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: ® Twist Grip™...
Page 4: Table Of Contents
ERVICE ANUAL ONTENTS SECTION ........PAGE 1 REFERENCE INFORMATION .
Page 5 REFERENCE INFORMATION REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE ..............4 ABBREVIATIONS USED IN THIS MANUAL .
Page 6: Safety Notice
SAFETY NOTICE Before working on any part of the outboard, read the SAFETY section at the end of this manual. This publication is written for qualified, factory- DO NOT perform any work until you have read trained technicians who are already familiar with and understood these instructions completely.
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: Abbreviations Used In This Manual
REFERENCE INFORMATION 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.
Page 9: Emission-Related Installation Instructions
REFERENCE INFORMATION EMISSION-RELATED INSTALLATION INSTRUCTIONS EMISSION-RELATED Owner’s Responsibility The owner/operator is required to have outboard INSTALLATION maintenance performed to maintain emission lev- els within prescribed certification standards. INSTRUCTIONS The owner/operator is not to, and should not allow Failing to follow these instructions when anyone to, modify the outboard in any manner installing a certified engine in a vessel violates that would alter the horsepower or allow emis-...
Page 10: Model Designation
REFERENCE INFORMATION MODEL DESIGNATION MODEL DESIGNATION STYLE: LENGTH: = 15” Std. J = Johnson E = Evinrude L = 20” Long Y = 22.5” Special MODEL RUN X = 25” X-long HORSEPOWER or SUFFIX Z = 30” XX-long E 200 DP X II MODEL YR: PREFIX: DESIGN FEATURES:...
Page 11: Models Covered In This Manual
REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 35.1 cubic inch (.57 L), 2-Cylinder Evinrude E-TEC mod- els. Description Model Displacement Gearcase Height Color E15DHPLII_ .57 L, 35.1 ci 13:28 / 0.46 H 20"...
Page 12: Service Specifications
REFERENCE INFORMATION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS 15 HO Models 25 – 30 HP Models Full Throttle 25 HP – 5500 to 6100 RPM 15 HP – 5500 to 6100 RPM Operating Range RPM 30 HP – 5500 to 6100 RPM 25 HP (30 kw) @ 5800 RPM Power 15 HP (11.2 kw) @ 5800 RPM...
Page 13 REFERENCE INFORMATION SERVICE SPECIFICATIONS 15 HO Models 25 – 30 HP Models Minimum Battery 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Requirements 15-Amp fully regulated Refer to Predelivery and Installation Guide for multiple battery Alternator applications.
Page 14: Standard Torque Specifications
REFERENCE INFORMATION 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 15: Routine Service
ROUTINE SERVICE ROUTINE SERVICE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 14 LIFTING THE OUTBOARD .
Page 16: Inspection And Maintenance Schedule
ROUTINE SERVICE 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. IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre- quent inspections and maintenance.
Page 17: Lifting The Outboard
ROUTINE SERVICE LIFTING THE OUTBOARD LIFTING THE Use an appropriate chain, at least 36 inches (91 mm) long with two snap hooks, each capable of OUTBOARD lifting 500 lbs. (227 kg). Attach hooks to lifting device and attach chain to WARNING hoist.
Page 18 ROUTINE SERVICE LIFTING THE OUTBOARD Lower outboard onto the pad. Use hoist to care- fully roll the outboard onto its port side. CAUTION To avoid damage to the outboard, DO NOT allow the outboard to fall unrestrained. 1. Lift eye 007212 Carefully lift engine with hoist.
Page 19: Outboard Rigging Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS OUTBOARD RIGGING Cable Retainer Clip Installation When installing retainer clips on control arm link- CONNECTIONS age pins, clips should be locked and must not be bent or deformed. IMPORTANT: For complete outboard rigging For proper installation, review the following steps: and remote control installation information, refer to •...
Page 20: Control Cable Installation
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable, Hose, and Wire Routing When grommet is in place and all cables have been installed, tighten a tie strap around the out- side of the grommet to form a watertight seal CAUTION around the cables. To prevent accidental starting while servic- Place blank sealing decal on lip of lower motor ing, disconnect the battery cables at the...
Page 21 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Adjust the shift cable trunnion to align with the adjust the trunnion nut so the casing fits onto the center of the trunnion block. throttle lever pin. 1. Shift linkage 007215 1. Throttle cable trunnion 007217 2.
Page 22: Systemcheck Harness Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS SystemCheck Harness Route trim and tilt connector under air silencer. Use tie strap to secure connector as shown. Connections Before installing electrical connectors, check that the seal is in place. Clean off any dirt from con- nectors.
Page 23: Battery And Battery Connections
ROUTINE SERVICE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from CONNECTIONS accessories. Finish this connection with a hex nut. WARNING Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion.
Page 24: Oetiker Clamp Servicing
ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide corrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
Page 25 ROUTINE SERVICE OETIKER CLAMP SERVICING 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 26: Adjustments
ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS • To STARBOARD decrease friction. Steering Friction Adjustment WARNING Steering friction device is not intended to hold boat on a set course. DO NOT overtighten steering friction for “hands-off” steering. Reduced steering control of the boat could result in loss of control by the operator, creating a risk of personal injury or property damage.
Page 27: Tiller Height Adjustment
ROUTINE SERVICE ADJUSTMENTS Tiller Height Adjustment Tiller Handle Friction The angle of the tiller handle can be raised or low- The tiller handle screw may be tightened to adjust ered by adjusting a thumbscrew under the handle. the amount of friction when tilting the tiller handle. 1.
Page 28: Trim Sending Unit Adjustment
ROUTINE SERVICE ADJUSTMENTS Shift the engine from NEUTRAL to FORWARD gauge mark with the outboard trimmed all the way gear. The Neutral/In Gear indicator must indicate DOWN. “In Gear.” Shift the engine from FORWARD gear to NEU- TRAL. The Neutral/In Gear indicator must indicate “Neutral.”...
Page 29: Trim Tab Adjustment
ROUTINE SERVICE ADJUSTMENTS • Tighten the trim tab screw as follows: If the needle was below the lowest mark, move the thick part of the cam AWAY from the contact • 15 – 30 HP: 60 to 80 in. lbs. (7 to 9 N·m). point.
Page 30: Operational Checks
ROUTINE SERVICE OPERATIONAL CHECKS OPERATIONAL CHECKS Emergency Stop / Key Switch Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emer- DANGER gency stop switch. Outboard must stop immedi- DO NOT run the engine indoors or without ately.
Page 31: Cooling System
ROUTINE SERVICE COOLING SYSTEM COOLING SYSTEM Water Pump Overboard Indicator A steady stream of water should flow from the Check the condition of cooling system compo- overboard indicator. nents regularly: • water intake screens • water pump • all internal water passages •...
Page 32: Engine Flushing
ROUTINE SERVICE COOLING SYSTEM Engine Flushing Turn water supply on. Flush the outboard with fresh water following each Run outboard at IDLE only until full operating tem- use in brackish, salt, or polluted water to minimize perature is reached. the accumulation of scale and silt deposits in cool- Leave the outboard in VERTICAL (DOWN) posi- ing system passages.
Page 33: Running The Outboard Using A Hose And Flushing Adapter
ROUTINE SERVICE COOLING SYSTEM Running the Outboard Using a to the powerhead. Water can drain from auxil- iary inlets, resulting in engine overheat. Hose and Flushing Adapter WARNING To prevent injury from contact with rotat- ing propeller, remove the propeller before running engine with a flushing adapter.
Page 34: Lubrication
ROUTINE SERVICE 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.
Page 35: Throttle And Shift Linkage
ROUTINE SERVICE 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 clips and washers from throttle and shift potential gearcase damage. lever pins.
Page 36: Gearcase Lubricant
ROUTINE SERVICE LUBRICATION Gearcase Lubricant Inspection Inspect the lube and the magnets on the plugs for Draining metal chips. The presence of metal fuzz can indi- cate normal wear of the gears, bearings, or shafts WARNING within the gearcase. Metal chips can indicate Gearcase lubricant may be under pressure extensive internal damage.
Page 37: Trim And Tilt
ROUTINE SERVICE LUBRICATION and new seal. Tighten plugs to a torque of 60 to • Remove filler cap and check fluid level. 84 in. lbs. (7 to 9.5 N·m). • Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads.
Page 38: Spark Plugs
ROUTINE SERVICE SPARK PLUGS SPARK PLUGS plug with the OPEN side of the ground electrode facing the fuel injector. Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs. Use only recommended spark plugs with the cor- rect gap setting.
Page 39: Fuel And Oil Systems
ROUTINE SERVICE FUEL AND OIL SYSTEMS FUEL AND OIL SYSTEMS Air Silencer The air silencer maximizes air flow while minimiz- Routine replacement of filters reduces the possi- ing noise. bility of foreign material restricting the incoming fuel or oil supplies. Replacement filter elements are available through Evinrude/Johnson Genuine Parts.
Page 40: Anti-Corrosion Protection
ROUTINE SERVICE 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 41: Storage
ROUTINE SERVICE STORAGE STORAGE Software Control Method Winterization can also be run using Evinrude Diagnostics software. With the outboard running, IMPORTANT: DO NOT start outboard without a start the process at the Settings/Adjustments water supply to the outboard’s cooling system. screen and follow the instructions.
Page 42: Additional Recommendations
ROUTINE SERVICE PRE-SEASON SERVICE Additional Recommendations PRE-SEASON SERVICE • Fill 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 43: Submerged Engines
ROUTINE SERVICE SUBMERGED ENGINES SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL SYSTEM PRIMING on p. 125 and.Oil Supply Priming on p. 150 Make sure all oil injection Once an outboard has been submerged in fresh hoses are clean and filled with oil. or salt water, it must be serviced within three (3) hours of recovery.
Page 44 ROUTINE SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 45: Engine Cover Service
ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 44 .
Page 46: Upper Cover Service
ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Front Insert bracket into pocket. Latch Hook Installation Rear Insert threaded bracket into pocket. 1. Bracket 007306 Apply Ultra-Lock to screw threads. Place hook into position with opening toward the back. Tighten screws securely.
Page 47: Lower Cover Service
ENGINE COVER SERVICE LOWER COVER SERVICE LOWER COVER SERVICE Lower Cover Installation Installation of lower motor covers will be easier if Lower Cover Removal the following steps are performed in order: • Install air silencer on throttle body. Remove cable entry cover screws, cover and cable entry grommets.
Page 48 ENGINE COVER SERVICE LOWER COVER SERVICE Start the bottom front screw next to draw cover Install remaining cover screws and tighten all halves together. screws to 24 to 36 in. lbs. (3 to 4 N·m). 1. Start this screw second 007312 Install the front latch sleeve and start the top front screw next to draw cover halves together.
Page 49: Latch Handle Installation
ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Apply Ultra-Lock to screw threads. Place spring washer and hook into position and tighten screw Apply a light coat of Triple-Guard grease to latch to a torque of 180 in. lbs. (20 N·m). handle shaft.
Page 50 ENGINE COVER SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 51: Engine Management Module (Emm)
ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............50 .
Page 52: Description
ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION DESCRIPTION The Engine Management Module (EMM) is a water-cooled engine controller. It controls many outboard systems including alternator output for the 55 V circuits. Operating voltage is supplied to the EMM by the stator. This section discusses the functions of the EMM and its various internal and external sensors.
Page 53: Emm Inputs And Outputs Diagram
ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM 1 2 3 1 2 3 3 2 1 007383 1. Engine Management Module (EMM) 7. Air Temperature Sensor (AT) 13. Oil Injection Pump and Manifold 2.
Page 54: Internal Sensors
ENGINE MANAGEMENT MODULE (EMM) INTERNAL SENSORS INTERNAL SENSORS If sensor reads less than -71°F (-57.4°C) or greater than 313°F (156°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 55: Circuit Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS EXTERNAL SENSORS 5 V Circuit Sensor Monitors the EMM’s 5 V sensor circuit. Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude If sensor voltage is less than 4.75 volts, the EMM: Diagnostics software to troubleshoot the sensors.
Page 56: Engine Temperature Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Engine Temperature Sensor Low Oil Switch Monitors cylinder head temperature. The low oil switch monitors the oil level in the oil tank. If cylinder head temperature exceeds 212° F (100° C) below 3500 RPM, the EMM: If the oil level falls below one-quarter capacity, the EMM begins counting oil pump pulse cycles.
Page 57: Throttle Position Sensor
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS Throttle Position Sensor Crankshaft Position Sensor The throttle position sensor receives a voltage sig- Ribs spaced on the flywheel mark crankshaft posi- nal from the EMM. As the throttle lever is rotated, tion. As the ribs pass the magnetic field of the the EMM receives a return voltage signal through CPS, an AC voltage signal is generated.
Page 58: Internal Emm Functions
ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM ENGINE MONITOR FUNCTIONS SYSTEM ROM Verification An optional engine monitoring system warns the operator of conditions that could damage the out- The EMM performs a self-test of programming board. The system includes a LOW OIL switch on every time it is turned ON.
Page 59: Warning System
ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM S.A.F.E. WARNING System Self-Test During engine start-up, pause with the key switch SYSTEM in the ON position. The horn self-tests by sound- ing a half-second beep. SystemCheck gauges The S.A.F.E. (Speed Adjusting Failsafe Electron- self-test by turning the indicator lights on simulta- ics) warning system alerts the operator and pro- neously, then off in sequence.
Page 60: Shutdown Mode
ENGINE MANAGEMENT MODULE (EMM) SHUTDOWN MODE SHUTDOWN MODE DIAGNOSTIC SOFTWARE FUNCTIONS Outboard “shutdown” will occur if specific faults are detected by the EMM: The EMM stores valuable information about the Code 29 Excessive EMM temperature outboard and its running history. This information Code 31 Excessive engine temperature can be used for troubleshooting, for checking Code 33 Excessive NO OIL condition...
Page 61: Static Information
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Static Information TART ODELS Diagnostic communications on non-running rope Static information is viewed when the outboard is start models requires that power is supplied to the NOT running. This includes manufacturing infor- EMM. mation.
Page 62: Dynamic Information
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 63: Dynamic Tests
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. 75. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.
Page 64: Oil Control Settings
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Oil Control Settings Powerhead Break-In Use the diagnostics software to start break-in oil- Set Oil Type ing after a powerhead rebuild. The break-in oiling The TC-W3 oil type setting is the standard setting program runs for two hours of outboard operation, for all outboards.
Page 65: 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 66: Fuel Injector Servicing
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 67: Software Replacement
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Software Replacement IMPORTANT: Software replacement requires a 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 68: Emm Servicing
ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING Installation Installation is the reverse of removal. Pay close IMPORTANT: attention when performing the following tasks. If a new EMM is being installed, refer to EMM Transfer on p. 65. Make sure isolator mount is in place on recoil starter housing.
Page 69: System Analysis
SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............68 .
Page 70: Diagnostic Procedures
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC Operational Inspections Run the outboard to confirm actual symptoms PROCEDURES before performing any unnecessary procedures. Inspection should include the following: Visual Inspections • Make sure the outboard can be cranked easily, Inspect wiring and electrical connections. Disas- with no mechanical binding.
Page 71: Troubleshooting
SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES Troubleshooting • Use the diagnostics software Dynamic Tests to isolate a faulty cylinder. See DYNAMIC TESTS Outboard will not crank, starter does not on p. 70. operate: • Use an inductive timing light to check ignition •...
Page 72: Dynamic Tests
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 73: Emm Led Indicators
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 74: Running
SYSTEM ANALYSIS EMM LED INDICATORS Running LED 3 – Sensor circuits (5 V), SENSOR FAULT. For LIGHT ON, check for possible fault codes: When the outboard is running, all of the LEDs • Code 12 – TPS circuit fault should be off. If a light is on, check for: •...
Page 75: Ignition Output Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS IGNITION OUTPUT Crankshaft Position Sensor • Provides EMM with input. TESTS • Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated. DANGER Alternator Output/System Voltage • System voltage from EMM (white/red) provides The electrical system presents a serious 55 VDC to the high pressure fuel pump, the oil shock hazard.
Page 76: Crankshaft Position Sensor (Cps) Test
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 77: Static Ignition Test
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Static Ignition Test IMPORTANT: This test is operating the ignition coil with 12 V battery power on the system voltage Perform the static ignition test using Evinrude (55 V) circuit. An inductive probe with low sensitiv- Diagnostics software and an inductive timing light.
Page 78: 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. 78 •...
Page 79: Ignition Control Circuit Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Control Circuit Tests Harness resistance test: If control signal is NOT present, calibrate multime- Use a digital multimeter to test the following: ter to low ohms scale. Use appropriate adapters • System voltage supply to ignition coil. on meter leads to avoid damaging harness con- •...
Page 80: Fuel Delivery Tests
SYSTEM ANALYSIS FUEL DELIVERY TESTS FUEL DELIVERY TESTS Voltage should be 55 V when the outboard is cranking or running. • The EMM controls the fuel pump ground (brown WARNING wire). Use an ohmmeter to check continuity between pin 2 of fuel pump connector and Protect against hazardous fuel spray.
Page 81: Running Fuel System Tests
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- • Check stator input to EMM, CPS operation, and ware to make sure voltage is present on the system voltage circuit.
Page 82 SYSTEM ANALYSIS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 83: Electrical And Ignition
ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............82 IGNITION SYSTEM CIRCUIT DIAGRAM .
Page 84: Service Chart
ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 66 to 70 ft. lbs. (90 to 95 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 31 to 48 in. lbs. (3.5 to 5.5 N·m) 84 to 106 in. lbs. (9.5 to 12 N·m) 60 to 84 in.
Page 85 ELECTRICAL AND IGNITION SERVICE CHART Tighten until screw 50 to 70 in. lbs. head is seated (5.6 to 7.9 N·m) 12 to 19 ft. lbs. (16.3 to 25.8 N·m) 31 to 48 in. lbs. 10 to 12 ft. lbs. (3.5 to 5.5 N·m) (14.5 to 16.5 N·m) 60 to 84 in.
Page 86: Ignition System Circuit Diagram
ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM IGNITION SYSTEM CIRCUIT DIAGRAM 008357 Key switch (stop circuit) Stator Ignition coil Tiller handle stop switch Main harness ground Powerhead neutral switch Crankshaft position sensor...
Page 87: Electrical Harness Connections
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 88: Ground Circuits
ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS FUSE All ground circuits are essential to reliable out- The engine harness 12 V (B+) circuit is protected board performance. Make sure all ground connec- by one automotive style 10 amp minifuse. tions are clean and tight. Refer to wiring diagrams The fuse is located on the top of the recoil starter for specific wiring details.
Page 89: Sensor Tests
ELECTRICAL AND IGNITION SENSOR TESTS SENSOR TESTS (1.37 mm). The acceptable clearance is 0.018 to 0.091 in. (0.45 to 2.38 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 90: Engine Temperature Sensor Test
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 91: Stator Tests
ELECTRICAL AND IGNITION STATOR TESTS STATOR TESTS To check for a grounded winding, connect one meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The stator consists of 2 windings (6 poles each) read no continuity.
Page 92 ELECTRICAL AND IGNITION STATOR TESTS Connect meter leads to terminals of adaptor tool. TART ODELS Use a Peak Reading Voltmeter, P/N 507972, to Rotate the flywheel with the starter rope, using a check stator output voltage. Set meter to the long, steady pull.
Page 93: Charging System Tests
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS Charging System Circuit Diagram FUSE 007351 1. Marine battery 6. Key switch connector 2. RED wire (POS) 7. Fuse (10 amp) 3. BLACK wire (NEG) 8. Stator 4. Starter solenoid 9. EMM 5.
Page 94 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS 12 V Charging Circuit Following the manufacturer’s directions, connect the variable load tester (carbon pile) across the To test the operation of the regulator in the battery battery terminals. Stevens model LB-85 and charge module, you must be able to run the out- Snap-On model MT540D are examples of testers board continuously at approximately 5000 RPM, available.
Page 95 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Start and run the outboard at approximately 5000 RPM. Use the variable load tester to draw the bat- tery down at a rate equivalent to the stator’s full output. • The ammeter should indicate nearly full output, approximately 15 A @ 5000 RPM.
Page 96: Electric Start Circuit
ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 –...
Page 97 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 300 RPM minal “B”.
Page 98: Electric Start Tests
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- •...
Page 99 ELECTRICAL AND IGNITION ELECTRIC START TESTS Starter Voltage Drop Test • Observe voltage reading. STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to To prevent accidental starting of outboard, starter motor terminal. disconnect crankshaft position sensor •...
Page 100: Remote Control Switch Tests
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 101: Neutral Start Switch Test
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 102: Tilt/Trim Relay Test
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 103: Systemcheck Circuit Tests
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS SystemCheck CIRCUIT instrument harness terminal 1 (purple wire) and terminal 2 (black wire). TESTS Evinrude E-TEC 15–30 hp models only provide warning for a “LOW OIL” condition. Check the condition of the warning system and associated wiring and connections.
Page 104 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck LOW OIL Circuit Test gauge. Turn the key switch ON. Using a jumper wire, con- nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW OIL light should turn on after 40 seconds.
Page 105: Tachometer Circuit Tests
ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT FLYWHEEL AND STATOR TESTS SERVICING Check voltage at the battery. Use this reading as a IMPORTANT: Weak flywheel magnets reference for battery voltage. cause low alternator output and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as a peak-reading voltmeter, which might cause unnecessary parts replacement.
Page 106: Stator Service
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywheel Holder, P/N 771311, or equivalent, Stator Service and a 28 mm socket to remove flywheel nut. Disconnect stator harness connector. Remove three allen head screws to remove stator. 007359 Apply Moly Lube grease to the threads of the 1.
Page 107: Ignition Coil Servicing
ELECTRICAL AND IGNITION IGNITION COIL SERVICING IGNITION COIL Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry. ™ SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis- connect ignition coil electrical connector. Remove two ignition coil retaining screws.
Page 108: Timing Adjustments
ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TIMING ADJUSTMENTS TPS Calibration Use Evinrude Diagnostics software to tell the Timing Pointer EMM what throttle position sensor voltage is when the throttle plates begin to open. The timing pointer on Evinrude E-TEC 15 – 30 HP models is not adjustable.
Page 109: Electric Starter Servicing
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Starter Disassembly Remove the retaining nut, spacers, spring and SERVICING starter pinion from pinion shaft. Starter Removal IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead.
Page 110: Starter Cleaning And Inspection
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove brush holder cap from armature and Clean the commutator with 300-grade emery frame assembly. Do not lose the brush springs. cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove any trace of oil or metal dust from commutator.
Page 111: Starter Assembly
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING If the pinion does not properly engage the fly- Compress the brushes and springs with a modi- wheel, the pinion and screw shaft assembly could fied putty knife. be worn, distorted, or dirty. Locate the cause of binding and correct it before completing the assembly.
Page 112 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Apply Locquic Primer and Screw Lock to the Install pinion, spacer and spring. threaded portion, and install the two thru-bolts. Tighten bolts to a torque of 100 to 110 in. lbs. (11 to 12.5 N·m). 007440 Install spacer and retaining nut.
Page 113: Starter Installation
ELECTRICAL AND IGNITION CONNECTOR SERVICING CONNECTOR Starter Installation Apply Triple-Guard grease to the threads of the SERVICING three starter screws and also to the washers. DEUTSCH Connectors Position the starter and install the screws and washers. Tighten screws to a torque of 168 to 192 IMPORTANT: Electrical Grease...
Page 114 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors Release terminal latch and gently pull on wire. IMPORTANT: Always use the appropriate meter test probes and adapters when testing compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. UPERSEAL Disconnect 1.
Page 115 ELECTRICAL AND IGNITION CONNECTOR SERVICING UPER The J1-A connector of the EMM is an AMP Super Seal connectors. Disconnect Depress BOTH latches and pull connector from plug. Connect Push connector into plug until latches engage. 1. Locking tab, plug 002447 2.
Page 116 ELECTRICAL AND IGNITION CONNECTOR SERVICING Packard Connectors Insert a thin tool into the connector above the ter- minal to release tab. IMPORTANT: Always use the appropriate meter test probes and adapters when testing compo- nents fitted with these terminals. Disconnect Lift latch(s).
Page 117: Fuel System
FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............116 FUEL SYSTEM HOSE ROUTING .
Page 118: Service Chart
FUEL SYSTEM SERVICE CHART SERVICE CHART NJECTORS APOR EPARATOR Tighten in 4 stages 4.5 ft. lbs. (6 N·m) 9 ft. lbs. (12.2 N·m) 14 ft. lbs. (19 N·m) 22 to 23.5 ft. lbs. (30 to 32 N·m) 31 to 48 in. lbs. (3.5 to 5.5 N·m) 84 to 106 in.
Page 119 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE 84 to 106 in. lbs. (9.5 to 12 N·m) 35 to 60 in. lbs. (4.0 to 6.8 N·m) Important: DO NOT lubricate TPS to throttle shaft surface 35 to 60 in. lbs. (4 to 6.8 N·m) 16 to 17 in.
Page 120: Fuel System Hose Routing
FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING Fuel Supply Fuel Supply Fuel Supply Fuel Supply (Internal Passage) (Internal Passage) Fuel Return Fuel Return (Internal Passage) (Internal Passage) 007408 Fuel fitting on outboard Fuel supply from boat fuel system Fuel lift pump (2 to 8 psi) Pulse hose from cylinder/crankcase Fuel supply to vapor separator...
Page 121: Fuel System Circuit Diagram
FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM 008046 Stator Fuel circulation pump BLUE WHITE/RED (55 V) GREEN Fuel injector BLACK ground wires BROWN...
Page 122: Fuel System Requirements
FUEL SYSTEM FUEL SYSTEM REQUIREMENTS FUEL SYSTEM Portable Fuel Tanks REQUIREMENTS WARNING If engine is equipped with a quick-discon- Regulations and Guidelines nect fuel hose, you MUST disconnect the Vessel manufacturer, and/or installer of an EPA fuel hose from the engine and the fuel tank certified outboard, must meet minimum specifica- to prevent fuel leaks: tions for boat fuel systems established by:...
Page 123: Fuel Requirements
FUEL SYSTEM FUEL SYSTEM REQUIREMENTS Fuel Requirements When using alcohol-extended fuels, be aware of the following: • The boat’s fuel system may have different WARNING requirements regarding the use of alcohol fuels. Gasoline is extremely flammable and Refer to the boat’s owner guide. highly explosive under certain conditions.
Page 124: Components
FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The fuel system includes the following compo- high-pressure components of the fuel system from nents: contaminants. Refer to INSPECTION AND MAIN- • Fuel Lift Pump TENANCE SCHEDULE on p.
Page 125: Fuel Circulation Pump
FUEL SYSTEM COMPONENTS Fuel Reservoir to flow to the intake manifold through the vent 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 126: Fuel Manifold
FUEL SYSTEM COMPONENTS Fuel Manifold Each service injector includes its fuel flow infor- mation on a 3.5 in. floppy disk. This software The vapor separator uses molded internal pas- allows the EMM to be reprogrammed for this injec- sages to route fuel directly to and from the injec- tor’s unique fuel flow characteristics.
Page 127: Fuel System Priming
FUEL SYSTEM FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System Vent Line Clamp WARNING Federal Regulations require that all outboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp installed.
Page 128: Fuel System Tests
FUEL SYSTEM FUEL SYSTEM TESTS FUEL SYSTEM TESTS START outboard and check pressure. System pressure should be 28 to 32 psi (193 to 220 kPa). WARNING Shut OFF outboard. Monitor pressure gauge. Pressure should not drop below 15 psi (103 kPa). Use caution when working on any pres- surized fuel system.
Page 129: Vapor Separator Vent Check
FUEL SYSTEM FUEL SYSTEM TESTS Vapor Separator Vent Check Fuel Injector Resistance Test Monitor the vapor separator vent hose. No fuel or Disconnect the battery cables at the battery. a trace of fuel is acceptable. Excessive fuel dis- Use a digital multimeter to measure the injector charge indicates a vapor separator vent malfunc- coil resistance.
Page 130: Circulation Pump Resistance Test
FUEL SYSTEM FUEL SYSTEM TESTS Circulation Pump Resistance Test Prime the fuel system and check for leaks. START outboard and run at idle speed. Hold gauge level Disconnect the battery cables at the battery. with inlet fitting and monitor gauge for pressure reading.
Page 131: Lift Pump Vacuum Test
FUEL SYSTEM FUEL SYSTEM TESTS Lift Pump Vacuum Test Lift Pump Diaphragm Test Confirm fuel supply to the fuel lift pump. Perform this test only if a damaged pump is sus- pected. This test does not confirm the perfor- Temporarily install a vacuum gauge, T-fitting, and mance of the internal fuel pump check valves.
Page 132: Anti-Siphon Valve Test
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 133: Fuel Filter Service
FUEL SYSTEM FUEL COMPONENT SERVICING Wrap a shop towel completely around the pres- Fuel Filter Service sure test valve while connecting fitting from Fuel Removal Pressure Gauge, P/N 5007100, to test fitting of fuel pump/vapor separator assembly. Disconnect the battery cables at the battery. Remove filter carefully to prevent spilling contents.
Page 134: Fuel Lift Pump Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Installation Connect the fuel hoses to the fuel pump. Secure The fuel lift pump is serviceable as a complete with Oetiker clamps. assembly. Refer to parts catalog for service parts. Place fuel pump in position on the oil tank. Secure Removal the fuel pump with new pushnuts, P/N 354365.
Page 135 FUEL SYSTEM FUEL COMPONENT SERVICING Disconnect vapor separator and fuel injector elec- Fuel Injector Removal trical connectors. Remove connectors from retain- Mark fuel injectors to show cylinder locations. ers. NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning.
Page 136 FUEL SYSTEM FUEL COMPONENT SERVICING Crush Ring Replacement NOTICE Injector crush rings must replaced if injector is installed in a different head or cylinder location. Use Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, to remove injector from mounting cup.
Page 137 FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Injector Installation Use the drop down menu to navigate to the saved coefficient file location. NOTICE All injectors must be installed in the The coefficient file name must match the serial correct cylinder by serial number. Improper number of the injector.
Page 138 FUEL SYSTEM FUEL COMPONENT SERVICING Install Injector Position fuel injector wiring, vapor separator wiring and electrical connectors as shown. The following items and their mating surfaces must be cleaned prior to reassembly: • Injector • Cylinder head • Adapter • Screws •...
Page 139 FUEL SYSTEM FUEL COMPONENT SERVICING Install vapor separator assembly onto the four fuel • Final torque is 22 to 23.5 ft. lbs. (30 to 32 N·m). injector fittings. Tighten Screws in Stages 007103 1. Fuel injector fittings 007101 Tighten vapor separator to powerhead mounting screw to 29 to 48 in.
Page 140: Intake Manifold Service
FUEL SYSTEM FUEL COMPONENT SERVICING Reconnect circulation fuel pump electrical con- Intake Manifold Service nector. Removal Disconnect vapor separator vent hose, main bear- ing vent hose, air temperature sensor, crankshaft position sensor, and throttle position sensor. Use Ball Socket Remover Tool, P/N 342226, to remove throttle link arm.
Page 141 FUEL SYSTEM FUEL COMPONENT SERVICING Disassembly Inspection All reed plate assembly and reed valve assem- Inspect the leaf plate assemblies for damage or blies must be cleaned prior to reassembly. DO contamination: NOT use strong carburetor cleaner or the hot •...
Page 142 FUEL SYSTEM FUEL COMPONENT SERVICING Prime screw threads with Locquic Primer and let Tighten the center screws first and expand out- dry. Apply Ultra Lock to threads. Position reed ward. Tighten in stages to a final torque of 84 to valve on reed plate and install screws.
Page 143: Oiling System
OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............142 OIL SUPPLY DIAGRAMS .
Page 144: Service Chart
OILING SYSTEM SERVICE CHART SERVICE CHART 31 to 48 in. lbs. Tighten until screw Tighten until screw (3.5 to 5.5 N·m) head is seated head is seated (Cap o-ring) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant 007317 See Service Manual instructions...
Page 145: Oil Supply Diagrams
OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS Oil supply to crankcase Oil supply to crankcase IMPORTANT: Note routing of oil sup- Oil supply to cylinder block Oil supply to cylinder block ply hoses through hose retainer to oil manifold. Oil supply to cylinder Oil supply to cylinder fittings (starboard)
Page 146: Oil Recirculation Diagram
OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM 007316...
Page 147: Oiling System Circuit Diagram
OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM 008047 Stator Main harness ground (BLACK) WHITE / RED wires (55 V) EMM injector control (BLUE) Oil injection pump Low oil switch Low oil switch to EMM (TAN/BLACK) Low oil signal to SystemCheck gauge (TAN/BLACK) MWS Connector...
Page 148: Oil System Requirements
OILING SYSTEM OIL SYSTEM REQUIREMENTS OIL SYSTEM COMPONENTS REQUIREMENTS The oiling system includes the following compo- nents: Recommended Lubricants • Oil tank • Oil injection pump and manifold assembly Evinrude/Johnson XD100, XD50, or XD30 out- • Electrical circuit board oils are recommended for use in Evinrude •...
Page 149: Electrical Circuit (55 V)
OILING SYSTEM COMPONENTS The oil manifold distributes the oil supplied by the LOW OIL Warning pump. A switch in the oil tank assembly monitors the oil level in the oil tank. If the oil level falls below one-quarter capacity, the EMM begins counting oil pump pulse cycles.
Page 150: Cylinder And Crankcase
OILING SYSTEM COMPONENTS Cylinder and Crankcase Oil Recirculation System The oil distribution manifold provides crankcase External hoses and fittings, and intake manifold lubrication through oil distribution hoses and passages are used to recirculate any accumula- pressed-in fittings on the crankcase and cylinder tion of oil from various locations in the powerhead.
Page 151: Oil Control Settings
OILING SYSTEM OIL CONTROL SETTINGS OIL CONTROL SETTINGS CAUTION Oil Injection Rate Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 EMM programming controls the rate of oil injection oil ratio will result in increased engine based on engine RPM.
Page 152: Break-In Oiling
OILING SYSTEM OIL CONTROL SETTINGS Install decals in a highly visible location, such as Oil Supply Priming one of the following: • Dashboard/deck of boat, next to key switch WARNING • Deck of boat, next to the remote oil fill Always use caution while working around •...
Page 153: Oiling System Tests
OILING SYSTEM OILING SYSTEM TESTS OILING SYSTEM TESTS Observe oil flow through all oil distribution hoses. Air must be purged during the priming procedure. IMPORTANT: Always perform visual inspections to identify oiling system leaks. Make sure the oil tank is filled and oil supply is not contaminated. Oil Injection Pump Voltage Test IMPORTANT: Do NOT perform static tests using...
Page 154: Oil Injection Pump Resistance Test
OILING SYSTEM OILING SYSTEM TESTS Use the Oil Injector test of Evinrude Diagnostic Set digital multimeter to a scale that reads 55 V software Static Test screen to activate the oil (DC). pump. Start the engine. Observe voltage at pin B. •...
Page 155: Oil Injection Pump Function Test
OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Function Test Oil Injection Fittings Flow Test Remove oil distribution hose from fitting at oil dis- Make sure the oil injection fittings of the cylinder tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.
Page 156: Oil Component Servicing
OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Installation Cut Replacement Oil Hose, P/N 778708, to the SERVICING correct length. Insert hose support in manifold end of hose. WARNING IMPORTANT: DO NOT insert distribution hoses into manifold without a hose support. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.
Page 157: Oil Tank Assembly
OILING SYSTEM OIL COMPONENT SERVICING Install cylinder #2 oil distribution hose to the out- Oil Tank Assembly board (furthest from powerhead) oil manifold port. Removal Disconnect the battery cables at the battery. Disconnect the electrical connector to the oil injec- tion pump.
Page 158: Oil Injection Pump
OILING SYSTEM OIL COMPONENT SERVICING Installation Oil Injection Pump Align grommets with pins on powerhead. Install oil Removal tank assembly on powerhead. Clean mounting screw and apply Nut Lock to threads. Install Remove oil distribution hoses from oil manifold. screws and tighten to a torque of 30 to 42 in. lbs. Refer to Oil Distribution Hoses on p.
Page 159: Cooling System
COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........158 COMPONENTS .
Page 160: Hose Routing And Water Flow Diagrams
COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS Water intake screens Water pump Water tube Exhaust housing Cylinder block Pressure relief valve Thermostat Water supply to vapor separator Water supply, vapor separator to EMM Overboard indicator, outgoing water from EMM Outgoing water (warm/hot)
Page 161: Components
COOLING SYSTEM COMPONENTS COMPONENTS IMPORTANT: The water pump housing includes a small vent hole to the side of the water outlet. Be Water Pump and Intakes sure to use the correct parts when replacing the water pump. External water intakes mounted in the gearcase housing collect water and must supply the inlet side of the water pump with an unrestricted and unaerated water supply.
Page 162: Pressure Relief Valve
COOLING SYSTEM COMPONENTS Pressure Relief Valve Thermostat A pressure relief valve is used to control water The thermostat controls water flow and operating flow and operating temperature at higher speeds temperature at lower speeds (below 1800 RPM). (above approximately 2800 RPM). The pressure relief valve opens as water pressure increases.
Page 163: Operation
COOLING SYSTEM OPERATION OPERATION At higher speeds, water pressure opens the pressure relief valve at approximately 2800 RPM. Water flows through the valve to the cylinder head All models use a two-stage cooling system and bypasses the thermostat. All water flows design.
Page 164: Engine Temperature Check
COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use Evinrude Diagnostics software to read tem- CHECK perature displays. IMPORTANT: The engine temperatures listed below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct propeller and place outboard in a test tank or in the water.
Page 165: Idle Operating Temperature Troubleshooting (Below Range)
COOLING SYSTEM ENGINE TEMPERATURE CHECK IMPORTANT: Check thermostat for cracks, heat damage, or If you get low or inaccurate read- signs of corrosion. Check for proper operation. ings with a digital pyrometer, coat the probe loca- Thermostat opens at 143°F (62°C). tion with Thermal Joint Compound, P/N 322170.
Page 166: Temperature Sender Servicing
COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT AND SERVICING PRESSURE RELIEF VALVE SERVICING Removal Loosen sensor and remove by hand. Use care to The thermostat and pressure relief valve should avoid breaking threads. be serviced at the same time. Disassembly Remove four screws.
Page 167: Inspection
COOLING SYSTEM THERMOSTAT AND PRESSURE RELIEF VALVE SERVICING Remove spring, thermostat, and gasket. Assembly Assembly is the reverse of disassembly. Pay close attention when performing the following additional tasks. Install a new plunger seal on plunger. Apply a light coat of Gasket Sealing Compound to a new o-ring and place in groove in plate.
Page 168 COOLING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 169: Powerhead
POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............168 COMPRESSION TESTING .
Page 170: Service Chart
POWERHEAD SERVICE CHART SERVICE CHART 50 to 70 in. lbs. (5.6 to 7.9 N·m) 84 to 106 in. lbs. (9.5 to 12 N·m) 12 to 19 ft. lbs. (16.3 to 25.8 N·m) 10 to 12 ft. lbs. (14.5 to 16.5 N·m) 84 to 106 in.
Page 171 POWERHEAD SERVICE CHART Triple-Guard Grease Gasket Sealing Compound Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Outboard Lubricant Permatex No. 2 Gel Seal II 007739 Extreme Pressure Grease...
Page 172: Compression Testing
POWERHEAD COMPRESSION TESTING COMPRESSION TESTING POWERHEAD REMOVAL Start and run outboard until it achieves operating WARNING temperature, then shut OFF. Protect against hazardous fuel spray. Disconnect crankshaft position sensor (CPS) con- Before starting any fuel system service, nector. Remove all spark plugs. carefully relieve fuel system pressure.
Page 173 POWERHEAD POWERHEAD REMOVAL Remove water intake screens. Remove the two exhaust housing to powerhead nuts and six exhaust housing to powerhead screws. 1. Water intake screen 007649 Remove the upper shift rod connector screw. 1. Powerhead nuts 007741 1. Powerhead screws Use a suitable tool to carefully separate the pow- erhead from exhaust housing.
Page 174: Powerhead Disassembly
POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Remove five inner exhaust housing screws and inner exhaust housing. DISASSEMBLY Systems Removal To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the oil tank. Refer to Oil Tank Assembly on p.
Page 175: Throttle Linkage Removal
POWERHEAD POWERHEAD DISASSEMBLY Throttle Linkage Removal Cylinder Head Removal Remove throttle cam and throttle lever. Loosen in stages and remove cylinder head retaining screws. Remove the cylinder head. Dis- card cylinder head gasket. 1. Throttle cam 007785 2. Throttle lever 1.
Page 176: Crankshaft Assembly Removal
POWERHEAD POWERHEAD DISASSEMBLY Connecting Rods and Pistons Remove crankcase flange screws. Loosen in stages and remove the main bearing screws. Use an appropriate ring expander to remove all piston rings from pistons. Discard the rings. WARNING Wear safety glasses to avoid injury. 1.
Page 177: Crankshaft Service
POWERHEAD POWERHEAD DISASSEMBLY necting rod. If necessary, use Wrist Pin Pressing Remove the lower bearing seal housing. Tool, P/N 326356, to remove the wrist pin. 007755 007753 Remove the housing O-ring. Discard O-ring. Crankshaft Service Remove upper seal from crankshaft. Discard the seal.
Page 178 POWERHEAD POWERHEAD DISASSEMBLY Inspect housing and replace if necessary. Remove the lower main bearing only if it needs to be replaced. Use external retaining ring pliers to Remove the O-ring from crankshaft sleeve and remove the lower bearing retaining ring. inspect it.
Page 179: Cylinder Block Cleaning
POWERHEAD CYLINDER BLOCK CLEANING CYLINDER BLOCK sealant from the cylinder block, crankcase, cylin- der head, and water cover. CLEANING WARNING IMPORTANT: Before inspecting or assembling To avoid personal injury, wear eye protec- powerhead, all internal components must be com- tion and rubber gloves when using Gel pletely clean and free of contaminants.
Page 180: Powerhead Inspection
POWERHEAD POWERHEAD INSPECTION POWERHEAD Cylinder Bore Use a Cylinder Bore Gauge to inspect each cylin- INSPECTION der bore for an out-of-round, oversize, or tapered condition. Be sure the gauge is perfectly square in For dimensions, refer to SERVICE SPECIFICA- the bore when measuring. TIONS on p.
Page 181: Pistons
POWERHEAD POWERHEAD ASSEMBLY POWERHEAD Pistons Visually inspect pistons for signs of abnormal ASSEMBLY wear, scuffing, cracks, or burning. Piston Rings IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called For new ring sets, place each ring separately in its for.
Page 182 POWERHEAD POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installa- Install a new O-ring on the lower housing. Before tion, thread Slide Hammer, P/N 391008, into installing crankshaft into cylinder block, apply a installer and pull it off. thin coat of Gasket Sealing Compound to outer edge of O-ring.
Page 183: Pistons And Connecting Rods
POWERHEAD POWERHEAD ASSEMBLY enclosed face toward flywheel. Do not apply Apply outboard lubricant to the wrist pin bearings, sealer to outside edge of the seal. wrist pin and wrist pin bore. Install the bearings in the small end of the connecting rod. 1.
Page 184: Crankshaft Assembly Installation
POWERHEAD POWERHEAD ASSEMBLY and tool. To seat retaining ring, swiftly strike the IMPORTANT: Be sure gap of ring fits squarely driver. around dowel pin. 002048 IMPORTANT: Before continuing, make sure that 007764 all Gel-Seal II has been removed from the cylinder block and crankcase mating flanges.
Page 185: Crankcase Assembly
POWERHEAD POWERHEAD ASSEMBLY • IMPORTANT: Align tab on lower bearing seal housing with slot Gel-Seal II has a shelf life of at in crankcase. least one year when stored at room temperature. • Test the Gel-Seal II or replace it if the age of the Align upper oil seal in groove.
Page 186: Cylinder Head Installation
POWERHEAD POWERHEAD ASSEMBLY Test that the crankshaft spins freely without bind- Cylinder Head Installation ing. Apply soapy water to water dam and insert into block. IMPORTANT: After powerhead been assembled, allow at least two hours for Gel-Seal II to cure before running outboard. Apply Gasket Sealing Compound to both sides of new inner and outer exhaust cover gaskets.
