Page 1 † 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 2: Table Of Contents
Service Manual Contents Section ........Page 1 Reference Information .
Page 3: Table Of Contents
Reference Information Reference Information Table of Contents Safety Notice ..............4 Abbreviations Used In This Manual .
Page 4: 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 5 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 propel- ler can continue to turn even after the engine is off.
Page 6: 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 7: 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 8: Emission-Related Installation Instructions
Evinrude dealers. Although an authorized Evinrude dealer has the in-depth technical knowledge and tools to service Evinrude outboard engines, the emission-related warranty is not conditioned on the use of an authorized Evinrude dealer or any other establishment with which BRP has a commercial relation- ship.
Page 9: Epa Emission Regulations
Reference Information Emission-Related Installation Instructions The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifica- tions. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.
Page 10: Model Designation
Reference Information Model Designation Model Designation Engine Identification MODEL IDENTIFICATION The first two characters identify DESIGN FEATURES: Model Version: C Counter Rotation AA A First major variant D Evinrude E-TEC AB A Second major variant Electric Start w/Remote Steering AF A Third major variant G Graphite Paint H High Output...
Page 11: Models Covered
Reference Information Model Designation Models Covered This manual covers service information on the following Evinrude E-TEC models: • 52.7 cubic inch (.86 L), 2-Cylinder starting with serial number 5409508. • 79 cubic inch (1.29 L), 3-Cylinder starting with serial number 5409506. Model Shaft Gearcase...
Page 12: Service Specifications, 40 - 60 Hp
Reference Information Service Specifications, 40 – 60 HP Service Specifications, 40 – 60 HP Service Specifications 40 H.O. Engine Full Throttle Operating Range 5000-6000 RPM 5000-6000 RPM 5500-6000 RPM 5500-6000 RPM 40 HP (29.4 kw) @ 40 HP (29.4 kw) @ 50 HP (36.8 kw) @ 60 HP (44.1 kw) Power...
Page 13 Reference Information Service Specifications 40 H.O. Oil System Lubricant – Preferred Lubricant Evinrude/Johnson XD100, XD50, XD30; or –Acceptable Lubricant NMMA TC-W3 certified Capacity 2 qt. (1.9 l) Cooling System Thermostat 143°F (62°C) Maximum Temperature 212°F (100°C) Water pressure 12 to 14 psi @ 5000 RPM Electrical System Minimum Battery Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32°...
Page 14: Service Specifications, 60 H.o. - 90 Hp
Reference Information Service Specifications, 60 H.O. – 90 HP Service Specifications, 60 H.O. – 90 HP Service Specifications 60 H.O. Engine Full Throttle Operating Range 5000-5500 RPM 4500-5500 RPM 4500-5500 RPM 4500-5500 RPM 60 HP (44.1 kw) 65 HP (47.8 kw) 75 HP (56 kw) 90 HP (67.1 kw) Power...
Page 15 Reference Information Service Specifications 60 H.O. Oil System Lubricant – Preferred Lubricant Evinrude/Johnson XD100, XD50, XD30; or –Acceptable Lubricant NMMA TC-W3 certified Capacity 2.4 qt. (2.3 l) Cooling System Thermostat 143°F (62°C) Maximum Temperature 212°F (100°C) Water pressure 19 to 21 psi @ 5000 RPM Electrical System Minimum Battery Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32°...
Page 16: Wire Size Table
Reference Information Wire Size Table Wire Size Table This table provides closest equivalent size cross references between American and metric wire sizes. American Wire Gauge Metric Wire Size American Wire Gauge (AWG) is a standardized Metric wire size is also standardized. Metric wire wire gauge system used in North America to iden- size is determined by the number of strands of tify the diameter of round, electrically conducting...
Page 17 Routine Service Routine Service Table of Contents Inspection and Maintenance Schedule ..........18 Lifting the Outboard .
