from Failure to regrease as recommended the upper or lower swivel bracket areas. could result in steering system corrosion. Corrosion can affect steering effort, mak- Coat the pivot points of the trailering bracket with ing operator control difficult.

  • Page 81: Throttle And Shift Linkage

    MAINTENANCE LUBRICATION Throttle and Shift Linkage Propeller Shaft Disconnect the battery cables at the battery. Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize Remove cable trunnion cover. Carefully, remove potential gearcase damage. throttle and shift cables from trunnion block. WARNING DO NOT disturb cable trunnion IMPORTANT:...
  • Page 82 MAINTENANCE LUBRICATION removing the lower, drain/fill plug. A tie strap can amount of water from normal water vapor conden- be used to check lubricant level. sation within the gearcase. Refer to GEARCASE LEAK TEST on p. 286. Overheated lubricant will have a black color and burned odor.

  • Page 83: Trim And Tilt

    MAINTENANCE LUBRICATION Trim and Tilt Check reservoir fluid level every three years or every 300 operating hours. System capacity is approximately 21 fl. oz. (620 • ml). Tilt the outboard and engage the tilt support. • 004277 Three Ram Trim System 1.

  • Page 84: Fuel And Oil Systems

    MAINTENANCE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY FUEL AND OIL SYSTEMS CONNECTIONS Routine replacement of filters reduces the possi- bility of foreign material restricting the incoming Check battery connections frequently. Periodically fuel or oil supplies. remove battery to clean and service connections. Replacement filter elements are available through WARNING Evinrude/Johnson Genuine Parts.

  • Page 85: Air Silencer

    MAINTENANCE FUEL AND OIL SYSTEMS Oil Filters and Oil Reservoir Air Silencer Perform visual inspections to identify oiling system The air silencer on Evinrude outboards maximizes leaks. Make certain the oil tank is filled and oil air flow while minimizing noise. supply is not contaminated.

  • Page 86: Spark Plugs

    MAINTENANCE SPARK PLUGS Apply Triple-Guard grease to the gasket surface SPARK PLUGS of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m). Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged If the mark is in unshaded area do not tighten any- spark plugs.
  • Page 87 MAINTENANCE EXHAUST PRESSURE FITTING With key ON, outboard NOT running, the exhaust EXHAUST PRESSURE pressure sensor reading should be close to zero. FITTING With the outboard running, make sure the exhaust pressure reading changes with throttle setting. The exhaust pressure fitting is threaded into the This reading will vary, based on actual outboard adapter housing and protrudes into the inner exhaust pressure conditions.

  • Page 88: Fuel System Treatment

    MAINTENANCE STORAGE STORAGE Software Control Method Winterization can also be run using Evinrude Diagnostics software. With the outboard running, DO NOT start outboard without a IMPORTANT: start the process at the Settings/Adjustments water supply to the outboard’s cooling system. screen and follow the instructions. Cooling system and/or powerhead damage could occur.

  • Page 89: Power Trim And Tilt

    MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE Additional Recommendations Top off oil reservoir. • If the outboard was removed from the boat for inspect the fuel filter. If there is debris in the fuel • storage, make sure it is reinstalled with factory filter, it must be replaced.

  • Page 90: Submerged Engines

    MAINTENANCE SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL SUBMERGED ENGINES AND OIL PRIMING on p. 58. Make sure all oil injection hoses are clean and filled with oil. Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) Make sure high pressure fuel system does not hours of recovery.
  • Page 91 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 90 .
  • Page 92 ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Upper Cover Cap Replacement Place new upper cap into position. Latch Hook Installation Place hook into position on bracket. 006815 Tighten self-tapping screws to a torque of 24 to 36 006962 in.
  • Page 93 ENGINE COVER SERVICE LOWER COVER SERVICE LOWER COVER Lower Cover Installation Install the lower engine covers and tighten all SERVICE screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m). Lower Cover Removal Remove lower engine cover screws. 004122 1.

  • Page 94: Engine Cover Service

    ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006827 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
  • Page 95 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............94 EMM INPUTS AND OUTPUTS DIAGRAM .

  • Page 96: Emm Functions

    ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION Stator to EMM connections; one 6-pin AMP and DESCRIPTION • J2 connector. The Engine Management Module (EMM) is a water-cooled engine controller. It controls many outboard systems including alternator output for the 12 V and 55 V circuits. Operating voltage is supplied to the EMM by the stator.

  • Page 97: Emm Inputs And Outputs Diagram

    ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS J1-A J1-B OUTPUTS 1. Engine Management Module (EMM) 10. Oil Pressure Sensor (component of 18) 19. Ignition Coil 2. Battery (12 volt) 11. Engine Temperature Sensor(s) 20.

  • Page 98: Engine Management Module (Emm)

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS If sensor reads less than -67°F (-55°C) or greater INTERNAL SENSORS than 311°F (155°C) a sensor circuit fault is detected and the EMM: Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude Stores service code 23 Diagnostics software to troubleshoot the sensors.
  • Page 99 ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS Barometric Pressure Sensor Supplies the EMM with barometric pressure read- Sensor inputs and internal EMM controllers are ing to compensate for changes in altitude and air used to control outboard operation. Use Evinrude density.

  • Page 100: Oil Pressure Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS If cylinder head temperature exceeds 194°F Oil Pressure Sensor (90°C) above 2000 RPM for 3 seconds, the EMM: The oil pressure sensor monitors oil pressure in Activates S.A.F.E. the oil distribution manifold. If the sensor does not detect pressure for 150 If cylinder head temperature exceeds 248°F pump cycles, the EMM: (120°C) for 3 seconds, the EMM:...

  • Page 101: Throttle Position Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Throttle Position Sensor Crankshaft Position Sensor The throttle position sensor receives a voltage sig- The CPS is a magnetic device. It is mounted on nal from the EMM. As the throttle lever is rotated, the reed plate, next to the flywheel.
  • Page 102 ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM Shift Interrupt The shift interrupt function of EMM programming FUNCTIONS shuts off fuel and spark to three cylinders for approximately one second to reduce drivetrain Start Assist Circuit (SAC) loads and ease shifting, then immediately restores When the ignition key is ON, the EMM Start Assist normal engine operation.

  • Page 103: Service Mode

    ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITORING SYSTEM The EMM activates the warning horn and gauge ENGINE MONITORING displays as follows: SYSTEM LOW OIL means that oil in the tank is at reserve • level (about 1/4 full). The engine monitoring system warns the operator NO OIL indicates the oil tank is empty, or the oil •...
  • Page 104 ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING SHUTDOWN MODE SYSTEM Outboard “shutdown” will occur if specific faults are detected by the EMM. The S.A.F.E. (Speed Adjusting Failsafe Electron- ics) warning system alerts the operator and pro- Conditions that initiate shutdown tects against engine damage from the following Code 29 Excessive EMM temperature abnormal conditions:...
  • Page 105 ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS DIAGNOSTIC Static Information Refers to information viewed when the outboard is SOFTWARE FUNCTIONS NOT running. This includes manufacturing infor- mation. The EMM stores valuable information about the outboard and its running history. This information The outboard model and serial numbers displayed can be used for troubleshooting, for checking on the Identity screen must match the identifica-...
  • Page 106 ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Information Hard Faults Dynamic information is viewed while the outboard A hard fault is a service code that currently exists. is running. Changes in data, such as voltages or Hard faults become stored faults only if the out- temperatures, are shown as they happen.
  • Page 107 ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Test Dynamic Tests Use the diagnostics software to test each ignition Dynamic tests are performed with the outboard circuit. Refer to Static Ignition Test on p. 120. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.
  • Page 108 ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Oil Control Settings Powerhead Break-In Use the diagnostic software to initiate break-in oil- Set Oil Type ing. Break-in is a predetermined oiling program The TC-W3 oil type setting is the standard setting that runs for two hours of outboard operation, for all outboards.

  • Page 109: Ignition Timing

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Timing TPS Calibration Use the Ignition Timing screen to check and TPS Calibration synchronizes throttle plate open- adjust EMM timing. EMM timing must be synchro- ing with throttle position sensor voltage. nized to crankshaft position. Refer to TPS CALIBRATION on p.
  • Page 110 ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Fuel Injector Servicing Reports All E-TEC fuel injectors use software program- Engine reports provide service records and can ming to compensate for variations in fuel flow. be used to document the running history of an out- Each injector and its location on the outboard is board.

  • Page 111: Emm Transfer

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Software replacement requires Software Replacement IMPORTANT: the use of “Bootstrap” Tool, P/N 586551. Engine Management Software programs are loaded into the EMM at the factory. Periodically, a new program may be available to enhance the operation of an outboard.
  • Page 112 ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING Installation Align slots in starboard side of EMM case with iso- lator mounts on cylinder block. Slide EMM into If a new EMM is being installed, IMPORTANT: position. refer to EMM Transfer on p. 109. Removal Disconnect exhaust pressure hose and cooling hoses from EMM.
  • Page 113 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............112 .

  • Page 114: Diagnostic Procedures

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Diagnostic Software Inspections Before running the outboard, use Evinrude Diag- PROCEDURES nostics software to review historical information stored in the EMM. Visual Inspections Check the Hard Faults and Stored Faults screens Inspect wiring and electrical connections. Disas- for current service codes.
  • Page 115 SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES first on the list. As each new record is added, Check the RPM Profile for long periods of low • the oldest record is removed. speed operation or periods of over-revving rpm. Check the Engine Temperature Profile for evi- •...

  • Page 116: System Analysis

    SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Use the diagnostics software Dynamic Tests to Troubleshooting • isolate a faulty cylinder. See DYNAMIC TESTS Outboard will not crank, starter does not on p. 115. operate: Use an inductive timing light to check ignition • Check condition of battery and cables (main •...