Page 187: Megaphone And Inner Exhaust Housing Installation
POWERHEAD POWERHEAD ASSEMBLY Following sequence on cylinder head, tighten all secure with three screws. Tighten screws to a screws in stages to a torque of 10 to 12 ft. lbs. torque of 84 to 106 in. lbs. (9.5 to 12 N·m). (14.5 to 16.5 N·m) 1.
Page 188: Shift Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Shift Linkage Installation Install shift lever and detent on shaft assembly. Install nut and tighten nut to a torque of 84 to 106 Place the spring, guide, and ball of the shift detent in. lbs. (9.5 to 12 N·m). assembly into the crankcase.
Page 189: Throttle Linkage Installation
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. 138. Insert spring into cavity of throttle return lever. Install oil recirculating hoses and check valves.
Page 190: Powerhead Installation
POWERHEAD POWERHEAD INSTALLATION POWERHEAD Loosely install all powerhead screws before tight- ening: INSTALLATION Powerhead Mounting Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.plines. Be sure water tube is placed in upper and lower grommets.
Page 191: Shift Linkage Adjustment
POWERHEAD POWERHEAD INSTALLATION Place the upper shift rod in the shift rod connector. Shift Linkage Adjustment Install the retaining screw and lock washer. Adjust shift linkage as follows: Tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Page 192: Final Adjustments
POWERHEAD POWERHEAD INSTALLATION STEP 3: Secure shift lever to shift lever detent. Final Adjustments • Remove one shift lever screw. Clean screw and apply Nut Lock to threads. NOTICE After installing a new or rebuilt • Reinstall the shift lever screw. powerhead, perform the following procedures •...
Page 193: Powerhead Views
POWERHEAD POWERHEAD VIEWS Port Electric Start Models POWERHEAD VIEWS 008359 Starboard Electric Start Models 008278...
Page 194: Port Rope Start Models
POWERHEAD POWERHEAD VIEWS Port Rope Start Models 008430 Starboard Rope Start Models 008431...
Page 195: Front
POWERHEAD POWERHEAD VIEWS Front 007809...
Page 196: Rear
POWERHEAD POWERHEAD VIEWS Rear 007810...
Page 197: Top
POWERHEAD POWERHEAD VIEWS 008280...
Page 198 POWERHEAD NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 199: Midsection
MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............198 EXHAUST HOUSING SERVICE .
Page 200: Service Chart
MIDSECTION SERVICE CHART SERVICE CHART , 15 HP P TERN RACKET OWER ODELS 60 to 84 in. lbs. (7.5 to 9 N·m) 24 to 36 in. lbs. (2.7 to 4 N·m) Use Triple-Guard grease on all pivot points 40 to 45 ft lbs. (54 to 61 N·m) 60 to 84 in.
Page 201 MIDSECTION SERVICE CHART , 25 – 30 HP P TERN RACKET OWER ODELS Use Triple-Guard grease on all pivot points 40 to 45 ft lbs. (54 to 61 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 35 to 61 in. lbs. (4 to 7 N·m) 10 to 16 in.
Page 202 MIDSECTION SERVICE CHART , 25 – 30 HP M TERN RACKET ANUAL ODELS 84 to 106 in. lbs. (9.5 to 12 N·m) 60 to 84 in. lbs. (7.5 to 9 N·m) 18 to 20 ft lbs. (24.5 to 27 N·m) Use Triple-Guard grease on all pivot points 144 to 168 in.
Page 203 MIDSECTION SERVICE CHART XHAUST OUSING 10 to 12 ft. lbs. (14.5 to 16.5 N·m) 10 to 12 ft. lbs. (14.5 to 16.5 N·m) 177 to 204 in. lbs. 10 to 12 ft. lbs. (20 to 23 N·m) 22 to 23 ft. lbs. (14.5 to 16.5 N·m) (30 to 32 N·m) 10 to 12 ft.
Page 204 MIDSECTION SERVICE CHART ILLER ANDLE 84 to 108 in. lbs. (9.5 to 12.2 N·m) 26 to 28 ft. lbs. (35 to 38 N·m) 18 to 24 in. lbs. (2 to 2.7 N·m) 10 to 20 ft. lbs. (24.5 to 27 N·m) 9 to 15 in.
Page 205: Exhaust Housing Service
MIDSECTION EXHAUST HOUSING SERVICE EXHAUST HOUSING Remove lower mount bracket rubber mount. Check condition of the lower front mount. Replace SERVICE if deteriorated or damaged. The exhaust housing contains no serviceable internal parts. The exhaust relief muffler and motor mounts can be serviced without removing the exhaust housing.
Page 206: Mount Service
MIDSECTION EXHAUST HOUSING SERVICE Mount Service Install mount to exhaust housing with two mount to exhaust housing screws. Install screws finger Individual upper and lower motor mounts can be tight at this time. serviced without removing the exhaust housing. Remove the lower motor covers. Refer to Lower Cover Removal on p.
Page 207 MIDSECTION EXHAUST HOUSING SERVICE Install washer. Align slot with pin as shown. Lower mount: Apply Triple-Guard grease to threads of the lower mount screws. Install rubber bumper and washer. Install screw through lower mount. Tighten screw to a torque of 22 to 23 ft. lbs. (30 to 32 N·m).
Page 208: Exhaust Relief Muffler
MIDSECTION EXHAUST HOUSING SERVICE Exhaust Relief Muffler Install muffler drain hose through hole. The exhaust relief muffler has no serviceable parts, replace as needed. Remove lower motor covers. Refer to Lower Cover Removal on p. 45 Remove overboard indicator grommet from muf- fler.
Page 209: Extension Service - 25" Models
MIDSECTION EXTENSION SERVICE – 25” MODELS EXTENSION SERVICE – Installation If studs are removed, clean threads with cleaning 25” Models solvent. Removal Apply Ultra Lock to upper threads of studs. Install studs and tighten to a torque of 10 to 12 ft. lbs. Remove gearcase.
Page 210: Stern Bracket - Power Tilt Models
MIDSECTION STERN BRACKET – POWER TILT MODELS STERN BRACKET – If equipped with a steering friction device, remove the steering friction nut. Power Tilt Models Stern Bracket Disassembly (Power Tilt) If outboard is equipped with a tiller arm, remove the tiller arm. Refer to TILLER HANDLE SER- VICE on p.
Page 211 MIDSECTION STERN BRACKET – POWER TILT MODELS Use an appropriate tool to pry the upper and lower Remove the trim/tilt cable connector. Refer to seals from the swivel bracket. TRIM AND TILT REPLACEMENT on p. 273. Remove the clip from the cylinder pin. 007687 1.
Page 212: Stern Bracket Assembly (Power Tilt)
MIDSECTION STERN BRACKET – POWER TILT MODELS Remove angle adjustment rod and remove the Check the condition of the anode. Replace the hydraulic unit. anode if it has been reduced to two-thirds its origi- nal size. 007693 007695 To separate stern and swivel brackets, remove tilt tube nuts, tilt tube, bushings, thrust washers, and Stern Bracket Assembly (Power cable clamp.
Page 213 MIDSECTION STERN BRACKET – POWER TILT MODELS Make sure cable clamp is positioned as shown. Install bushings in hydraulic unit. Position hydrau- lic unit between stern brackets and install the angle adjustment rod. 1. Cable clamp 007696 Route the hydraulic unit and trim sender har- 007699 nesses through the grommet in the port stern bracket.
Page 214 MIDSECTION STERN BRACKET – POWER TILT MODELS Install the cylinder pin and secure with clip. Install the upper and lower bushings in the swivel bracket. 1. Clip 007637 007689 Tighten the locknuts to a torque of 60 to 84 in. lbs. 007690 (7 to 9.5 N·m).
Page 215 MIDSECTION STERN BRACKET – POWER TILT MODELS Apply Triple-Guard grease to both sides of thrust Align dowel pin and steering friction lever as washer. Install thrust washer on steering arm. shown. 1. Thrust washer 007617 5. Dowel pin 007458 6. Steering friction lever Slide the steering arm with thrust washer through Install locking nut.
Page 216: Trim Sending Unit Removal
MIDSECTION STERN BRACKET – POWER TILT MODELS Trim Sending Unit Removal Install lower mount retaining screws. Tighten screws to a torque of 10 to 12 ft. lbs. (14.5 to 16.5 Remove two screws. Remove sending unit and N·m). washers from swivel bracket. 1.
Page 217: Trim Sending Unit Installation
MIDSECTION STERN BRACKET – POWER TILT MODELS Trim Sending Unit Installation CAUTION Route trim sending unit harness through port stern When reinstalling screws in composite bracket grommet. Secure harness in wire clamp materials turn screws COUNTER-CLOCK- as shown. WISE until threads of screw engage threads of screw boss.
Page 218: Stern Bracket - Manual Tilt Models
MIDSECTION STERN BRACKET – MANUAL TILT MODELS STERN BRACKET – Apply Locquic Primer to the threads of the screw and allow it to dry four to five minutes. Then apply Manual Tilt Models Ultra Lock to threads. Install shoulder screw and swivel plate onto clamp Clamp Screw Service screw and handle assembly.
Page 219 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Use a soft mallet to remove lower mount bracket Remove the steering friction lever, washers and and thrust washer. plate. 1. Mallet 007583 1. Steering friction lever 007686 2. Lower mount bracket 2. Steering friction washers 3.
Page 220 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Remove the friction screw and spring. Remove Remove the tilt pin, two tie bar screws and tie bar. upper and lower bushings from the swivel bracket. 1. Tie bar screws 007590 1. Friction plate 007618 2.
Page 221 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Use an appropriate tool to unhook the two springs Push down on link. Unhook reverse lock release from the top of the swivel bracket. Remove the rod from pin and remove rod from bellcrank. springs.
Page 222 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Remove retaining clips from both sides of the Remove the shallow water drive link and reverse swivel bracket. lock assembly from the swivel bracket. 1. Clip 007599 007601 Remove pins from shallow water drive link and Remove cotter pins and disassemble shallow swivel bracket.
Page 223: Stern Bracket Assembly (Manual Tilt)
MIDSECTION STERN BRACKET – MANUAL TILT MODELS Stern Bracket Assembly (Manual Assemble reverse lock link and reverse lock lever as shown. Install pin and secure with new cotter Tilt) pin. Install a new bushing through hole in tilt lock assembly. Press bushing into swivel bracket until fully seated.
Page 224 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Place the shallow water drive link and reverse Use an appropriate tool to hook the straight end lock assembly into the swivel bracket as shown over the pin as shown. Install one pin as shown and secure pin with clip. 1.
Page 225 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Install reverse lock release rod on bellcrank. Con- Attach the two reverse lock springs to the reverse nect rod to pin as shown. lock lever. Use an appropriate tool to connect the reverse lock springs to the top of the swivel bracket.
Page 226 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Install pin through each lock assembly and stern Install friction screw and spring in swivel bracket. bracket. Install washers and nuts, and tighten to a Apply a light coat of Triple-Guard grease to the torque of 18 to 20 ft.
Page 227 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Apply a light coat of Triple-Guard grease to the Apply Triple-Guard grease to both sides of thrust outside of the lower bushing. Install bushing in the washer. Install thrust washer on steering arm. swivel bracket.
Page 228 MIDSECTION STERN BRACKET – MANUAL TILT MODELS Align dowel pin and steering friction lever as Apply Triple-Guard grease to both sides of thrust shown. washer. Install thrust washer on steering arm. Install lower mount bracket on steering arm. 5. Dowel pin 007458 6.
Page 229: Tiller Handle Service
MIDSECTION TILLER HANDLE SERVICE TILLER HANDLE Remove clip and washer from shift lever pin and remove shift cable connector from shift lever pin. SERVICE Remove cable anchor screw and washer from shift cable retainer. Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads.
Page 230: Disassembly
MIDSECTION TILLER HANDLE SERVICE Remove rear steering handle screw and washer. Remove eight screws and bottom cover of tiller handle. 1. Rear steering arm screw and washer 007461 1. Cover screws 007528 Remove tiller handle assembly. Remove shift handle screw and shift handle. Disassembly Loosen throttle friction control so there is no restriction on grip.
Page 231 MIDSECTION TILLER HANDLE SERVICE Remove start switch, stop switch, housing, spring, Remove screw and washer from shift link. button, and spacer. Remove shift cable and shift link. 1. Start switch 007531 1. Shift link 007535 2. Stop switch 3. Housing Remove cotter pin from shift link and remove shift 4.
Page 232 MIDSECTION TILLER HANDLE SERVICE Remove two shift detent retaining screws. Use Twist-Grip Remover, P/N 390767, to depress Remove detent spring. the grip detents. Tighten screw and remove the grip by pulling grip. 1. Screws 007538 2. Shift detent spring 1. Twist-Grip Remover 007541 2.