Page 18: 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 19: Lifting The Outboard
Routine Service Lifting the Outboard Engine Care Products The engine care products listed in the table below are referenced in this service manual, and are recom- mended for use with Evinrude E-TEC outboards. Engine Care Product Notes HPF Pro Gearcase Lubricant Containers available in various sizes, see PAC Catalog Biodegradable TNT Fluid, P/N 763439 Use only in Power Trim &...
Page 20: Outboard Rigging Connections
Routine Service Outboard Rigging Connections Outboard Rigging Con- Cable Retainer Clip Installation When installing retainer clips on control arm link- nections 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 21 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 servicing, disconnect the battery cables at the battery.
Page 22 Routine Service Outboard Rigging Connections If there are not enough threads on the shift cable for the adjustment, or if the gearcase does not shift fully into FORWARD or REVERSE, refer to Refer to Shift Rod Adjustment in the Gearcase Service Manual.
Page 23 Routine Service Outboard Rigging Connections SystemCheck Harness Arrange connectors in flywheel cover. Connections NOTICE BE SURE all harnesses and wires are not pinched, cannot contact flywheel, and do not interfere with moving throttle or shift link- ages. Place the wiring harness through notch in lower motor cover and route to the recess in the fly- wheel cover.
Page 24 Routine Service Outboard Rigging Connections the TPS wiring, and behind the battery cable. Connect the I-Command Engine Interface Cable Loosely install tie straps as shown. to the EMM CANbus connector. 2 Cylinder Models 006736 1. I-Command network connector 006735 1. Flywheel cover 2.
Page 25 Routine Service Outboard Rigging Connections 3 Cylinder Models switch is on. I-Command Digital networks do not use this connection. EMM CANbus connector cap is clipped to EMM cooling water hose. Remove clip from cap and install on I-Command harness connector. 1.
Page 26: Battery And Battery Connections
Routine Service Battery and Battery Connections Use Evinrude Diagnostics software to adjust net- Battery and Battery Con- work settings in the EMM. From the Settings nections screen, select Engine Options. WARNING Battery electrolyte is acidic—handle with care. If electrolyte contacts any part of the body, immediately flush with water and seek medical attention.
Page 27 Routine Service Battery and Battery Connections Connecting the Battery Outboard Battery Rating Model NOTICE 40–90 HP 640 CCA (800 MCA) or Do not use wing nuts to fasten ANY battery 800 CCA (1000 MCA) below cables. Wing nuts can loosen and cause elec- 32°...
Page 28: Oetiker Clamp Servicing
Routine Service Oetiker Clamp Servicing Oetiker Clamp Servicing on the hose and does not result in excessive com- pression or expansion of the band material. WARNING IMPORTANT: Use only Oetiker recommended tools to close Oetiker stepless clamps. DO NOT re-use Oetiker clamps. Fuel leakage could contribute to a fire or explosion.
Page 29: Adjustments
Routine Service Adjustments Adjustments Clamp Removal Method 1: Position Oetiker pincers across clamp Steering Friction Adjustment ear and cut clamp. WARNING Do not over-tighten. The steering friction screw is not intended to allow “hands off” steering. Tiller models are equipped with a steering friction adjustment.
Page 30: Throttle Friction Adjustment
Routine Service Adjustments Throttle Friction Adjustment Tilt Limit Switch Adjustment (3-Cylinder Models) WARNING Tighten knob only enough to hold throttle at a WARNING constant engine speed. Over-tightening will If the outboard does not clear all boat parts prevent quick throttle change in case of emer- when tilted fully or turned side to side, safety gency.
Page 31: Trim Sending Unit Adjustment (2-Cylinder Models)
Routine Service Adjustments Place the outboard in normal operating position. gauge mark with the outboard trimmed all the way DOWN. Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. 1.
Page 32: Trim Sending Unit Adjustment (3-Cylinder Models)
Routine Service Adjustments point. Tighten the screw, and recheck the gauge Loosen the sending unit screws, to allow the reading. sending unit to pivot. 1. Lever DR5090 1. Screws 27339 2. Eccentric cam 3. Contact point 4. Cam screw Disengage the tilt support. Lower the outboard against the thrust rod.