  • Page 117: Fuel Control Adjustment

    SYSTEM ANALYSIS DYNAMIC TESTS DYNAMIC TESTS Fuel Control Adjustment Use this test is to help identify a cylinder that may Cylinder Drop Tests be too rich or too lean. This feature should not be used by itself to identify a faulty injector. Use the Evinrude Diagnostics software Dynamic Tests to momentarily disable one cylinder while Evinrude Diagnostics software allows temporary...
  • Page 118 SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS Starting Starting mode occurs from the time the flywheel The EMM LED indicators provide a quick refer- begins to turn until the outboard is running for 2 ence to the status of several outboard systems. seconds.
  • Page 119 SYSTEM ANALYSIS EMM LED INDICATORS Code 7 – PORT Knock sensor circuit fault Running • Code 8 – STBD Knock sensor circuit fault • When the outboard is running, all of the LEDs Code 12 – TPS circuit fault • should be off.

  • Page 120: Wiring Inspection

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS IGNITION OUTPUT Crankshaft Position Sensor Provides EMM with input. • TESTS Outboard cranking speed exceeds 75 RPM and • a steady CPS signal is generated. DANGER Alternator Output/System Voltage System voltage from EMM (white/red) provides •...
  • Page 121 SYSTEM ANALYSIS IGNITION OUTPUT TESTS Crankshaft Position Sensor (CPS) System Voltage Test Test The ignition system is powered by the 55 V sys- tem. When the CPS is working properly, EMM LED 2 turns on while the outboard is being started. Use the Evinrude Diagnostics software Monitor screen to check system voltage.
  • Page 122 SYSTEM ANALYSIS IGNITION OUTPUT TESTS Static Ignition Test Perform the static ignition test using Evinrude Diagnostics software and an inductive timing light. DO NOT use a spark checker tool IMPORTANT: with E-TEC models. Radio Frequency Interfer- ence (RFI) generated by the arcing current can cause erratic behavior in the EMM.

  • Page 123: Running Ignition Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Running Ignition Tests Results: Steady voltage and strobe, engine misfires: Use Evinrude Diagnostics software to monitor Inspect or replace spark plugs • system voltage (55 V). Refer to FUEL DELIVERY TESTS on p. 123. • Voltage readings at a specific speed (RPM) •...

  • Page 124: Ignition Coil Tests

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS If circuits test good, replace EMM. Ignition Control Circuit Tests Use a digital multimeter to test the following: Ignition Coil Tests System voltage supply to ignition coil. • There are no simple ignition coil tests available. Ignition control signal from EMM.
  • Page 125 SYSTEM ANALYSIS FUEL DELIVERY TESTS If the pump does not run: FUEL DELIVERY TESTS The EMM controls power to the fuel pump (pur- • ple/black wire). Check voltage at pin 1 of fuel WARNING pump connector. Voltage should be 12 V when KEY is first ON, when fuel pump test activated, Protect against hazardous fuel spray.
  • Page 126 SYSTEM ANALYSIS FUEL DELIVERY TESTS Results: Results: No injectors actuate: No light activation on any injector wires (outboard cranks and starter turns flywheel): Use the Monitor screen of the diagnostics soft- • ware to make sure voltage is present on the Check stator input to EMM, CPS operation, and •...
  • Page 127 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............126 IGNITION SYSTEM CIRCUIT DIAGRAM .
  • Page 128 ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 50-70 In. lbs. (5.6-8 N·m) 30-42 In. lbs. 30-42 In. lbs. (3-5 N·m) (3-5 N·m) 30-42 In. lbs. (3.5-4.7 N·m) 30-42 In. lbs. 140-160 Ft. lbs. (3.5-4.7 N·m) (190-217 N·m) 15-30 Ft.
  • Page 129 ELECTRICAL AND IGNITION SERVICE CHART 60-84 in. lbs (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 168-192 in. lbs (19-21.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 004100 Liquid Neoprene...

  • Page 130: Electrical And Ignition

    ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM CIRCUIT DIAGRAM FUSE 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Fuse Crankshaft position sensor Main harness ground Stator Capacitor +12 V from battery...
  • Page 131 ELECTRICAL AND IGNITION DASH CONNECTIONS, INSTRUMENT HARNESS DASH CONNECTIONS, INSTRUMENT HARNESS 3-pin connector – Connect to trim switch located in the handle of the remote control or to trim switch mounted on the boat dash. 6-pin connector – Connect to a pre-wired remote control or to a dash-mounted key switch.
  • Page 132 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
  • Page 133 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 1 Blue Injector, cylinder 2 Blue vacant Injector, cylinder 3 Purple Isolated B+ Red/Black vacant Battery ground Black...
  • Page 134 ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS Additional Ground Tests Check connections and continuity at the following All ground circuits are essential to reliable out- locations: board performance. Make sure all ground connec- Trim and Tilt module ground at main ground ter- •...
  • Page 135 ELECTRICAL AND IGNITION SENSOR TESTS (1.85 mm). The acceptable clearance is 0.036 to SENSOR TESTS 0.110 in. (1 to 2.8 mm). All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the EMM.
  • Page 136 ELECTRICAL AND IGNITION SENSOR TESTS Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test meter lead to terminal “C.” Rotate the sensor lever Remove the electrical connector from the air tem- through its range of travel. Resistance reading perature sensor.
  • Page 137 ELECTRICAL AND IGNITION STATOR TESTS To check for a grounded winding, connect one STATOR TESTS meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The stator consists of 3 windings (6 poles each) read no continuity.
  • Page 138 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS 12 V Charging Circuit To test the operation of the regulator in the EMM, you must be able to run the outboard continuously at approximately 5000 RPM, such as in a test tank or on a marine dynamometer.

  • Page 139: V Alternator Circuit

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS With outboard running at 1000 RPM, voltage must Auxiliary Battery Charge Wire read higher than with key OFF and increase The auxiliary battery charge feature requires aux- steadily to approximately 14.5 V as the outboard iliary battery charge kit, P/N 5006253 (or equiva- RPM increases.
  • Page 140 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 004112 1. Marine battery 10. 26-pin J1-B EMM connector 2. RED wire (POS) 11. 34-pin J1-A EMM connector 3. BLACK wire (NEG) 12. Engine Management Module (EMM) 4.
  • Page 141 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The starter must engage and turn the flywheel. Red/purple wire provides 12 V to key switch ter- • The outboard must crank a minimum of 100 RPM minal “B”.
  • Page 142 ELECTRICAL AND IGNITION ELECTRIC START TESTS Key Switch, START Position ELECTRIC START TESTS Key switch START: Starter Solenoid Test Switches 12 V to terminal “S” of key switch and • to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- A closed neutral safety switch provides 12 V to •...

  • Page 143: No Load Current Draw Test

    ELECTRICAL AND IGNITION ELECTRIC START TESTS After re-installing the solenoid, coat all wires and Use an inductive ammeter or connect a 0 to 100 terminals with Black Neoprene Dip. amp ammeter in series with a heavy jumper between the battery positive (+) terminal and the starter positive (+) terminal.
  • Page 144 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or continuity light to test the SWITCH TESTS continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
  • Page 145 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Switch Test Emergency Stop Switch Test Use an ohmmeter or a continuity light to test neu- This switch can be part of the key switch or tral start switch operation. installed as a separate switch. Either style con- nects the “M”...
  • Page 146 ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST Test Procedure Make sure red and black wires are connected to The tilt and trim (TNT) module contains the cir- 12 V battery power supply. cuitry and relays required for power trim and tilt operation.

  • Page 147: Systemcheck Circuit Tests

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS instrument harness terminal 1 (purple wire) and SystemCheck CIRCUIT terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...

  • Page 148: Check Engine Circuit Test

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test gauge. The tan wire of engine harness and the MWS har- ness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head.

  • Page 149: Low Oil Circuit Test

    ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT LOW OIL Circuit Test Turn the key switch ON. Using a jumper wire, con- TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW Check voltage at the battery.

  • Page 150: Flywheel Removal

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Assemble the following components from Univer- FLYWHEEL AND sal Puller Set, P/N 378103: STATOR SERVICING Body, P/N 307636 • Screw, P/N 307637 • Handle, P/N 307638 • Weak flywheel magnets IMPORTANT: Three screws P/N 309492 •...

  • Page 151: Flywheel Installation

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING DO NOT over apply Nut Lock on Flywheel Installation IMPORTANT: flywheel taper. This prevents Nut Lock from Install the outer edge of flywheel key parallel with migrating into upper seal of crankshaft. centerline of crankshaft. Align the flywheel keyway and install the flywheel.

  • Page 152: Ignition Coil Installation

    ELECTRICAL AND IGNITION IGNITION COIL SERVICING Remove four screws and bracket. IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil. Remove two ignition coil retaining screws. Do not lose the rubber washers between coil and bracket. Disconnect ignition coil electrical connector.

  • Page 153: Timing Adjustments

    ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Rotate flywheel counterclockwise until the num- TIMING ADJUSTMENTS ber 1 piston contacts the tool. Keep pressure on the flywheel to position the piston firmly against Timing Pointer the tool. Mark the flywheel directly across from the The timing pointer must be adjusted to indicate pointer.
  • Page 154 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS location to align with the cast-in TDC boss on the Check ignition timing after any of the following flywheel. Tighten retaining screw. procedures: Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement • CPS replacement •...

  • Page 155: Starter Removal

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the screws, lock washers, and pinion ELECTRIC STARTER housing. SERVICING Starter Removal Do not clean the starter drive IMPORTANT: while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator.
  • Page 156 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Hit the socket with a mallet to lower the spacer Remove pinion and plastic weather cover from and expose the retaining ring under the spacer. pinion shaft. 30368 Remove the driven gear and thrust washer. 30371 30367 30360...
  • Page 157 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the two thru-bolts. Mark the end cap ori- Note the alignment marks by the positive terminal entation, and remove the cap. stud. Hold the armature in place, and slide the frame away from the gear housing. 30365 Gently tap the starter frame with a rubber mallet to loosen it.
  • Page 158 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING matter which could contribute to failure of wind- Starter Cleaning and Inspection ings. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. 24058 TYPICAL Check permanent magnets. Make sure they 30349 strongly attract any steel or iron object held inside frame.