Page 233 MIDSECTION TILLER HANDLE SERVICE Remove the throttle cable. Remove nut, washer and bushing from port side of tiller handle. 007544 1. Nut 007547 2. Washer The twist grip and trim switch wiring can now be 3. Bushing removed from the inner handle. Remove steering handle screw.
Page 234: Inspection
MIDSECTION TILLER HANDLE SERVICE If replacing tilt detent pawl, tilt release lever, tilt Inspection detent pin or spring, remove cotter pin and roll Inspect the throttle cable for kinks and wear. pins as needed. Replace if necessary. Inspect the shift cable for kinks and wear. Replace if necessary.
Page 235 MIDSECTION TILLER HANDLE SERVICE Install tilt detent pawl on tilt detent pin. Secure Hook spring to roll pin and recess in base as with new cotter pin. shown. Turn tilt release lever one turn to apply tension to the spring. Hold lever in position and install base in bracket.
Page 236 MIDSECTION TILLER HANDLE SERVICE Use an appropriate tool to align screw hole Press the trim switch into the twist grip. Be sure through the tiller handle, bracket and base. Install trim switch UP position aligns with the twist grip steering handle screw. Tighten screw so tiller han- indicator line as shown.
Page 237 MIDSECTION TILLER HANDLE SERVICE Push wire guide into place until locking tab is in Make sure trim switch wiring is NOT twisted place as shown. before proceeding. 1. Locking tab 007555 1. Inner tiller handle 006675 2. Wire guide 007556 3.
Page 238 MIDSECTION TILLER HANDLE SERVICE Apply Lubriplate to the ends of pin, guides, rollers, Be sure the twist-grip's speed indicator line is helix grooves and inner handle guide slot. Place positioned with the speed range symbol on the the guides over the roller pin and into the slots of handle.
Page 239 MIDSECTION TILLER HANDLE SERVICE Route wiring under throttle cable as shown. Install shift lever assembly. Install four shift lever bracket retaining screws. Tighten screws securely. 007562 1. Screws 007537 2. Shift lever bracket Install shift cable on shift link. Secure with a new cotter pin.
Page 240 MIDSECTION TILLER HANDLE SERVICE If trim switch was removed, install tie straps on Install start switch. Tighten start switch nut harness. connectors. securely. Install stop switch housing, spring, but- ton and stop switch. Secure with two screws. Tighten screws securely. 1.
Page 241: Installation
MIDSECTION TILLER HANDLE SERVICE Install shift handle. Install shift handle screw. Install rear washer and screw in appropriate loca- Tighten screw securely. tion. Tighten both screws to a torque of 18 to 20 ft. lbs. (25 to 27 N·m). 1. Screw 007529 2.
Page 242: Control Cable Installation
MIDSECTION TILLER HANDLE SERVICE Connect tiller electrical connector. Secure to Control Cable Installation retainer on starter housing. Make sure throttle and shift cable ends are fully seated. 1. Wire routing 007474 2. Retainer 3. Throttle cable end 007473 4. Shift cable end Place battery cables and trim wiring through hole in port lower motor cover.
Page 243 MIDSECTION TILLER HANDLE SERVICE • Throttle Cable Adjustment Lock the retainer by moving the angled section behind the straight section. Install throttle cable connector with Ball Socket Installer tool, P/N 342225. Locked Retainer Clip 007465 1. Angled section behind straight section Pull firmly on shift cable casing to remove back- lash.
Page 244 MIDSECTION TILLER HANDLE SERVICE Adjust cable anchor so throttle cam is against Install washer between anchor and boss. Install IDLE stop when anchor screw hole aligns with screw. Tighten screw to a torque of 84 to 106 in. screw boss on block. lbs.
Page 245: Gearcase
GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............244 PROPELLER SERVICE .
Page 246: Service Chart
GEARCASE SERVICE CHART SERVICE CHART 60 to 84 in. lbs. (7 to 9.5 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 60 to 84 in. lbs. (7 to 9.5 N·m) 128 to 146 in. lbs. (14.5 to 16.5 N·m) 10 to 14 in.
Page 247: Propeller Service
GEARCASE PROPELLER SERVICE PROPELLER SERVICE Propeller Selection Inspection CAUTION Carefully examine propeller and outboard for the Selection of the wrong propeller could following: reduce engine service life, affect boat per- • Damaged blades and signs of propeller cavita- formance, or cause serious damage to the tion (burned paint, etc.) powerhead.
Page 248: Propeller Hardware Installation
GEARCASE PROPELLER SERVICE When selecting a propeller, consider the following: Install the spacer over the propeller shaft splines. • Use an accurate tachometer to determine the engine’s full-throttle RPM. • The outboard should be trimmed for top speed. • Select a propeller that suits the customer’s application and allows the engine to run near the midpoint of the full-throttle operating range when the boat has a normal load.
Page 249: Gearcase Leak Test
GEARCASE GEARCASE LEAK TEST GEARCASE LEAK TEST TRIM TAB SERVICE Removal Drain lubricant before testing. Note where the index mark on the gearcase aligns Use Gearcase Pressure Tester, P/N 507977. with the index mark of the adjustable trim tab so Install lubricant drain/fill plug and seal, thread the trim tab can be installed in the same position.
Page 250: Gearcase Removal And Installation
GEARCASE GEARCASE REMOVAL AND INSTALLATION GEARCASE REMOVAL Remove the six gearcase retaining screws or nuts (25 inch models). AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly.
Page 251 GEARCASE GEARCASE REMOVAL AND INSTALLATION Slide the gearcase into place, making sure that: screw. Tighten screw, with washer, to a torque of • 60 to 84 in. lbs. (7 to 9.5 N·m). Driveshaft engages the crankshaft • Water tube enters grommet on water pump •...
Page 252: Water Pump Service
GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE Inspection Check impeller for overheating, hub separation, Disassembly and other wear or damage. Remove the impeller housing screws. Check liner and wear plate for scoring, distortion, and impeller material transfer. Inspect the housing for cracks or melting. Make sure gasket surface is clean and smooth.
Page 253 GEARCASE WATER PUMP SERVICE Lightly coat the exterior of the impeller cup with Apply Adhesive 847 to the outer seal groove of Gasket Sealing Compound. Align tabs of impeller the impeller housing. Install a new seal into the cup with location holes of impeller housing and groove.
Page 254 GEARCASE WATER PUMP SERVICE Sharp edge of the key is leading edge during Turn the driveshaft until holes of the impeller driveshaft rotation. Slide the impeller housing housing are aligned with holes of the gearcase. down the driveshaft. Engage the impeller with the Apply Gasket Sealing Compound to threads of the key.
Page 255: Gearcase Disassembly
GEARCASE GEARCASE DISASSEMBLY GEARCASE • Hydrostatic Seal Grooves — Must be in good 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). IMPORTANT: Clean and inspect all parts during disassembly.
Page 256: Propeller Shaft Bearing Housing Removal
GEARCASE GEARCASE DISASSEMBLY Propeller Shaft Bearing Housing Remove the retaining ring using Retaining Ring Pliers, P/N 331045. Removal CAUTION Remove the two propeller shaft bearing housing screws. Retaining ring is under extreme pressure during removal and installation. To pre- vent personal injury, wear safety glasses and proceed with care to avoid unsnap- ping the ring from the pliers.
Page 257: Shifter, Gear And Propeller Shaft Removal
GEARCASE GEARCASE DISASSEMBLY Shifter, Gear and Propeller Shaft Remove the propeller shaft and reverse gear components from the gearcase. Removal Unscrew the lower shift rod from the shifter yoke and remove the shift rod from the gearcase. 1. Propeller shaft 007675 2.
Page 258: Bearing And Seal Removal
GEARCASE BEARING AND SEAL REMOVAL Use long-nose pliers to remove the clutch and BEARING AND SEAL shifter lever assembly. Use no force. Tilting the REMOVAL shifter lever slightly will allow you to remove it from the gearcase. IMPORTANT: Inspect bearings for damage while in place.
Page 259: Pinion Bearings
GEARCASE BEARING AND SEAL REMOVAL Pinion Bearings Shift Rod Bushing and O-ring Assemble the following components from Univer- Position Shift Rod Bushing Remover, P/N 327693, sal Pinion Bearing Remover and Installer, under the shift rod bushing. P/N 5005927. Thread the adapter of the Slide Hammer, P/N 391008, in the slide hammer.
Page 260: Propeller Shaft Bearing Housing Seals And O-Ring
GEARCASE BEARING AND SEAL INSTALLATION Propeller Shaft Bearing Housing BEARING AND SEAL Seals and O-ring INSTALLATION Remove and discard the propeller shaft bearing housing O-ring. IMPORTANT: Make no dry assemblies. Lubri- cate all bearings, shafts, and gears with gearcase lubricant. Press the bearings into the housings until the tools are seated on the housing.
Page 261: Propeller Shaft Bearing Housing Seals And O-Ring
GEARCASE BEARING AND SEAL INSTALLATION Propeller Shaft Bearing Housing Shift Rod Bushing and O-ring Seals and O-ring Coat the shift rod O-ring with Triple-Guard grease and install in shift rod bushing. Install new seals back to back in aft end of the propeller shaft bearing housing using Seal Place a new washer and bushing on Shift Rod Installer, P/N 335821.
Page 262: Pinion Bearings
GEARCASE BEARING AND SEAL INSTALLATION Pinion Bearings Driveshaft Bearing Install the pinion bearings using the following Oil and install a new driveshaft bearing in the components of the Universal Pinion Bearing bearing sleeve using Bearing Installer, Remover and Installer, P/N 5005927, and two tool P/N 322923.
Page 263: Driveshaft Seals
GEARCASE GEARCASE ASSEMBLY GEARCASE ASSEMBLY Driveshaft Seals Apply Gasket Sealing Compound to the metal Propeller Shaft, Gear and Shifter casing of the seals before installing. Installation Use Seal Installer, P/N 326552, to install the inner seal with flush lip facing into the gearcase, then IMPORTANT: Make no dry assemblies.
Page 264 GEARCASE GEARCASE ASSEMBLY Use a right angled rod to install the pinion assem- Install the shifter cradle and clutch dog in the bly in the gearcase. gearcase using long-nose pliers. COA3290 38637 Place the forward gear into the gearcase. Apply Triple-Guard grease to a new pivot pin O- ring.
Page 265 GEARCASE GEARCASE ASSEMBLY Slide the Shift Detent Sleeve, P/N 328081, over • Gently tap propeller shaft with a rawhide mallet the propeller shaft. Align slot in the tool with hole to seat detent assembly. in the propeller shaft. 38638 1. Shift detent sleeve 26727 Remove detent tool.
Page 266: Propeller Shaft Bearing Housing Installation
GEARCASE GEARCASE ASSEMBLY Holding the shifter yoke a with long-nose pliers, Thread the shift rod into the shifter yoke until the install the yoke at a tilted position, locating top of rod bottoms in the yoke. yoke into upper gearcase cavity. 1.
Page 267 GEARCASE GEARCASE ASSEMBLY Lightly apply Gasket Sealing Compound to the aft NOTICE The retaining ring is under extreme support flange of the bearing housing. Align the pressure during installation. Make sure that propeller shaft bearing housing on the guide pin the ring is seated in groove.
Page 268 GEARCASE GEARCASE ASSEMBLY Install one screw in the bearing housing. Remove the guide pin and install the second screw. Tighten screws to a torque of 124 to 142 in. lbs. (14 to 16 N·m). Apply Adhesive 847 to the bottom of a new exhaust seal assembly and install it into the slot in the gearcase.
Page 269 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............268 SYSTEM DESCRIPTION .
Page 270: Service Chart
TRIM AND TILT SERVICE CHART SERVICE CHART 30 to 50 in. lbs. (4 to 5.6 N·m) 45 to 55 in. lbs. (5 to 6 N·m) 45 to 55 in. lbs. (5 to 6 N·m) Triple-Guard Grease 007632 Biodegradable TNT Fluid...
Page 271: System Description
TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket And Tilt Support The power trim/tilt hydraulic system is completely These outboards are equipped with combination contained between the outboard's stern brackets. tilt support/trailering brackets. The system consists of: Tilt the outboard up fully, engage the bracket, then •...
Page 272: Routine Inspections
TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General Use the following guidelines to check a single pis- ton trim/tilt unit that is not working correctly. Check for external signs of fluid leakage. Correct causes as necessary. Cylinder Leakdown: • Manual release valve seals Check the battery and make sure it is in good •...