Page 33: Trim Tab Adjustment
Routine Service Adjustments Trim Limiter Rod • If the boat pulled to the left, move rear of the trim tab slightly to the left. WARNING Tighten the trim tab screw as follows: When the outboard is returned to the cus- •...
Page 34: Dual-Outboard Alignment
Routine Service Adjustments Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.
Page 35: Operational Checks
Routine Service Operational Checks Operational Checks • Squeeze fuel primer bulb until hard or activate electric primer. Observe all fuel hoses and con- nections. Repair any leaks. DANGER • Start outboard. Inspect all hoses and connec- DO NOT run the engine indoors or without tions.
Page 36: Cooling System
Routine Service Cooling System • Cooling System Adjust dial on back of tachometer to required setting (the outboard should not be running). Regularly inspect cooling system components for Outboard Model Tachometer Setting corrosion, damage, leaks, or restrictions: 40–90 HP 6 Pulse or 12 Pole •...
Page 37: Running The Outboard Using A Hose And Flushing Adapter
Routine Service Cooling System Flushing — Outboard Running Running the Outboard Using a Hose and Flushing Adapter WARNING To prevent injury from contact with rotating WARNING propeller, remove the propeller before flush- ing. To prevent injury from contact with rotating propeller, remove the propeller before run- Place outboard in VERTICAL (DOWN) position in ning engine with a flushing adapter.
Page 38: Lubrication
Routine Service Lubrication A steady stream of water should flow from the Lubrication overboard indicator while the engine is running. Steering System Monitor engine water pressure gauge when: • WARNING Engine speed is above 3000 RPM • Running engine on a dynamometer. Failure to re-grease as recommended could result in steering system corrosion.
Page 39: Swivel Bracket And Trailering Bracket
Routine Service Lubrication 1. Tiller handle fittings – Long handle 008197 3-Cylinder models DR5073 1. Grease fitting 2. Pivot points Swivel Bracket and Trailering 3. Lower swivel bracket area Bracket Tilt Tube Lubricate the swivel bracket with Triple-Guard Lubricate the tilt tube grease fittings with Triple- grease.
Page 40: Propeller Shaft
Routine Service Lubrication • Gearcase Lubricant Inner casings of both the throttle and shift cables. Draining WARNING Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury. IMPORTANT: Always check the fill level of the gearcase lubricant at the upper plug before remov- ing the lower, drain/fill plug.
Page 41: Trim And Tilt
Routine Service Lubrication Inspection and new seal. Tighten plugs to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Inspect the lubricant and the magnets on the plugs for metal chips. The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase.
Page 42 Routine Service Lubrication • • Tilt the outboard and engage the tilt support. Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. 1. Tilt support bracket, 2-cylinder models 18954 Single Ram System, 2-Cylinder Models 008018 1.
Page 43: 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 44: 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 45: Anti-Corrosion Protection
Routine Service Anti-Corrosion Protection Anti-Corrosion Protec- Testing Procedure – Continuity tion Connect ohmmeter leads between engine ground 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 46: Gearcase Removal And Installation
Routine Service Gearcase Removal and Installation Gearcase Removal and Remove the trim tab retaining screw and trim tab from the gearcase. Installation Gearcase Removal WARNING Turn the key switch OFF, and disconnect the Crankshaft Position Sensor (CPS), to prevent accidental starting while servicing. During service, the outboard may drop unex- pectedly.
Page 47 Routine Service Gearcase Removal and Installation Remove the gearcase assembly from the exhaust Remove the gearcase assembly from the exhaust housing, being careful not to bend the shift rod. housing, being careful not to bend the shift rod. 3-Cylinder Models Gearcase Installation Remove the 3/8-16 in.
Page 48 Routine Service Gearcase Removal and Installation • exhaust cavity. Apply Triple-Guard grease to the 5/16 in. screw – 10 to 12 ft. lbs. (13.5 to 16 seal’s inner surfaces. N·m) 1. 3/8 in. screws 001994 1. Exhaust housing seal 008354 Slide the gearcase into place, making sure: •...