  • Page 159: Starter Assembly

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Align the starter frame and make sure the long Starter Assembly alignment mark matches the mark next to the pos- itive terminal stud on the gear housing. If removed, apply Locquic Primer IMPORTANT: and Screw Lock to the brush card screws before Push the armature down firmly and slide the installing.
  • Page 160 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Install the two thru-bolts. Tighten to a torque of 50 Guard grease. Install the thrust washer and driven to 65 in. lbs. (5.6 to 7.3 N·m). gear. 30362 30363 Install the weather cover. Lightly coat the drive gear with Triple-Guard grease, and install it on the armature shaft.

  • Page 161: Starter Installation

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Lightly coat the pinion shaft splines (helix) with Install the bracket. Apply Nut Lock to the thru- Starter Bendix Lube. Lower the pinion into place bolts. Install the nuts and tighten to a torque of 50 without displacing the driven gear or thrust to 65 in.

  • Page 162: Connector Servicing

    ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire. CONNECTOR SERVICING DEUTSCH Connectors recom- IMPORTANT: Electrical Grease mended. Incorrect grease application can cause electrical or warning system problems. 42329 1. Terminal latch (receptacle) 2. Terminal latch (plug) To disconnect the connector, press the latch and pull the connectors apart.
  • Page 163 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors Always appropriate IMPORTANT: meter test probes and adapters when testing com- ponents fitted with these terminals. Electrical grease is NOT used on AMP connectors. † UPERSEAL Disconnect Lift latch. Pull connectors apart. 002447 1.
  • Page 164 ELECTRICAL AND IGNITION CONNECTOR SERVICING † † UPER OWER IMER ERIES The J1-A and J1-B connectors of the EMM are The J2 connector of the EMM is a AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOTH latches and pull connector from Use a screw driver to open latch.
  • Page 165 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back side of the terminal engages a terminal with seal into connector housing until shoulder in the connector housing to hold the ter- seated.
  • Page 166 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Install wire gasket on wires and feed wires through the correct terminal position of the con- nector housing. Terminal is crimped onto wire and then pulled back into connector housing until lock- ing tab engages and terminal is seated. 002304 Crimping Terminals Strip insulation back 3/16 in.
  • Page 167 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............166 FUEL SYSTEM HOSE ROUTING .
  • Page 168 FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 30-42 In. lbs. (3.5-4.7 N·m) 60-84 In. lbs. (7-9.5 N·m) 100-110 In. lbs. (11-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) (Lower screw only) Hand tighten to seal contact then 1/2 - 1 turn 60-84 In.
  • Page 169 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Important:: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 60-84 in. lbs. (7-9.5 N·m) Start at center and use a spiral torque pattern 60-80 in. lbs. (7-9.5 N·m) 30-42 in.

  • Page 170: Fuel System

    FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Tighten in 3 stages 60-84 in. lbs. (6.8-9.5 N·m) 120 in. lbs. (14 N·m) 24-26 Ft. lbs. 24-36 in. lbs (33-35 N·m) (2.7-4 N·m) S = Supply R = Return Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...

  • Page 171: Fuel System Hose Routing

    FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Return 3.3 L Models 003985 Fuel Supply Fuel Return 3.4 L Models 006977 Fuel supply from boat fuel system Electric fuel circulation pump (20 to 35 psi) Fuel lift pump (2 to 8 psi) Fuel supply manifold Pulse hose(s) from cylinder/crankcase...
  • Page 172 FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM J1-A J1-B 007109 Injectors Capacitor High pressure fuel pump Grounds (neg) Fuel filter/water separator 55 V circuit (white/red) Fuel Injector grounds...

  • Page 173: Fuel Lift Pump

    FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The water separating fuel filter protects the vapor The fuel system includes the following compo- separator and the high-pressure components of nents: the fuel system from water and contaminants. Fuel Lift Pump • Refer to INSPECTION AND MAINTENANCE Fuel Filter •...
  • Page 174 FUEL SYSTEM COMPONENTS to flow to the intake manifold through the vent Fuel Reservoir hose. The vapor separator accumulates fuel in an inter- nal fuel reservoir and supplies fuel to the electric As the vapor pressure in the vapor separator circulation pump.

  • Page 175: Fuel Injectors

    FUEL SYSTEM COMPONENTS The EMM is programmed to compensate for vari- Fuel Manifolds ations in fuel flow. Each injector and its location on The fuel supply and return manifolds route fuel the outboard is identified by the EMM. DO NOT through the high pressure side of the fuel system.
  • Page 176 FUEL SYSTEM FUEL SYSTEM TESTS Shut OFF outboard. Monitor pressure gauge. FUEL SYSTEM TESTS Pressure should not drop below 15 psi (103 kPa). If outboard does not run, prime WARNING IMPORTANT: fuel system and crank outboard; check circulation Use caution when working on any pres- pump operation;...
  • Page 177 FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 181 to This test requires Injector Test Fitting kit, remove vapor separator. P/N 5005844. Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.
  • Page 178 FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Resistance Test Circulation Pump Resistance Test Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter to measure the fuel pump coil resistance.
  • Page 179 FUEL SYSTEM FUEL SYSTEM TESTS START outboard and run at FULL THROTTLE for Results: at least two minutes. Monitor clear vinyl hose for Normal pressure the presence of air. Air bubbles indicate a faulty Perform the Lift Pump Vacuum Test on •...

  • Page 180: Relieving Fuel System Pressure

    FUEL SYSTEM FUEL COMPONENT SERVICING Anti-Siphon Valve Test FUEL COMPONENT Remove anti-siphon valve from fuel tank. Install SERVICING adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve. WARNING Gasoline is extremely flammable and highly explosive under certain conditions.
  • Page 181 FUEL SYSTEM FUEL COMPONENT SERVICING Pressure Gauge, P/N 5007100, to top test fitting Fuel Filter Service of fuel pump/vapor separator assembly. Removal Disconnect the battery cables at the battery. Use an appropriate filter wrench to turn the filter in a counterclockwise direction. Remove the filter carefully to prevent spilling the filter’s contents.
  • Page 182 FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Installation Place fuel pump bracket, with rubber isolator The fuel lift pump is serviceable as a complete mounts, in front of the throttle body. assembly. Refer to parts catalog for service parts. Apply Nut Lock to screws and install screws into Removal throttle body.
  • Page 183 FUEL SYSTEM FUEL COMPONENT SERVICING Vapor Separator Service Fuel Manifold Service Removal Removal Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Relieve fuel system pressure. Refer to Relieving Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p.
  • Page 184 FUEL SYSTEM FUEL COMPONENT SERVICING Disconnect fuel manifold fittings from fuel injector Fuel Injector Service ports, then remove the manifold assemblies. Mark fuel injectors to show cylinder locations. Installation Fuel injectors must be installed in IMPORTANT: Check condition of sealing O-rings on fuel mani- the correct cylinder locations.
  • Page 185 FUEL SYSTEM FUEL COMPONENT SERVICING Remove injector screws. tor filter. Install new crush ring and O-rings. Lubri- † cate O-rings with STP Oil Treatment. 004267 1. Injector screws 002196 1. Adaptor Remove fuel injector and insulator. Crush Ring Replacement Injector crush rings must be IMPORTANT: replaced if injector is installed in a different head or cylinder location.
  • Page 186 FUEL SYSTEM FUEL COMPONENT SERVICING through mounting flange of injector and into cylin- Installation der head. All injectors must be installed in IMPORTANT: the correct cylinder by serial number. Improper injector installation can result in powerhead fail- ure. Installation of replacement injectors requires the use of diagnostics software and fuel flow data supplied with all replacement injectors on 3.5 in.
  • Page 187 FUEL SYSTEM FUEL COMPONENT SERVICING Intake Manifold Service Disassembly All reed plate assembly and reed valve assem- Removal blies must be cleaned before reassembly. DO Disconnect vapor separator vent hose, throttle NOT use strong carburetor cleaner or the hot position sensor connector, and throttle link arm. soaking tank method for cleaning.
  • Page 188 FUEL SYSTEM FUEL COMPONENT SERVICING Inspect the intake manifold. All gasket surfaces Installation must be cleaned, smooth, and free of nicks. Use a Place reed plate assembly on cylinder/crankcase. machinist’s straight-edge to check flatness in all directions. Surface must be flat, ±0.004 in. (0.10 Apply Nut Lock to screws.
  • Page 189 FUEL SYSTEM FUEL COMPONENT SERVICING Connect throttle linkage and throttle position sen- Position clamps as shown. sor connector. DO NOT lubricate TPS to throttle IMPORTANT: shaft surface. 004248 1. Throttle linkage 2. TPS electrical connector 3. Vapor separator vent hose 006990 1.
  • Page 190 FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 191 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............190 OILING SYSTEM CIRCUIT DIAGRAM .
  • Page 192 OILING SYSTEM SERVICE CHART SERVICE CHART Engine Oil Programming Labels *IMPORTANT* *IMPORTANT* XD 100 XD 30 This outboard has This outboard has been programmed been programmed for use of ® for use of Evinrude ® /Johnson /Johnson Evinrude ® ® (Blue) XD 50 TCW3RL OIL...
  • Page 193 OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM 1 2 3 4 5 J1-A 1 2 3 4 5 J1-B 004110 Oil Injection Pump 55 V Circuit (WHITE/RED) Grounds, NEG (BLACK) EMM to Oil Solenoid (BLUE) Oil Pressure Sensor, +5 V analog (RED) Oil Pressure Sensor Signal (TAN/WHITE) Capacitor...

  • Page 194: Oiling System

    OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS Rear oil manifold delivers oil to cylinder sleeves 1. Cylinder 1 2. Cylinder 2 3. Cylinder 3 4. Cylinder 4 5. Cylinder 5 6. Cylinder 6 Primary oil manifold delivers oil to crankcase fittings and rear oil manifold 1.
  • Page 195 OILING SYSTEM OIL SUPPLY DIAGRAMS 3.3 L models Rear View Top View 006870...
  • Page 196 OILING SYSTEM OIL SUPPLY DIAGRAMS 3.4 L models Port View Starboard View 007256...
  • Page 197 OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 004111a...