Page 273: Electrical Circuit Tests
TRIM AND TILT ELECTRICAL CIRCUIT TESTS ELECTRICAL CIRCUIT Connect a 0 to 100 A DC ammeter in series 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 274: Trim And Tilt Motor No Load Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim and Tilt Motor No Load Test If test results vary, replace the motor. Trim Gauge Test IMPORTANT: Securely fasten motor in a suit- able fixture before proceeding with this test. STEP 1 Use a battery rated at 360 CCA (50 Ah) or higher Turn key switch ON.
Page 275: Trim Sender Test
TRIM AND TILT TRIM AND TILT REPLACEMENT TRIM AND TILT Trim Sender Test REPLACEMENT IMPORTANT: To avoid immediate meter dam- age, never apply an ohmmeter to an electrical cir- Removal cuit where voltage is present. Raise the outboard and engage the tilt support. Disconnect the 3-pin connector between the instrument harness and engine trim harness.
Page 276: Installation
TRIM AND TILT TRIM AND TILT REPLACEMENT Remove the clip from the cylinder pin. Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw. 15493 Thread Adapter, P/N 340624, onto Slide Hammer, 1.
Page 277: Trim And Tilt Service
TRIM AND TILT TRIM AND TILT SERVICE TRIM AND TILT SERVICE Lubricate the angle adjustment rod with Triple- Guard grease. Install the rod. Tighten the locknuts to a torque of 20 to 25 ft. lbs. (27 to 34 N·m). Disassembly Thoroughly clean the unit before disassembling.
Page 278: Assembly
TRIM AND TILT TRIM AND TILT SERVICE Slowly remove the manual release valve. There Remove drive coupler from either the motor or the may be pressure behind the valve—wear safety pump assembly. glasses. 002532 002529 Assembly Inspect the manual release valve. Discard the O- rings on the housing.
Page 279 TRIM AND TILT TRIM AND TILT SERVICE Position the motor on the manifold and install four Fill the oil reservoir up to the fill plug with new screws and lock washers. Tighten the screws Evinrude/Johnson Biodegradable Fluid. 35 to 50 in. lbs. (4 to 5.6 N·m). Install the fill plug.
Page 280 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 281: Manual Starter
MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS SERVICE CHART ..............280 RECOIL STARTER REMOVAL .
Page 282: Service Chart
MANUAL STARTER SERVICE CHART SERVICE CHART 84 to 106 in. lbs. (9.5 to 12 N·m) Tighten securely 124 to 141 in. lbs. (14 to 16 N·m) Red Ultra Lock Blue Nut Lock Lubriplate 777 007733 See Service Manual...
Page 283: Recoil Starter Removal
MANUAL STARTER RECOIL STARTER REMOVAL RECOIL STARTER Remove two EMM mounting screws and move the EMM to the side. REMOVAL WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. Remove all electrical connectors from the recoil starter housing.
Page 284: Recoil Starter Installation
MANUAL STARTER RECOIL STARTER INSTALLATION RECOIL STARTER Install stator connector in retainer groove of starter housing. INSTALLATION Position the wiring in the retaining bracket of recoil starter housing. 1. Stator connector 007229 NOTICE To prevent damage to wiring from rotating flywheel, make sure stator connector 2.
Page 285: Recoil Starter Disassembly
MANUAL STARTER RECOIL STARTER DISASSEMBLY RECOIL STARTER Position the charge module harness, connectors and wiring as shown. DISASSEMBLY Assemble and tighten tie straps through the tie strap slots of the recoil housing. WARNING Attach fuse holder to retainer. Wear safety glasses while disassembling Attach remaining connectors to retainers on recoil and assembling manual starters because housing as shown.
Page 286 MANUAL STARTER RECOIL STARTER DISASSEMBLY Remove rope from pulley rope channel and untie Remove starter spindle screw and lock nut. knot. Remove rope from starter assembly. 1. Lock nut 007711 1. Rope channel 007709 2. Knot IMPORTANT: Hold pulley down in housing and lift out spindle.
Page 287: Recoil Starter Cleaning And Inspection
MANUAL STARTER RECOIL STARTER CLEANING AND INSPECTION RECOIL STARTER Turn housing over and tap on bench to remove spring. CLEANING AND INSPECTION Wash metal components in solvent and dry with compressed air. Inspect the rewind spring for broken end loops and weak tension.
Page 288: Recoil Starter Assembly
MANUAL STARTER RECOIL STARTER ASSEMBLY RECOIL STARTER Clamp base of Starter Spring Winder and Installer, P/N 342682, in a vise. Place spring around base ASSEMBLY as shown. WARNING Wear safety glasses while disassembling and assembling manual starters because of rewind spring tension. If removed, install the rope guide to the starter housing.
Page 289 MANUAL STARTER RECOIL STARTER ASSEMBLY pulley. Secure retainer with left-hand threaded Turn pulley counterclockwise 3.5 turns, until the nut. pulley rope channel aligns with the rope guide. 1. Retainer tapered end 007719 1. Rope channel 007734 2. Rope guide Install handle on pulley pin. Pull lightly on spring Secure pulley by placing stop tool through the and turn pulley counterclockwise with handle until holes in the pulley and housing.
Page 290 MANUAL STARTER RECOIL STARTER ASSEMBLY Route rope through the rope guide and into the Remove left-hand threaded nut and retainer from pulley rope channel. tool base. Remove starter assembly. 1. Rope guide 007723 1. Left-hand threaded nut 007727 2. Rope channel 2.
Page 291 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 292 S–2...
Page 293: Marine Products And The Safety Of People Who Use Them
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 294: 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 295: 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 296: 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;...
Page 297 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. rigging •...
Page 298: Outboard Fuel, Electrical System, And Safety
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? •...
Page 299 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 Sleeves, boots, shields •...
Page 300 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 GASOLINE Check for leaks under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.
Page 301: 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 302 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 303: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety
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. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.
Page 304: 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 from the emergency stop / key switch.
Page 305 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 306: Summing Up
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 307: Marine Products And The Safety Of People Who Fix Them
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: •...
Page 308 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 309 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 310 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 311: Handling Lead/Acid Batteries
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 312: Gasoline - Handle With Care
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 313: 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” It’s all on the back of the can or bottle label.
Page 314: 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 315: Index
INDEX INDEX Break-In EMM Programming 150, 190 Abbreviations 6 Gearcase 249, 266 Accessories Oiling 150 XD100 Outboard Oil Decal, P/N 352369 Procedure 62 Adjustments Control Cable 18, 240 Cable, Hose, and Wire Routing 18 Neutral Switch 25 Clamp Screw Service 216 Shift Linkage 189, 264 Connecting Rods Steering Friction 24...
Page 316 INDEX Assembly 179, 182 Disassembly 174, 175 Electrical Circuits Crankshaft Position Sensor EMM Pin Locations 85 Description 55 Fuse 86 Operation Test 74 Ground Circuits 86 Resistance Test 87 Key Switch 96 Cylinder Bore Start Circuit 94 Honing 177 SystemCheck 101 Inspection 178 Electrical Connectors Cylinder Head...
Page 317 INDEX Removal 248 Seal Flushing, Cooling System 30 Installation 258 Flywheel Removal 256 Installation 104 Water Pump Service 250 Removal 103 Grommet 18 Forward Bearing Installation 259 Removal 257 Honing 177 Fuel Injectors Hoses Crush Ring Replacement 134 Inspection 37 Electrical Circuits 119 Oil Distribution 154, 155 EMM Programming 133, 135...
Page 318 INDEX Lubrication Oil Distribution 143 Engine Oil 10, 146 Oil Distribution Hoses 143, 154, 155 Gearcase 11, 34 Oil Filters 37 Power Trim 11 Oil Recirculation 148 Propeller Shaft 33 Oil Tank 146, 155 Swivel Bracket 32 Oiling Rate 62, 149 Throttle and Shift Linkage 33 Priming 150 Tiller handle 32...
Page 319 INDEX Fuel System 125 Powerhead 168 Propeller Shift Cable Adjustment, Tiller 240 Inspection 245 Shift Linkage Installation 246 Adjustment 189 Selection 245 Installation 186 Propeller Shaft Lubrication 33 Installation 261 Removal 173 Lubrication 33 Shift Rod Bushing Removal 255 Installation 259 Propeller Shaft Bearing Housing Removal 257 Bearing Installation 258...
Page 320 INDEX Inspection 232 Description 55 Installation 239 Resistance Test 87 Removal 227 Tiller handle Steering System Lubrication 32 Lubrication 32 Tilt Support 269 Steering Arm and Shaft 208, 217 Tilt Tube Steering Friction 24 Lubrication 32 Steering Torque 27 Timing Adjustments Stern Bracket Timing Pointer 106 Assembly 210, 221...
Page 321 INDEX Primary Lock Tool, P/N 777077 112 Removal 273 Puller Bridge, P/N 432127 256, 258 Reservoir Fluid 11, 270 Retaining Ring Pliers, P/N 331045 254, 264 Troubleshooting 270, 271 Seal Installer, P/N 326552 – 25/30 261 Trim Gauge Test 272 Seal Installer, P/N 335821 –...
Page 322 INDEX I–8...
Page 323: 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 324 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. In gear–Tiller models Make sure outboard is in neutral No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return...
Page 325 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 326 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 327 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE SystemCheck light Outboard is in S.A.F.E. Check Service Codes and SystemCheck warning Refer to specifications, check recommended WOT Incorrect propeller RPM; water test and install correct pitch propeller Setup or rigging change Incorrect outboard mounting...
Page 328 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 329 Hose Routing and Water Flow Diagram 15 – 30 HP E-TEC Inline 2 Cylinder 1. Intake water screens 2. Water pump 3. Water tube 4. Exhaust housing 5. Cylinder block 6. Pressure relief valve 7. Thermostat 8. Water supply to vapor separator 9.
Page 330 MWS Instrument Wiring Harness DRC6165R...
Page 331 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
Page 332 MWS Key Switch and Neutral Safety Switch START 000691...
Page 333 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH VOLTMETER TRIM/TILT WATER PRES. FUEL FUEL TANK SENDER WARNING HORN DRC6278R...
Page 334 Tiller Harness 15 – 30 HP E-TEC 1. Tiller to Engine Harness Connector 2. Trim Switch Connector 3. Trim Switch 4. Power Connector (Trim Switch) 5. Start Switch 6. Stop Switch 7. Touch Troll Switch...
Page 335 Evinrude E-TEC EMM LED Diagnostic Indicators In-line 15–30HP Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS P/N 3011635 in the Service Manual. KEY ON: LED’s illuminate to indicate circuit function Sensors / 5V Circuits OK FLASHING LED –...
Page 337 15 – 30 HP E-TEC 1. Air Temperature Sensor A B C 2. Throttle Position Sensor 3. Crankshaft Position Sensor 4. Stator 5. Tiller Arm Connector 6. CANbus Connector 34 33 32 31 30 29 28 27 26 7. Key Switch Connector 8.
Page 339 EVINRUDE 15 – 30 HP EMM SERVICE CODE CHART TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE Throttle Position Sensor TPS Voltage > 1.71 V with key ON (or cranking). Becomes stored fault when outboard starts. 2 seconds (TPS) out of idle range When both hard and stored faults are present, check for improperly adjusted throttle cable.
Page 340 TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE 49 Air Temperature ABOVE range LED 3: OFF (Cranking) / ON (Running) 8 seconds Air temperature > 158° F (70° C). 51 Fuel injector circuit #1 OPEN LED 2: ON (Running) 8 seconds Check injector/circuit resistance—2 to 3 Ω...