Page 49 Routine Service Gearcase Removal and Installation Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. • Water tube enters the water pump. • Lower inner exhaust housing installs correctly. • Shift rod does not turn and is positioned prop- erly in the shift rod lever below the crankcase.
Page 50: Storage
Routine Service Storage Storage IMPORTANT: DO NOT start outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur. Fuel System Treatment Stabilize the boat’s fuel supply with Evin- rude/Johnson 2+4 Fuel Conditioner following the 3-Cylinder Models 002013 instructions on the container.
Page 51 Routine Service Storage Software Control Method Additional Recommendations Winterization can also be run using Evinrude WARNING Diagnostics software. With the outboard running, start the process at the Settings/Adjustments Failure to check for fuel leakage could allow a screen and follow the instructions. leak to go undetected, resulting in fire or explosion.
Page 52: Pre-Season Service
Routine Service Pre-Season Service Pre-Season Service If the outboard was removed from the boat for storage, make sure it is reinstalled with factory specified hardware. Refer to the Predelivery and Installation Guide. Outboard Mounting Bolts • Check and re-tighten outboard mounting bolts to a torque of 40 ft.
Page 53: Submerged Engines
Routine Service Submerged Engines Submerged Engines ing on p. 171. Make sure all oil injection hoses are clean and filled with oil. Once an outboard has been submerged it must be Make sure high pressure fuel system does not serviced within three (3) hours of recovery. Imme- contain water.
Page 54: Oetiker Clamp Chart
Routine Service Submerged Engines...
Page 55 Engine Cover Service Engine Cover Service Table of Contents Upper Cover Service ............56 Latch Hook Installation .
Page 56: Upper Cover Service
Engine Cover Service Upper Cover Service Upper Cover Service Lower Cover Service Latch Hook Installation Lower Cover Removal Insert threaded bracket into pocket. Remove lower engine cover screws. 1. Bracket 006468 Apply Ultra-Lock to screw threads. Place hook into position with opening toward the front. Tighten 1.
Page 57: Latch Handle Installation
Engine Cover Service Lower Cover Service • Install remaining cover screws and tighten all Place port side cover into position on outboard. screws to 24 to 36 in. lbs. (3 to 4 N·m). 1. Trim cable grommet 002216 2. Trim/tilt switch connector 1.
Page 58: Trim Switch Installation
Engine Cover Service Lower Cover Service to a torque of 180 in. lbs. (20 N·m). Install electrical connector. Refer to Connector Servicing on p. 122. 1. Spring washer 006471 2. Hook 006748 3. Screw Trim Switch Installation Place switch into position through cover. 006746 Install nut on switch.
Page 59 Engine Management Module (EMM) Engine Management Module (EMM) Table of Contents Description ..............60 EMM Functions .
Page 60: Description
Engine Management Module (EMM) Description Description • Stator to EMM connections; one 6-pin AMP and J2 connector. The Engine Management Module (EMM) is a water-cooled engine controller. It controls many outboard systems including alternator output for the 12 V and 55 V circuits. Operating voltage is supplied to the EMM by the stator.
Page 61: 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 1 2 3 4 5 6 INPUTS OUTPUTS 1 2 3 C A B 010344 1. Engine Management Module (EMM) 8.
Page 62: 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 Stores service code 23 used to control outboard operation.
Page 63: 5 V 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 If sensor voltage is less than 4.75 volts, the EMM: used to control outboard operation. Use Evinrude Diagnostics software to troubleshoot the sensors.
Page 64: Low Oil Switch
Engine Management Module (EMM) External Sensors If cylinder head temperature exceeds 212° F If cylinder head does not reach operating tem- (100° C) above 3500 RPM, or 230° F (110° C) perature (104°F / 40°C below 2300 RPM) in 10 below 3500 RPM, the EMM: minutes, the EMM: Activates SHUTDOWN...
Page 65: Crankshaft Position Sensor
Engine Management Module (EMM) External Sensors If TPS voltage is greater than 0.78 volts when the tion and speed, generate a tachometer signal, and key is turned to ON, or the recoil starter is pulled, control fuel and ignition timing. the EMM: If the sensor is damaged or the signal is intermit- Creates service code 11...