  • Page 198: Oil Injection Pump

    OILING SYSTEM COMPONENTS COMPONENTS Oil Injection Pump The oil injection pump is an electric (55 V) actua- The oiling system consists of the following compo- tor style pump. It draws oil from the oil tank nents: through the oil supply hose [25 ft. (7.6 m) maxi- Oil tank •...

  • Page 199: Cylinder And Crankcase

    OILING SYSTEM COMPONENTS The sensor provides an output voltage to the LOW OIL Warning EMM based on oil manifold pressures. A sending unit in the oil tank pick-up assembly 5 VDC Input on RED wire • monitors the oil level in the oil tank. This sending 0.5 - 4.5 V Output on TAN / WHITE wire •...

  • Page 200: Oil Recirculation System

    OILING SYSTEM COMPONENTS On 3.3 L models, one oil distribution hose is cylinders into the incoming air stream in front of routed to a tee fitting at the top of the block, above the top reed valve. #2 cylinder. 004337 1.

  • Page 201: Oiling Rates

    OILING SYSTEM OIL CONTROL SETTINGS hoses which route to a fitting at the top of the OIL CONTROL SETTINGS block, above #2 cylinder. Oil Priming The oiling system of the outboard must be primed: When the outboard is first installed. •...
  • Page 202 OILING SYSTEM OILING SYSTEM TESTS OILING SYSTEM TESTS Oil Injection Pump Voltage Test Check voltage at pin 1 (white/red wire) of oil tank Always perform visual inspec- IMPORTANT: electrical connector. tions to identify oiling system leaks. Make sure the Acceptable voltage readings: oil tank is filled and oil supply is not contaminated.
  • Page 203 OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Circuit Oil Supply Vacuum Test Resistance Test WARNING The complete oil injection pump IMPORTANT: Wear safety glasses to avoid personal electrical circuit includes EMM alternator output, injury, and set compressed air pressure to the engine wire harness, the injection pump wind- less than 25 psi (172 kPa).
  • Page 204 OILING SYSTEM OILING SYSTEM TESTS Attach a vacuum tester to the outboard side of oil Running Test supply hose and draw 7 in. Hg (24 kPa) vacuum Start the outboard and observe oil flow. Confirm on the hose for at least five minutes. Repair or that a small amount of oil is discharged while replace any leaking components.

  • Page 205: Oil Component Servicing

    OILING SYSTEM OIL COMPONENT SERVICING Once hose is removed from the manifold, make OIL COMPONENT sure hose support is in the end of the hose. SERVICING WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery. Oil Distribution Hoses The oil distribution hoses from each manifold MUST be the same length.

  • Page 206: Oil Injection Pump Installation

    OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Route oil distribution hoses from the oil distribu- Removal tion manifold to the crankcase oil delivery fittings Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP- PLY DIAGRAMS on p.
  • Page 207 OILING SYSTEM OIL COMPONENT SERVICING Install oil pump on bracket with clamp and retain- Reconnect oil supply hose to the inlet fitting of oil ing screw. Tighten to a torque of 24 to 36 in. lbs. (3 pump. Fasten with Oetiker clamp. to 4 N·m).
  • Page 208 OILING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 209 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAM ......... 208 COMPONENTS .
  • Page 210 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAM HOSE ROUTING AND WATER FLOW DIAGRAM PORT REAR Port Rear Water intake screens Water pump Hose Routing & Water Flow Diagram Water tube 200-250HP/90ºV6- Evinrude E-TEC Adapter housing Water supply, adapter to cylinder block (port and starboard) Water supply to EMM (cylinder block vent) 1.

  • Page 211: Adapter Housing

    COOLING SYSTEM COMPONENTS COMPONENTS Water Supply Tube The water pump outlet connects with the water Water Pump and Intakes supply tube located in the outboard’s midsection. Grommets seal the water tube to the water pump External water intakes mounted in the gearcase housing and the inner exhaust housing.

  • Page 212: Cooling System

    COOLING SYSTEM COMPONENTS Pressure Relief Valve Thermostats A pressure relief valve is used to control water Thermostats control water flow and operating flow and operating temperature at higher speeds temperature at lower speeds (below 1200 RPM). (above approximately 1200 RPM). The pressure Overheating: A restricted or faulty thermostat typ- relief valve opens as water pressure increases.
  • Page 213 COOLING SYSTEM OPERATION At low speed, the pressure valve is against the OPERATION seat and the thermostats are closed. Warm water from the cylinder block gradually migrates to the All models use a two-stage cooling system thermostat pocket at the top of each cylinder design.
  • Page 214 COOLING SYSTEM ENGINE TEMPERATURE CHECK adapter. The water reduces inner exhaust temper- ENGINE TEMPERATURE atures and cools the propeller hub. CHECK The engine temperatures listed IMPORTANT: below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and place outboard in a test tank or in the water.

  • Page 215: Software Method

    COOLING SYSTEM ENGINE TEMPERATURE CHECK Typical temperatures observed at IDLE speed Software Method with pyrometer should be 143°F ± 15°F (62°C ± Use Evinrude Diagnostics software to read tem- 8°C) perature displays. If you get low or inaccurate read- IMPORTANT: ings with a digital pyrometer, coat the probe loca- tion with Thermal Joint Compound, P/N 322170.
  • Page 216 COOLING SYSTEM ENGINE TEMPERATURE CHECK If IDLE temperature is below specific operating Start the outboard and check IDLE operating tem- range, pinch off the water outlet hoses from pres- perature using Evinrude Diagnostics software pro- sure relief valve to cylinder heads. gram.

  • Page 217: Thermostat Servicing

    COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 007209 004338 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.

  • Page 218: Pressure Relief Valve Servicing

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Inspection Inspect all parts for cracks, heat damage, or signs VALVE SERVICING of corrosion. Replace damaged parts. Clean debris from housing and parts. The pressure relief valve assembly should be ser- viced at the same time as the thermostats. Assembly Disassembly Assembly is the reverse of disassembly.
  • Page 219 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............218 TAPER PIN TOOL .
  • Page 220 POWERHEAD SERVICE CHART SERVICE CHART Triple-Guard Grease Gasket Sealing Compound 60-84 In. lbs. (7-9.5 N·m) Moly Lube Red Ultra Lock 60-84 In. lbs. Blue Nut Lock (7-9.5 N·m) Outboard Engine Lubricant 30-42 In. lbs. Thermal Grease (3.5-5 N·m) Pipe Thread Sealing Compound 120-144 In.
  • Page 221 POWERHEAD SERVICE CHART 96-120 In. lbs. (11-13.5 N·m) 60-65 Ft. lbs. (81-88 N·m) 96-120 In. lbs. (11-13.5 N·m) 96-120 In. lbs. (11-13.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Extreme Pressure Grease See Service Manual Text 004108...

  • Page 222: Powerhead

    POWERHEAD TAPER PIN TOOL TAPER PIN TOOL Scale: FULL SIZE – Hole for Storage COMPRESSION TESTING Start and run outboard until it achieves operating If engine shows a variation greater than 15 psi temperature, then shut OFF. (100 kPa) between cylinders, check for: damaged cylinder head •...
  • Page 223 POWERHEAD POWERHEAD REMOVAL Remove water hoses and exhaust back pressure POWERHEAD REMOVAL hose from adapter. WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 178. To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
  • Page 224 POWERHEAD POWERHEAD REMOVAL On each side, remove the powerhead retaining screws and nuts. 005041 1. Trim harness 2. Clamp 004240 1. Screws and nuts Remove pin and washer from shift rod lever to release the lower shift rod. Remove the rear powerhead nut. 004252 1.

  • Page 225: Powerhead Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Throttle Linkage Removal Remove throttle cam and throttle lever. DISASSEMBLY General To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p.

  • Page 226: Crankcase Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY Remove the upper crankcase head screws. Crankcase Disassembly Use the TAPER PIN TOOL, or equivalent, to push the crankcase taper pins toward the front side of the engine. Do not use a tapered punch or IMPORTANT: any other tool that could jam in or damage the taper bore when removing the pin.

  • Page 227: Cylinder Head Removal

    POWERHEAD POWERHEAD DISASSEMBLY Separate crankcase and cylinder block. It may be Connecting Rods and Pistons necessary to tap on crankshaft with a rawhide or Use a permanent marker to identify each connect- rubber mallet to loosen. ing rod cap, connecting rod, and piston by cylinder number.
  • Page 228 POWERHEAD POWERHEAD DISASSEMBLY Use one hand to support the piston, and remove Remove wrist pin retaining rings. Discard retaining the rod cap screws with your other hand. Remove rings. each piston and rod assembly. 000689 Use Wrist Pin Pressing Tool, P/N 396747, to 49432 remove wrist pin.
  • Page 229 POWERHEAD POWERHEAD DISASSEMBLY Use a drift punch to remove the upper crankshaft Remove the O-ring from crankshaft sleeve and seal. Remove and discard two crankcase head inspect it. Replace the O-ring if it is not in good O-rings. condition. 0865 30057 If the lower crankcase head is to be resealed or Inspect the crankshaft sleeve and replace, if nec-...
  • Page 230 POWERHEAD POWERHEAD DISASSEMBLY Remove center main bearings and split sleeves If the lower main bearing is IMPORTANT: for inspection. DO NOT mix parts. Note location of removed from the crankshaft, it must be dis- bearings for reassembly. carded. DO NOT reuse it. Use a bearing separator to support the bearing, and press off the crankshaft.
  • Page 231 POWERHEAD CYLINDER BLOCK CLEANING Use Gel Seal and Gasket Remover to remove all CYLINDER BLOCK traces of gaskets, adhesives, and Gel-Seal II™ CLEANING sealant from the cylinder block and crankcase. WARNING Before inspecting or assembling IMPORTANT: powerhead, all internal components must be com- To avoid personal injury, wear eye protec- pletely clean and free of contaminants.