This manual is also suitable for:

Evinrude e15dhtlii series Evinrude e15hpsxii series Evinrude e15dhplii series Evinrude e15hpslii series Evinrude e25drii series Evinrude e15htsxii series ... Show all

BRP Evinrude E-TEC Series Service Manual

S M Ervice Anual

Safety Notice

Abbreviations Used in this Manual

Units of Measurement

List of Abbreviations

Emission-Related Installation Instructions

Manufacturer's Responsibility

Dealer's Responsibility

Owner's Responsibility

Epa Emission Regulations

Model Designation

Models Covered in this Manual

Service Specifications

Standard Torque Specifications

Product Reference and Illustrations

Table of Contents

Inspection and Maintenance Schedule

Lifting the Outboard

Outboard Rigging Connections

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Engine Cover Service Notes Notes

System Analysis

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

System Analysis Notes Notes

Fuel System

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagram

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Oiling System

Cooling System

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat and Pressure Relief Valve Servicing

Temperature Sender Servicing

Cooling System Notes Notes

Service Chart

Powerhead Removal

Compression Testing

Powerhead Disassembly

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Powerhead Installation

Powerhead Views

Quick Links

Chapters

Troubleshooting

Related Manuals for BRP Evinrude E-TEC Series

Summary of Contents for BRP Evinrude E-TEC Series