Page 66: Internal Emm Functions
Engine Management Module (EMM) Internal EMM Functions Internal EMM Func- Engine Monitor and Warning Systems tions Refer to Engine Monitor System on p. 67. ROM Verification Refer to S.A.F.E. Warning System on p. 68. The EMM performs a self-test of programming Refer to Shutdown Mode on p.
Page 67: Engine Monitor System
Engine Management Module (EMM) Engine Monitor System Engine Monitor Refer to the EMM Service Code Chart at the back of this manual for a complete list of all fault codes. System System Self-Test All remote controlled outboards must be equipped with an engine monitoring system to warn the During engine start-up, pause with the key switch operator of conditions that could damage the out-...
Page 68: Warning System
Engine Management Module (EMM) S.A.F.E. Warning System S.A.F.E. Warning Shutdown Mode System Outboard “shutdown” will occur if specific faults are detected by the EMM: The S.A.F.E. (Speed Adjusting Failsafe Electron- Code 29 Excessive EMM temperature ics) warning system alerts the operator and pro- Code 31 Excessive engine temperature tects against engine damage from the following...
Page 69: Diagnostic Software Functions
Engine Management Module (EMM) Diagnostic Software Functions Diagnostic Soft- The EMM is also turned ON when it begins to receive AC voltage from the stator while the out- board is being cranked. ware Functions Rope Start Models Diagnostic communications on non-running rope The EMM stores valuable information about the start models requires a power supply to the EMM.
Page 70: Static Information
Engine Management Module (EMM) Diagnostic Software Functions • The outboard model and serial numbers displayed Oil injector on the Identity screen must match the identifica- tion label on the outboard swivel bracket. 1. External power connector 007280 If Diagnostic Power Supply Tool, P/N 587005, is not available, a Battery Cable, P/N 584348, can be connected to the engine mounted solenoid.
Page 71: Dynamic Information
Engine Management Module (EMM) Diagnostic Software Functions Dynamic Information Active Faults Dynamic information is viewed while the outboard An active fault is a service code that currently is running. Changes in data, such as voltages or exists. Active faults become occurred faults only if temperatures, are shown as they happen.
Page 72: 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. 87. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.
Page 73: Tiller/Remote Programming
Engine Management Module (EMM) Diagnostic Software Functions Set Oil Type program runs for two hours of outboard operation, above 2000 RPM. The TC-W3 oil type setting is the standard setting for all outboards. Set TC-W3 for: • Operation with all TC-W3 outboard oils includ- ing XD30, XD50, or XD100 •...
Page 74: Tps Calibration
Engine Management Module (EMM) Diagnostic Software Functions Refer to Timing Adjustments on p. 119. Refer to TPS Calibration on p. 121. 1. TPS Calibration button 008572 008581 Check timing after any of the following proce- Perform TPS Calibration after replacing or adjust- dures: ing any throttle body or throttle linkage parts.
Page 75: Reports
Engine Management Module (EMM) Diagnostic Software Functions identified by the EMM. DO NOT install an injector Click the print button in a window of the diagnos- without updating the compensation software. tics software to print engine data, or to export the information to a computer file.
Page 76: Emm Transfer
Engine Management Module (EMM) Diagnostic Software Functions the Utilities menu and refer to the instructions pro- between engine and boat harness key/stop switch vided with the program. connectors as instructed by update program. 002383 Transfer 1. Software Update button 008594 EMM Transfer is used to save engine history data IMPORTANT: If using Diagnostic Power Supply...
Page 77: Emm Servicing
Engine Management Module (EMM) EMM Servicing EMM Servicing Make sure isolator mounts are placed in slots in of EMM case. Slide EMM into position. IMPORTANT: If a new EMM is being installed, refer to EMM Transfer on p. 76. Removal Disconnect cooling hoses from EMM.
Page 78 Engine Management Module (EMM) Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 79 System Analysis System Analysis Table of Contents Diagnostic Procedures ............80 Visual Inspections .