  • Page 232: Cylinder Head

    POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diameter of each crankpin and main INSPECTION bearing journal. The lower main bearing journal would only be measured if the bearing was For dimensions, refer to SERVICE SPECIFICA- removed for another reason. TIONS on p. 10. Before any inspection process IMPORTANT: can begin, all internal components must be com-...

  • Page 233: Piston Rings

    POWERHEAD POWERHEAD INSPECTION Cylinder Bore Pistons Visually inspect pistons for signs of abnormal Use Cylinder Bore Gauge, P/N 771310, to inspect wear, scuffing, cracks, or burning. each cylinder bore for an out-of-round, oversize, or tapered condition. Be sure the gauge is per- Piston Rings fectly square in the bore when measuring.
  • Page 234 POWERHEAD POWERHEAD ASSEMBLY Bearings POWERHEAD Inspect center main bearing and split sleeves for ASSEMBLY excess wear, nicks, or scratches. Replace if nec- essary. Proceed slowly. Make no forced IMPORTANT: assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant.
  • Page 235 POWERHEAD POWERHEAD ASSEMBLY new sleeve onto the crankshaft until the installer Use retaining ring pliers to install bearing retaining contacts the lower main bearing. ring with sharp edge facing away from bearing. 30061 Lubricate a new driveshaft O-ring and lightly lubri- 30074 cate crankshaft splines with Moly Lube.
  • Page 236 POWERHEAD POWERHEAD ASSEMBLY Lightly coat the outside diameter of a new crank- Install new seals on the four bearing retainer shaft seal with Gasket Sealing Compound. Use screws. Apply Nut Lock to the threads of the Seal Installation Tool, P/N 325453, to install seal screws and tighen to a torque of 96 to 120 in.

  • Page 237: Pistons And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Lightly coat two new O-rings with Gasket Sealing Apply outboard lubricant to the wrist pin bearings. Compound, and install on upper crankcase head. Install the bearings in the wrist pin bore. Keep sealer away from oil passage. Oil the wrist pin bore and wrist pin.

  • Page 238: Cylinder Head Installation

    POWERHEAD POWERHEAD ASSEMBLY in each wrist pin hole. Gap of retaining ring faces Before continuing, make sure that IMPORTANT: away from notch in piston. all Gel-Seal II has been removed from the cylinder block and crankcase mating flanges. If traces of hardened Gel-Seal II are left, main bearings could be misaligned.
  • Page 239 POWERHEAD POWERHEAD ASSEMBLY Install cylinder head with the thermostat toward Gently lower crankshaft into place. the top. Apply Triple-Guard grease to threads and Turn all crankcase seal ring gaps to face up. • install the cylinder head screws. DO NOT use any Locate each main bearing on its dowel pin.
  • Page 240 POWERHEAD POWERHEAD ASSEMBLY Lubricate rod cap screw threads and under screw Install Rod Cap Alignment Fixture, P/N 396749, head mating surface with a light coat of Triple- before tightening rod cap screws. Align the flat Guard grease. Apply outboard lubricant to screw marked “SET”...
  • Page 241 POWERHEAD POWERHEAD ASSEMBLY Apply a light coat of outboard lubricant to the cor- Loosen both rod cap screws one-quarter turn. ners of the connecting rod and rod cap. Place Use Torquing Socket, P/N 346187, to tighten rod frame on connecting rod using the following pro- cap screws in three stages: cedure: Apply first torque of 40 to 60 in.
  • Page 242 POWERHEAD POWERHEAD ASSEMBLY The use of Locquic Primer is NOT Crankcase Assembly IMPORTANT: recommended. If primer is used, crankcase Thoroughly clean and degrease the mating halves must be assembled and tightened within flanges of the crankcase and cylinder block with a ten minutes after the Gel-Seal II has been applied.
  • Page 243 POWERHEAD POWERHEAD ASSEMBLY Apply Permatex No. 2 to crankcase flange screws Shift Linkage Installation where threaded hole is open to crankcase.Install Lubricate shift linkage bosses at the base of the screws and tighten to to a torque of 84 to 108 in. crankcase with Triple-Guard grease.
  • Page 244 POWERHEAD POWERHEAD ASSEMBLY Throttle Linkage Installation Final Powerhead Assembly Apply Nut Lock to threads of throttle lever screw. Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 185. Insert spring into cavity of throttle lever. Install oil recirculating hoses and check valves.
  • Page 245 POWERHEAD POWERHEAD INSTALLATION Apply Gasket Sealing Compound to the threads of POWERHEAD all powerhead screws. INSTALLATION Loosely install all fasteners before tightening. Apply Permatex No. 2 to both sides of a new base Tighten the 3/8 in. diameter powerhead screws to gasket around the exhaust port only.
  • Page 246 POWERHEAD POWERHEAD INSTALLATION 004252 1. Rear powerhead nut 005042 1. Cooling hose (to exhaust plenum) Place the shift rod in the shift rod lever. Install the 2. Exhaust back pressure hose (to EMM) retaining pin and washer. Tighten pin to a torque of 60 to 84 in.
  • Page 247 POWERHEAD POWERHEAD INSTALLATION Install air temperature sensor, air silencer, and fly- Perform the following procedures IMPORTANT: wheel cover. Tighten flywheel cover screws to a before returning outboard to service: torque of 30 to 42 in. lbs. (3.5 to 5 N·m). Index all spark plugs.
  • Page 248 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings – 3.3 L models 006951...
  • Page 249 POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.3 L models 006952...
  • Page 250 POWERHEAD POWERHEAD VIEWS Port Hose Routings – 3.4 L models 007153...
  • Page 251 POWERHEAD POWERHEAD VIEWS Starboard Hose Routings – 3.4 L models 007154...
  • Page 252 POWERHEAD POWERHEAD VIEWS Port – 3.3 L models 007139...
  • Page 253 POWERHEAD POWERHEAD VIEWS Starboard – 3.3 L models 007138...
  • Page 254 POWERHEAD POWERHEAD VIEWS Port – 3.4 L models 007143...
  • Page 255 POWERHEAD POWERHEAD VIEWS Starboard – 3.4 L models 007144...
  • Page 256 POWERHEAD POWERHEAD VIEWS Front – 3.3 L models 007140...
  • Page 257 POWERHEAD POWERHEAD VIEWS Front – 3.4 L models 007145...
  • Page 258 POWERHEAD POWERHEAD VIEWS Rear – 3.3 L models 007141...
  • Page 259 POWERHEAD POWERHEAD VIEWS Rear – 3.4 L models 007142...
  • Page 260 POWERHEAD POWERHEAD VIEWS 007146...
  • Page 261 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............260 .
  • Page 262 MIDSECTION SERVICE CHART SERVICE CHART Stern Bracket 40-50 In. lbs. (4.5-5.5 N·m) 64-72 Ft. lbs. (87-98 N·m) 8-12 In. lbs. 10-16 In. lbs. (0.9-1.4 N·m) (1.1-1.8 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.5 N·m) 28-30 Ft.
  • Page 263 MIDSECTION SERVICE CHART Exhaust Housing – 3.3 L models 22-24 Ft. lbs. (30-33 N·m) See Assembly Instructions 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (14-16 N·m) 144-168 In. lbs. 60-84 In. lbs. (16-19 N·m) (7-9.5 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In.

  • Page 264: Midsection

    MIDSECTION SERVICE CHART Exhaust Housing – 3.4 L models 22-24 Ft. lbs. (30-33 N·m) 144-168 In. lbs. (16.5-19 N·m) 144-168 In. lbs. (16.5-19 N·m) 9-12 Ft. lbs. (12-16 N·m) 60-84 In. lbs. (7-9.5 N·m) 40-42 Ft. lbs. 144-168 In. lbs. (54-57 N·m) (16.5-19 N·m) 60-84 In.
  • Page 265 MIDSECTION SERVICE CHART Muffler...
  • Page 266 MIDSECTION TILT TUBE Remove the nut from the starboard side. TILT TUBE The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist. Pull the locking tabs on the tilt limit cam loose from 30747 the collar.
  • Page 267 MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of thread are WARNING engaged. Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.
  • Page 268 MIDSECTION EXHAUST HOUSING Remove the exhaust housing. EXHAUST HOUSING Exhaust Housing Removal Before removing the midsection: Remove the gearcase. Refer to Gearcase • GEARCASE REMOVAL INSTALLA- TION on p. 287. Remove the powerhead. Refer to POWER- • HEAD REMOVAL on p. 221. Remove and discard four lower mount screws.
  • Page 269 MIDSECTION EXHAUST HOUSING Mark the water tube for correct reassembly loca- Exhaust Housing Disassembly – tion. Remove six inner exhaust housing screws. 3.3 L models Remove the inner exhaust housing. Remove two front adapter to outer exhaust hous- ing screws. Remove three nuts at rear of the adapter.
  • Page 270 MIDSECTION EXHAUST HOUSING Loosen and remove the upper mount plate screws Exhaust Housing Disassembly – and remove the mount plate. 3.4 L models Remove two front adapter to outer exhaust hous- ing screws. 32588 Lubricate the upper mount with soapy water and pry up to remove it from the adapter housing.