Page 80: Diagnostic Procedures
System Analysis Diagnostic Procedures Diagnostic Procedures The occurred fault screen displays detailed infor- mation about the operating conditions of the engine at the time the code was set. Visual Inspections Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals.
Page 81: Operational Inspections
System Analysis Diagnostic Procedures • Identity screen, press the Print button. Next, press Check the Engine Temperature Profile for evi- dence of cold running or overheating. Printer to print, or PDF File to save the report. Engine Identity Report 008590 Engine Temperature Profile 008588 Operational Inspections...
Page 82 System Analysis Diagnostic Procedures • • Evinrude Diagnostics software Use the diagnostics software Logging function Occurred Faults screen to check for current ser- to record engine data as a problem is occurring. vice codes. If there are multiple occurred sensor codes, inspect all 5 V sensor circuits for broken or grounded wiring.
Page 83: 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 84: Emm Led Indicators
System Analysis EMM LED Indicators EMM LED Indicators LED 2 – CRANK POSITION OKAY – input from CPS, EMM powered ON. For NO LIGHT, check for: The EMM LED indicators provide a quick refer- • Code 16 – CPS, intermittent loss of sync ence to the status of several outboard systems.
Page 85: Ignition Output Tests
System Analysis Ignition Output Tests Ignition Output Tests • Code 82 – no. 2 ignition coil circuit open • Code 83 – no. 3 ignition coil circuit open • Code 90 – Water injection solenoid short DANGER • Code 91 – fuel pump circuit open The electrical system presents a serious •...
Page 86: Wiring Inspection
System Analysis Ignition Output Tests • Crankshaft Position Sensor (CPS) Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated. Test Alternator Output/System Voltage When the CPS is working properly, EMM LED 2 turns on while the outboard is being started. •...
Page 87: Static Ignition Test
System Analysis Ignition Output Tests Use the Evinrude Diagnostics software Monitor the arcing current can cause erratic EMM opera- screen to check system voltage. tion. The outboard must NOT be running and the emer- gency stop switch lanyard must be installed. Monitor Screen, System voltage 008566A Results:...
Page 88: Running Ignition Tests
System Analysis Ignition Output Tests Steady spark on all cylinders: • Refer to Ignition Control Circuit Tests on • p. 88 Refer to Running Ignition Tests on p. 88 and • Dynamic Tests on p. 83. Refer to Ignition Coil Tests on p. 89. IMPORTANT: If a running problem occurs at Running Ignition Tests...
Page 89: Ignition Coil Tests
System Analysis Ignition Output Tests Harness resistance test: If the resistance reading starts as a negative num- ber, or the reading goes down in value, the capac- If control signal is NOT present, calibrate multime- itor already retains some stored energy. Ground ter to low ohms scale.
Page 90: 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 Protect against hazardous fuel spray. Before between pin 2 of fuel pump connector and ground.
Page 91: Running Fuel System Tests
System Analysis Fuel Delivery Tests No injectors actuate: • See Fuel Injector Resistance Test on p. 145. • Use the Monitor screen of the diagnostics soft- Steady light activation on all injector wires and ware to make sure voltage is present on the consistent voltage readings, EMM injector control system voltage circuit.
Page 92: Exhaust Water Valve
System Analysis Exhaust Water Valve (40 H.O./60 HP, 2-Cylinder) Exhaust Water Valve Disconnect the water valve outlet hose. (40 H.O./60 HP, 2-Cylinder) During rapid acceleration, the EMM opens a valve that injects water into the exhaust. This water changes exhaust tuning, boosting midrange horsepower as the boat comes on plane.
Page 93 Electrical and Ignition Electrical and Ignition Table of Contents Service Charts ..............94 Ignition System Circuit Diagram, 2-Cylinder Models .
Page 94: Service Charts
Electrical and Ignition Service Charts Service Charts 5 to 8 in lbs. (.6 to .9 N·m) 120 to 140 in lbs. (13.5 to 16 N·m) 168 to 192 in lbs. 100 to 115 ft. lbs. (19 to 21 N·m) (136 to 156 N·m) 84 to 106 in lbs.