  • Page 271: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING Inspect the water tube for obstructions or kinks, Cleaning and Inspection which may restrict water flow. WARNING Exhaust Housing Assembly – Wear safety glasses to avoid personal 3.3 L models injury, and set compressed air to less than Lightly coat both sides of a new gasket with Gas- 25 psi (172 kPa).
  • Page 272 MIDSECTION EXHAUST HOUSING Coat the outside diameter of a new water tube Install a new inner exhaust housing seal. Apply grommet with Adhesive 847. Install grommet in Adhesive 847 to the seal groove. the inner exhaust housing. Install the water tube. 7715 13640 Lightly coat both sides of a new inner exhaust...
  • Page 273 MIDSECTION EXHAUST HOUSING Lubricate the upper mount with soapy water and Tighten the small adapter to exhaust housing push into place in the adapter housing. The mount screws and nuts to a torque of 60 to 84 in. lbs. (7 radius must face aft with the “TOP”...
  • Page 274 MIDSECTION EXHAUST HOUSING Cleaning Solvent. Apply Gel-Seal II sealant to the Exhaust Housing Assembly – adapter flange of the exhaust housing. 3.4 L models Apply Adhesive 847 to the bottom flange of the inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.
  • Page 275 MIDSECTION EXHAUST HOUSING Lubricate the upper mount with soapy water and Tighten the small adapter to exhaust housing push into place in the adapter housing. The mount screws and nuts to a torque of 60 to 84 in. lbs. (7 radius must face aft with the “TOP”...
  • Page 276 MIDSECTION EXHAUST HOUSING Attach the ground lead and star washer to the Exhaust Housing Installation steering arm’s starboard side. Bring the exhaust housing into position with the stern bracket. Install four new lower mount screws with lock- patch. Tighten screws to a torque of 38 to 45 ft. lbs.
  • Page 277 MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer. It STERN BRACKET may be necessary to tap the steering shaft out using a wood dowel and mallet. Removal Before servicing the stern bracket: Remove gearcase. Refer to Gearcase GEAR- •...
  • Page 278 MIDSECTION STERN BRACKET Remove the anode. Remove the tilt limit switch and retainer from the swivel bracket. 30762 1. Anode 30758 1. Tilt limit switch Remove the swivel bracket. Inspect and, if neces- 2. Retainer sary, replace the tilt tube bushings. Disconnect the trail lock spring and remove it from the swivel bracket.
  • Page 279 MIDSECTION STERN BRACKET Remove the two trim rod rollers from the swivel Stern Bracket Assembly bracket. Before proceeding, make sure all IMPORTANT: components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evi- dence of deterioration.
  • Page 280 MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in. (25 to 27 N·m).
  • Page 281 MIDSECTION STERN BRACKET Install the steering shaft keeper. Apply Locquic Coat the bushings and seal lips with Triple- • Primer and Nut Lock to the splines of the steering Guard grease. shaft and lower mount bracket. 30765 / 30764 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.
  • Page 282 MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY The overboard indicator and flush port in the EXHAUST RELIEF exhaust relief grommet connect to the adaptor MUFFLER ASSEMBLY housing assembly with a hose. This hose is not connected to the muffler assembly. The exhaust relief muffler is located at the rear of the adaptor housing and concealed by the lower motor covers.
  • Page 283 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............282 GEARCASE TYPES .
  • Page 284 GEARCASE SERVICE CHART SERVICE CHART V6 P “L2”-T ERFORMANCE ODELS EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (3-4 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft. lbs. 26-28 Ft. lbs. (24-27 N·m) 60-84 in.
  • Page 285 GEARCASE SERVICE CHART V6 S “M2”– TANDARD OTATION TYPE EARCASE 60-84 In. lbs. (7-9.5 N·m) 24-36 In. lbs. (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 18-20 Ft.

  • Page 286: Gearcase

    GEARCASE SERVICE CHART V6 C “M2”-T OUNTER OTATION EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 45-50 Ft. lbs. (61-68 N·m) 60-84 in. lbs. 18-20 Ft.
  • Page 287 GEARCASE GEARCASE TYPES GEARCASE TYPES Housing Outboard Model Description of Features Gear Ratio Type high speed profile, external water screens, pressed in 14:26 (.538) 90°V6 20 in. “L2” propeller bearing housing, performance gearset (V6). 90°V6 25 in. .583 ratio is original equipment on 225HO/250/300 HP. 14:24 (.583) 90°V6 20 in.
  • Page 288 GEARCASE PROPELLER SERVICE PROPELLER SERVICE GEARCASE LEAK TEST Drain lubricant before testing. Inspection Carefully examine propeller and outboard for the Install lubricant drain/fill plug and seal, thread following: pressure test gauge fitting and seal in lubricant Damaged blades and signs of propeller cavita- •...
  • Page 289 GEARCASE SHIFT INTERRUPT SWITCH SHIFT INTERRUPT GEARCASE REMOVAL SWITCH AND INSTALLATION The shift interrupt switch is in contact with the shift Gearcase Removal lever (positioned at the base of the powerhead). The switch is normally open and activates WARNING momentarily as the shift linkage moves. To prevent accidental starting while ser- Excessive shift loads activate the switch.
  • Page 290 GEARCASE GEARCASE REMOVAL AND INSTALLATION Remove the forward screw with the washer, and Gearcase Installation remove middle screw. WARNING During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.
  • Page 291 GEARCASE GEARCASE REMOVAL AND INSTALLATION Apply Gel-Seal II to gearcase mating surface pads Apply Gasket Sealing Compound to threads of the on exhaust housing. Slide the gearcase into gearcase retaining screws. Tighten the screws to place, making sure that: a torque of: Driveshaft engages the crankshaft.
  • Page 292 GEARCASE WATER PUMP SERVICE ft. lbs. (47 to 54 N·m). For adjustment, refer to WATER PUMP SERVICE Trim Tab Adjustment on p. 70. Disassembly Rotate the driveshaft counterclockwise to unlock the impeller key. Remove the four impeller hous- ing screws. COA3663 1.
  • Page 293 GEARCASE WATER PUMP SERVICE On outboard models with 1/2 in. diameter water Assembly tube, install the water tube grommet with the Apply a drop of Adhesive 847 in the seal ring inside taper facing up. groove at each of the four ribs. Do not allow any adhesive to get IMPORTANT: into the air bleed groove in the impeller housing.
  • Page 294 GEARCASE WATER PUMP SERVICE Guard grease to the o-rings and reinstall water Apply a thin bead of Adhesive 847 in the seal tube in exhaust housing. groove, and install the special shaped O-ring seal. 007152 34815 1. O-rings 1. O-ring Apply Triple-Guard grease to screw threads and Apply Gasket Sealing Compound to both sides of install the impeller housing cover.
  • Page 295 GEARCASE WATER PUMP SERVICE slide water pump down over key. Be sure impeller On 25 in. and 30 in. outboard models, place the key does not fall out of position. appropriate water tube spacer and grommet on the impeller housing cover. CO2995 1.
  • Page 296 GEARCASE SHIFT ROD ADJUSTMENT The NEUTRAL detent is a two- SHIFT ROD IMPORTANT: step design. Make sure the NEUTRAL detent ball ADJUSTMENT is in the center step before checking shift rod height. Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Shift Rod Heights Rod Height Gauge, P/N 389997.
  • Page 297 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Hydrostatic Seal Grooves — Must be in good GEARCASE – STANDARD ROTATION GEARCASE • condition to help prevent propeller ventilation. DISASSEMBLY Pre-Disassembly Inspection WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).
  • Page 298 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove the propeller shaft bearing housing from Propeller Shaft Bearing Housing the gearcase using: Removal – “L2” and “M2” Type Propeller Shaft Bearing Housing Puller Kit, • P/N 354060. Identify gearcase type before dis- IMPORTANT: assembly.
  • Page 299 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Pull propeller shaft and bearing housing far Pinion Gear and Driveshaft enough to loosen the PRESSED bearing housing Removal from the gearcase housing. Adjust the shift rod to move the clutch dog as far forward as possible.

  • Page 300: Gearcase – Standard Rotation

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove driveshaft from the gearcase. The bear- Locked Driveshaft Removal ing housing, shims, thrust bearing, and thrust The driveshaft to pinion taper is a locking taper. If washer will come out with the driveshaft. necessary, use Driveshaft Puller, P/N 390706, and Backing Plate, P/N 325867, to break the lock.

  • Page 301: Driveshaft Service

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Install the roll pin to the specified dimension. Driveshaft Service To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin. Replace the damaged component. 0.125 in. (3.2 mm) DR4610 1.
  • Page 302 GEARCASE – STANDARD ROTATION GEARCASE HOUSING INSPECTION Remove propeller shaft assembly from gearcase. GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection. Inspect pinion bearing and forward thrust surface of gearcase housing. Use Gearcase Alignment Gauge Kit, P/N 5006349 to check the condition of gearcase housing prior to reassembly.
  • Page 303 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the gear, thrust bearing, and thrust SHIFTER, BEARING AND washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. The shift housing and bearing are IMPORTANT: serviced as an assembly.
  • Page 304 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a shop cloth to catch ball the ball, remove the tool and position detent to and spring. Rotate the shifter detent 90° in either engage NEUTRAL position. direction, then pull the detent out of the housing.
  • Page 305 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Rest the cradle on the shift shaft. Bearing and washer must be IMPORTANT: installed in the correct order. 004512 1. Cradle 006905 1. Thrust bearing 2. Shift shaft 2. Thrust washer Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro- shift cradle.
  • Page 306 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING of the pin, MAKING SURE NONE OF THE COILS Use a 7/8 in. wrench to hold the remover in place. OVERLAP OR ARE LOOSE. Use a 3/4 in. wrench to turn flange nut clockwise. Draw the bearing up from the housing.
  • Page 307 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Apply Needle Bearing grease to the needle bear- Driveshaft Bearing Housing ings and insert them into the bearing case. Service Place the bearing on the installer tool with the let- The driveshaft bearing is not serviceable. Replace tered side of the bearing facing the top of the the bearing housing assembly if the bearing is gearcase.
  • Page 308 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING groove is an oil passage. Gearcase damage could Propeller Shaft Bearing Housing result. Service Rear Seal Removal Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.
  • Page 309 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Inspect the bearing housing anode. Replace Bearing Installation anode if it is reduced to two-thirds of original size. Oil, then install new bearings in bearing housing. Tighten screws to a torque of 108 to 132 in. lbs. (12 to 15 N·m).
  • Page 310 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICING Rear Seal Installation OUNTER OTATION HOUSING Bearing Installation Tool: Apply Gasket Sealing Compound to metal casings P/N 432401 – front bearing • of the seals before installing. P/N 354139 – rear bearing •...
  • Page 311 GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING The original pinion nut may be DRIVESHAFT SHIMMING IMPORTANT: used for shimming, but must NOT be used in final assembly. If new pinion gear is needed, IMPORTANT: replace gear set before shimming. Select collar, P/N 341440, and the correct shim gauge bar: Pinion gear backlash is achieved by using shims “M2”: Shim gauge bar, P/N 349957...
  • Page 312 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Check squareness of the bearing housing mount- GEARCASE ASSEMBLY ing surface by holding the shim gauge bar against the pinion while rotating just the bearing hous- Water Intake Screens ing. Use a feeler gauge to measure clearance Install water intake screens.
  • Page 313 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Shift Rod Cover “L2” T EARCASES Apply Gasket Sealing Compound to both sides of Lubricate a new shift rod cover O-ring with Triple- a new shift rod cover gasket. Place the gasket on Guard grease. Install the O-ring into the shift rod the gearcase.
  • Page 314 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Apply Gasket Sealing Compound to the threads of Using Driveshaft Seal Protector, P/N 318674, the shift rod cover screws. Tighten the screws to a slide the driveshaft bearing housing onto the torque of 60 to 84 in. lbs. (7 to 9.5 N·m). driveshaft and into position in the gearcase.
  • Page 315 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY the driveshaft by hand to thread the nut on to Pad handle of holder to prevent damage to gear- shaft. case. 006923 Apply Gasket Sealing Compound to the threads of 006875 the driveshaft bearing housing screws. Tighten 1.
  • Page 316 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Slide the gear assembly onto the propeller shaft gearcase. Align and level gearcase assembly in until it engages the pinion gear. fixture as shown. Secure fixture to floor press. 006843 006844 1. Thrust bearing and thrust washer Lightly apply Triple Guard Grease to a new bear- Housing must be completely seated in gearcase ing housing O-ring.
  • Page 317 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Place bearing housing in gearcase. Propeller Shaft Bearing Housing and Gear Installation – “M2” Type The propeller shaft bearing hous- IMPORTANT: ing on the “M2” type gearcases is PRESSED into the gearcase housing. Oil and install thrust bearing and thrust washer on hub of reverse gear.
  • Page 318 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY gearcase. Align and level gearcase assembly in Apply Ultra Lock to threads and install two retain- fixture as shown. Secure fixture to floor press. ing screws. Tighten screws to a torque of 18 to 20 ft.
  • Page 319 GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY Install the threaded adaptor from the puller kit on GEARCASE – COUNTER ROTATION GEARCASE to the propeller shaft until seated. DISASSEMBLY Counter rotation (CR) gearcases IMPORTANT: use unique components and require different ser- vice procedures. Use care when working on counter rotation gearcases.
  • Page 320 GEARCASE – COUNTER ROTATION GEARCASE HOUSING INSPECTION Remove propeller shaft, forward gear and bearing shaft assembly. Remove propeller shaft assembly housing assembly from gearcase. from the gearcase. 006850 Pinion Gear Removal and Driveshaft Servicing Refer to Pinion Gear and Driveshaft Removal on p.
  • Page 321 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the gear, thrust bearing, and thrust SHIFTER, BEARING AND washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. The shift housing and bearing are IMPORTANT: serviced as an assembly.

  • Page 322: Gearcase – Counter Rotation

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a shop cloth to catch ball able tool. Once the detent is past the ball, remove and spring. Pull the shifter detent straight out of the tool and position detent to engage NEUTRAL. the housing.
  • Page 323 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Install arms of shift lever into detent slots. Align Coat thrust bearing and thrust washer with Needle the pivot holes and insert the retaining pin. Push Bearing grease. Place the bearing on the back of shifter detent down.
  • Page 324 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Slide the propeller shaft onto the shift shaft, align the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring. Place three coils over each end of the pin, MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE.
  • Page 325 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Push propeller shaft out of the bearing housing. used.) Use depth gauge to measure distance from flange of housing to flat surface as shown. 006939 006855 1. Flange Remove the thrust washer and thrust bearing. Add the appropriate shims to create a dimension of 0.140 in.
  • Page 326 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Coat bearing surfaces of propeller shaft with gear- Use Spanner Wrench, P/N 432400, to tighten the case lubricant. Slide the propeller housing onto gear assembly to a torque of 100 ft. lbs. (136 the propeller shaft.
  • Page 327 GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar: DRIVESHAFT SHIMMING “M” and “M2”: Shim gauge bar, P/N 349957 • If new pinion gear is needed, IMPORTANT: Slide the collar onto the driveshaft with large end replace gear set before shimming.
  • Page 328 GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Check squareness of the bearing housing mount- Remove the driveshaft from the tool and add the ing surface by holding the shim gauge bar against required shims between the bearing housing and the pinion while rotating just the bearing hous- the thrust washer.

  • Page 329: Propeller Shaft Bearing Housing And Gear Installation

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Cover Refer to Shift Rod Cover on p. 311 Water Intake Screens Pinion Gear and Driveshaft Install water intake screens. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Installation Refer to Pinion Gear and Driveshaft Installation on p.
  • Page 330 GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Align retaining holes in bearing housing with Housing must be completely seated in gearcase screw holes in gearcase. Thread Alignment Pins, to install retainer screws. Bearing housing is P/N 354140, into gearcase. approximately level with gearcase. 006926 1.
  • Page 331 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............330 SYSTEM DESCRIPTION .
  • Page 332 TRIM AND TILT SERVICE CHART SERVICE CHART 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 58-87 Ft. lbs. 84-108 In. lbs. (79-118 N·m) (9.5-12 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-70 Ft. lbs. (81-95 N·m) DO NOT OVER TIGHTEN 45-55 In.

  • Page 333: System Description

    TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket and Tilt Support The power trim/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in the tilted position. This bracket The system consists of: protects the hydraulic system from damage.

  • Page 334: Trim And Tilt

    TRIM AND TILT MODES OF OPERATION MODES OF OPERATION The trim/tilt hydraulic assembly achieves trim and tilt movement through the following modes of operation. Trim-OUT / Tilt-UP Mode When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.
  • Page 335 TRIM AND TILT MODES OF OPERATION Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, the trim/tilt motor rotates counterclockwise (as viewed from pump end) and turns the pump gears. Fluid pressure passes through the DOWN shuttle valve to the UP shuttle valve, which mechanically opens the UP check valve.
  • Page 336 TRIM AND TILT MODES OF OPERATION Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is com- pressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact.
  • Page 337 TRIM AND TILT MODES OF OPERATION Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.
  • Page 338 TRIM AND TILT MODES OF OPERATION Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve. Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring. 001988 1.
  • Page 339 TRIM AND TILT MODES OF OPERATION Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylin- ders (in the trim range), and past the manual release valve.

  • Page 340: Routine Inspections

    TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING If the power trim/tilt system has malfunctioned and General the cause has not been determined, the Symp- Check for external signs of fluid leakage. Correct toms Chart on p. 339 should help locate the causes as necessary.

  • Page 341: Service Procedures

    TRIM AND TILT TROUBLESHOOTING If the outboard does not tilt as high as it should, STEP 3 and the tilt motor TURNS OFF at maximum tilt Go to TILT/TRIM RELAY TEST on p. 144 to (does not sound like it is stalled at the maximum determine if problem is power supply.
  • Page 342 TRIM AND TILT TROUBLESHOOTING bypass the reservoir cap. These steps will relieve The “B” adapter, P/N 336659, checks operation • the pressure in the unit. of the DOWN circuit. 41739 27340 1. Manual release valve 1. A Adapter 2. Reservoir cap 2.
  • Page 343 TRIM AND TILT TROUBLESHOOTING all rods must be completely extended to check Remove the manual release valve. Install pres- fluid level. sure gauge and adapter “B” to check problems in the DOWN circuit. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure.
  • Page 344 TRIM AND TILT ELECTRICAL CIRCUIT TESTS Connect a 0 to 100 A DC ammeter in series ELECTRICAL CIRCUIT between the battery side of the starter solenoid TESTS and the red lead to the trim/tilt relay module. Relay Testing When the trim-UP button is pressed, the UP relay is energized and connects the blue trim motor wire to the battery positive (+) terminal.

  • Page 345: Trim And Tilt Motor No Load Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS The motor shaft must rotate clockwise, as viewed B. High current draw – Check for: from the pump end, when positive (+) is applied to Pump binding • the blue lead, and negative (–) is connected to Motor binding •...