Page 95 Electrical and Ignition Service Charts 24 to 36 in lbs. 2.7 to 4 N·m) 15 to 30 ft. lbs. (20 to 41 N·m) 60 to 84 in lbs. (7 to 9.5 N·m) 30 to 42 in lbs. (3.4 to 4.8 N·m) 24 to 36 in lbs.
Page 96: Ignition System Circuit Diagram, 2-Cylinder Models
Electrical and Ignition Ignition System Circuit Diagram, 2-Cylinder Models Ignition System Circuit Diagram, 2-Cylinder Models 6 5 4 3 2 1 3 2 1 J1-A J1-B 3 2 1 010342 1. Key switch (stop circuit) 4. EMM 7. Ignition coil 2.
Page 97: Ignition System Circuit Diagram, 3-Cylinder Models
Electrical and Ignition Ignition System Circuit Diagram, 3-Cylinder Models Ignition System Circuit Diagram, 3-Cylinder Models 6 5 4 3 2 1 3 2 1 J1-A 3 2 1 J1-B 3 2 1 010343 1. Key switch (stop circuit) 4. EMM 7.
Page 98: Electrical Harness Connections
Electrical and Ignition Electrical Harness Connections Electrical Harness Con- EMM J1-A Connector nections 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 99 Electrical and Ignition Electrical Harness Connections EMM J1-B Connector EMM J2 Connector 001876 001877 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 2, 3-cylinder models Purple Stator winding, 1S Yellow Injector, cylinder 2, 2-cylinder models Green Stator winding, 2S Brown Injector, cylinder 3, 3-cylinder models Green...
Page 100: 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 port side of the power- for specific wiring details.
Page 101: Sensor Tests
Electrical and Ignition Sensor Tests Sensor Tests (1.85 mm). The acceptable clearance is 0.036 to 0.110 in. (1 to 2.8 mm). All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the EMM.
Page 102: Engine Temperature Sensor Test
Electrical and Ignition Sensor Tests through its range of travel. Resistance reading Use a digital multimeter to measure sensor resis- must change evenly as the sensor lever is moved. tance. AT Sensor Resistance Connect red meter lead on terminal “B” and black 680 Ω...
Page 103: Stator Tests
Electrical and Ignition Stator Tests Stator Tests Stator Voltage Output Test The stator consists of 3 windings (4 poles each) Electric Start Models on a 5 inch diameter core and generates an out- WARNING put voltage of 55 VAC (1100 watts maximum). To prevent accidental starting of outboard, This voltage is converted by the EMM to provide disconnect crankshaft position sensor (CPS).
Page 104: Charging System Tests
Electrical and Ignition Charging System Tests Disconnect stator (6-pin) connector from the Charging System Tests engine harness (6-pin) connector. WARNING Connect Stator Test Adaptor tool, P/N 5005799, to stator connector. Excessive battery discharge rates might overheat battery causing electrolyte gas- Connect meter leads to terminals of adaptor tool.
Page 105 Electrical and Ignition Charging System Tests Snap-On model MT540D are examples of testers 55 V Alternator Circuit available. Check battery ground cable for continuity. With the key switch ON, check battery voltage at battery (12 V). Then, use Electrical Test Probe Kit, P/N 342677, and a digital multimeter set to read 55 VDC to check voltage on white/red wires at J2 connector of EMM.
Page 106: Electric Start Circuit
Electrical and Ignition Electric Start Circuit Electric Start Circuit Start Circuit Diagram J1-A J1-B – – 010349 1. Marine battery 9. PURPLE wire (switched B+) 2. RED wire (POS) 10. Engine Management Module (EMM) 3. BLACK wire (NEG) 11. YELLOW/RED wire, start 4.
Page 107 Electrical and Ignition Electric Start Circuit Start Circuit Operation • Provides 12 V input to terminal 28 of EMM J1-B connector. EMM turns ON. The starter must engage and turn the flywheel. The outboard must crank a minimum of 300 RPM to start.