  • Page 346: Trim Gauge Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim Gauge Test Trim Sender Test To avoid immediate meter dam- STEP 1 IMPORTANT: age, never apply a multimeter to an electrical cir- Turn key switch ON. Using a voltmeter, check for cuit where voltage is present. voltage between the trim gauge “I”...
  • Page 347 TRIM AND TILT TRIM AND TILT SERVICE Separate the trim/tilt unit wires in the braided tube TRIM AND TILT SERVICE to permit removal through the hole in the stern bracket. Removal Remove lower engine cover and disconnect the trim/tilt connectors. Refer to LOWER COVER SERVICE on p.
  • Page 348 TRIM AND TILT TRIM AND TILT SERVICE Remove the external snap rings from the upper Use a punch to remove the lower pin and remove pin. the trim/tilt unit from the stern brackets. 25064 25076 Use a punch to remove the upper pin. Installation Place trim/tilt unit into position.
  • Page 349 TRIM AND TILT TRIM AND TILT SERVICE Install external snap rings onto upper pin with Attach the ground wire to the trim/tilt unit. sharp edge facing out. 25057 1. Ground wire 25064 Release the tilt support and lower the outboard. Place trim/tilt wires in braided tube and install Tighten the manual release valve to a torque of 45 through hole in the stern bracket.
  • Page 350 TRIM AND TILT TRIM AND TILT SERVICE Screw the manual release valve in. Remove the Disassembly retaining ring using retaining ring pliers. Remove the manual release valve. WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down momentarily and loosen the reservoir cap one full turn.
  • Page 351 TRIM AND TILT TRIM AND TILT SERVICE Remove the three Pozidriv screws securing the Remove the four screws securing motor to pump reservoir to cylinder body. Remove reservoir. manifold assembly. 41753 41760 Remove the reservoir O-ring from the cylinder Remove the wire shield from the pump manifold. body.
  • Page 352 TRIM AND TILT TRIM AND TILT SERVICE solvent and inspect it for tears, clogging, or other Remove the manifold. Remove five O-rings from damage. cylinder body. Check machined surfaces for nicks and scratches. 41763 1. Coupler 2. Filter screen 41799 Remove the three Allen head screws securing the Tilt Piston Removal pump manifold assembly to cylinder body.
  • Page 353 TRIM AND TILT TRIM AND TILT SERVICE Slowly pull the piston out with a rag wrapped Remove the washer. Slide the tilt piston off the around the rod and the top of the cylinder. Drain rod. Be careful not to lose the springs, plungers, the remaining fluid from the cylinder.
  • Page 354 TRIM AND TILT TRIM AND TILT SERVICE Two of the piston relief holes are small, the other Use a screwdriver to carefully pry the scraper out two holes are larger. Two of the springs have five of the end cap. Discard the scraper. Remove and coils and the other two have nine coils.
  • Page 355 TRIM AND TILT TRIM AND TILT SERVICE Use a wire brush to clean all thread-locking mate- Clean any thread-locking material from the rial from the threads on the tilt rod. threads on the inside of the nut. Spray threads of with Locquic Primer and let dry.
  • Page 356 TRIM AND TILT TRIM AND TILT SERVICE Drain the remaining fluid from the cylinders. Trim Rod Removal Inspect both bores of the trim cylinders for exces- Unscrew trim cylinder end caps using Trim Cylin- sive scoring. If one or both trim bores are scored der End Cap Remover/Installer, P/N 436710, or or damaged, the hydraulic assembly must be Universal Spanner Wrench, P/N 912084, and a...
  • Page 357 TRIM AND TILT TRIM AND TILT SERVICE Remove the rod from the vise. Use a small screw- Lubricate and install a new O-ring and two new driver to carefully pry the scraper out of the end back-up rings on the trim rod piston. Place one cap.
  • Page 358 TRIM AND TILT TRIM AND TILT SERVICE removed later for the Pressure Leakdown Test Manifold and Reservoir on p. 339. Installation Lubricate five new manifold body O-rings. Place them in the cylinder body. 41851 Install the reservoir filter screen in the cylinder body.
  • Page 359 TRIM AND TILT TRIM AND TILT SERVICE Attach the reservoir to the cylinder body with three P/N 912084. Tighten caps to a torque of 60 to 70 Pozidriv screws. Tighten the screws to a torque of ft. lbs. (81 to 95 N·m). 35 to 52 in.
  • Page 360 TRIM AND TILT TRIM AND TILT SERVICE P/N 912084. Tighten cap to a torque of 58 to 87 ft. Install the filter screen. lbs. (79 to 118 N·m). 41856 1. Filter screen 41870 Lubricate and place a new O-ring on the motor. Make sure the cable is on the transom side of the Motor Installation unit;...
  • Page 361 TRIM AND TILT ADJUSTMENTS Fill the reservoir to the bottom of the fill hole with Check the tilt rod bushings. Replace them if they Power Trim/Tilt & Steering Fluid. Install and are worn excessively. tighten the reservoir cap. Turn the manual release valve in until it seats.
  • Page 362 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 363 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 364 S–2...
  • Page 365 SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.

  • Page 366: Outboard Shift Systems And Safety

    SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...

  • Page 367: Outboard Speed Control System And Safety

    SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...

  • Page 368: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: Must not come apart; • Must not jam; and •...
  • Page 369 SAFETY How can loss of steering control be minimized? Use a steering system recommended by the outboard manufacturer which meets • Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions • When Follow warnings marked “ ” closely. •...
  • Page 370 SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? Fuel leakage must be eliminated.
  • Page 371 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads •...
  • Page 372 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard Check for leaks GASOLINE under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 373: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: outboard parts • bolts, nuts, and washers • boat’s transom • What is most important? Outboard must stay in position on boat’s transom. • What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
  • Page 374 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.
  • Page 375 SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? Shock absorption system must always be ready to absorb • some blows to the lower parts of the outboard. Outboard must not trim in too far suddenly. •...

  • Page 376: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled •...
  • Page 377 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.
  • Page 378 SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...

  • Page 379: Handling Outboards

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: Rigging boats •...
  • Page 380 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
  • Page 381 SAFETY Running outboard too fast (Overspeeding) “Too fast” means running faster than outboard normally runs on boat. • Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 382 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.
  • Page 383 SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.
  • Page 384 SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...

  • Page 385: Hazardous Products

    SAFETY Hazardous Products Know how items in the shop can hurt people... READ “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an • emergency arise “How to dispose of can” •...

  • Page 386: Safety Awareness Test

    SAFETY Safety Awareness Test The Technician’s Safety Awareness Test..1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations...
  • Page 387 INDEX INDEX Batteries n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Battery Charge Isolator 32 Abbreviations 6 Battery Switches 30...
  • Page 388 INDEX Control Cable Cylinder Head Adjustments 53, 54 Inspection 230 Identification 44 Installation 236 Installation 53 Removal 225 Routing 29, 40 Cooling System n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Components 209 Dash Connections 129 Cylinder Block Venting 210...
  • Page 389 INDEX Exhaust Housing n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Assembly 269, 272 Electrical Circuits Cleaning and Inspection 269...
  • Page 390 INDEX Fuse 132 Intake Manifold Assembly 186 Disassembly 185 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Inspection 185 Gauges CANbus 56...
  • Page 391 INDEX Piston Rings n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n End Gap 236 Neutral Start Switch Inspection 231...
  • Page 392 INDEX Shift Housing, Counter Rotation n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Disassembly 319 Relays Removal 318...
  • Page 393 INDEX Swivel Bracket Tilt Piston Installation 279 Assembly 352 Lubrication 78 Identification 351 Removal 276 Removal 350 SystemCheck Tilt Rod Circuits 144, 145 Assembly 352 Dash Connections 129 Installation 357 Gauges 28, 101 Tilt Support 331 Oil System Warnings 197 Tilt Tube Operation Check 64 Installation 265...
  • Page 394 INDEX Gearcase Alignment Gauge Kit, P/N Taper Pin Tool 220 5006349 300 Temperature Gun, P/N 772018 213 Gearcase Alignment Kit, P/N 5007231 289 Terminal Release Tool, P/N 351413 162 Gearcase Fixture, P/N 354059 314, 315, Test Propeller 10, 12 Thermal Joint Compound, P/N 322170 213 Guide Rods, P/N 383175 234 Tilt Cylinder End Cap Remover/Installer, P/ Hydraulic Cylinder Rod Holder, P/N...
  • Page 395 INDEX Trim and Tilt Motor n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Current Draw Tests 342 Upper Mount Installation 358...

  • Page 397: Trouble Check Chart

    TROUBLE CHECK CHART OUTBOARD WILL NOT START TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Battery switch not ON Check battery switch operation Discharged battery Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit.
  • Page 398 TROUBLE CHECK CHART OUTBOARD WILL NOT START OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Check wiring and emergency stop switch. Check Stop circuit grounded the safety lanyard is installed and stop circuit is not grounded. No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return Water in fuel manifold.
  • Page 399 TROUBLE CHECK CHART OUTBOARD HARD TO START OUTBOARD HARD TO START OBSERVATION POSSIBLE CAUSE PROCEDURE Weak battery Check battery, recharge or replace Clean and tighten connections, check voltage Battery cables and connections drop on high amperage circuit Starter or bendix/drive gears Check starter, inspect bendix/drive gears Check water separator/fuel filter, sample fuel from Water in fuel system...
  • Page 400 TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OBSERVATION POSSIBLE CAUSE PROCEDURE Check key switch and ground to key switch, refer Key switch or wire harness to SYSTEM ANALYSIS and ELECTRICAL AND ground IGNITION Outboard starts and Check EMM LED indicators.
  • Page 401 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM service codes and check System- SystemCheck light Outboard is in S.A.F.E. Check warning Refer to specifications, check recommended WOT Incorrect propeller RPM;...
  • Page 402 TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSERVATION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F.E. Access EMM fault codes Incorrect, fouled, or worn spark Replace spark plugs plugs Check water separator/fuel filter, sample fuel from Water in fuel system fuel return manifold test port Contaminated or poor fuel...
  • Page 403 MWS Instrument Wiring Harness DRC6165R...
  • Page 404 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
  • Page 406 CANbus Keyswitch/TNT Wiring Harness A. Trim down B. Trim up C. Trim sender 47 ohm 1/4 watt resistor 5. Battery + (12V) 1. Stop circuit 2. Start solenoid 3. Ground (B-) 6. Choke 4. Switched B+ (12V) Switched B+ (12V) 10 Amp Fused B+ (12V) Ground (B-)
  • Page 407 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH WATER PRES. FUEL VOLTMETER TRIM/TILT FUEL TANK SENDER WARNING HORN TO OUTBOARD DRC6278R...
  • Page 408 Evinrude E-TEC EMM LED Diagnostic Indicators V Models In-line Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS in the Service Manual. KEY ON : LED’s illuminate to indicate circuit function Start assist circuit (SAC) OK (V models only) Sensors / 5V Circuits OK FLASHING LED –...
  • Page 409 FUSE 90°V6 / 200-300HP E-TEC 1 2 3 1 2 3 4 5 1 2 3 4 5 J1-A 1. Oil Injector 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor J1-B 5. Crankshaft Position Sensor 6. Stator 7.
  • Page 410 EVINRUDE 115 – 300 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied. 1-6 Excessive knock detected LED 3: ON (Running) CHECK ENGINE...
  • Page 411 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY 2nd digit indicates affected cylinder. 51-6 Fuel injector circuit OPEN LED 2: ON (Running) 10 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C). CHECK ENGINE TPS <...

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