Page 108: Electric Start Tests
Electrical and Ignition Electric Start Tests • Electric Start Tests A closed neutral safety switch provides 12 V to the engine wire harness yellow/red wire and solenoid (terminal “A”). Starter Solenoid Test Disconnect the B+ (POS) battery cable at the bat- tery.
Page 109 Electrical and Ignition Electric Start Tests Starter Voltage Drop Test STEP 4: Connect positive (+) lead to starter cable of solenoid terminal. Connect negative (–) lead to WARNING starter motor terminal. • Activate starter motor and observe voltage To prevent accidental starting of outboard, reading.
Page 110: Remote Control Switch Tests
Electrical and Ignition Remote Control Switch Tests Remote Control Switch Neutral Start Circuit Test Use an ohmmeter or continuity light to test the Tests continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
Page 111 Electrical and Ignition Remote Control Switch Tests IMPORTANT: All wiring must be disconnected wire (black) and one “M” terminal is the stop circuit from the switch before proceeding with this test. wire (black/yellow). Disassemble the remote control and remove the neutral start switch.
Page 112: Tilt/Trim Relay Test
Electrical and Ignition Tilt/trim Relay Test Tilt/trim Relay Test The meter must indicate battery voltage (12 V) with B+ connected to either terminal. The tilt and trim (TNT) module contains the cir- cuitry and relays required for power trim and tilt operation.
Page 113: Exhaust Water Valve Test
Electrical and Ignition Exhaust Water Valve Test Exhaust Water Valve Test SystemCheck Circuit Tests Disconnect electrical connector from water valve solenoid. Use an ohmmeter to measure solenoid Make sure the SystemCheck engine monitor can resistance. warn the operator during a “NO OIL,” “WATER TEMP”...
Page 114 Electrical and Ignition SystemCheck Circuit Tests instrument harness terminal 1 (purple wire) and the two connectors, replace SystemCheck gauge. terminal 2 (black wire). 1. Purple wire DRC6280 1. Test adapter(s) 42761 2. Tan/blue wire 2. Connector, SystemCheck gauge Turn the key switch OFF and reconnect all discon- •...
Page 115 Electrical and Ignition SystemCheck Circuit Tests Using a jumper wire, connect tan wire (pin 6) of If the LOW OIL light does not turn on after con- the engine harness connector to a clean engine necting the terminal to ground, test circuit for con- ground.
Page 116: Tachometer Circuit Tests
Electrical and Ignition Tachometer Circuit Tests Tachometer Circuit Tests Flywheel and Stator Ser- vicing Check voltage at the battery. Use this reading as a reference for battery voltage. IMPORTANT: Weak flywheel magnets 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 117 Electrical and Ignition Flywheel and Stator Servicing Disconnect wiring harness and remove wiring Use Flywheel Holder, P/N 771311, or equivalent, from cover. and a 1 5/16 in. socket to remove flywheel nut. Discard flywheel nut. 1. MWS harness 002086 002088 Remove fuse holder from flywheel cover.
Page 118: Stator Service
Electrical and Ignition Flywheel and Stator Servicing Stator Service Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry. Disconnect stator harness connector. Remove three allen head screws to remove stator. 002093 Align the flywheel keyway and install flywheel. 1.
Page 119: Ignition Coil Servicing
Electrical and Ignition Ignition Coil Servicing Ignition Coil Servicing Timing Adjustments Ignition Coil Removal Timing Pointer Remove spark plug lead from ignition coil and dis- WARNING connect ignition coil electrical connector. To prevent accidental starting of outboard: Remove two ignition coil retaining screws. •...
Page 120: Timing Verification
Electrical and Ignition Timing Adjustments the tool. Mark the flywheel directly across from the Repeat the entire adjustment process to make pointer. Label this mark “A.” sure pointer is aligned correctly. Install spark plugs. Refer to Spark Plug Indexing on p. 43. Timing Verification Use Evinrude Diagnostics software to synchronize the mechanical timing of the outboard with the...
Page 121: Tps Calibration
Electrical and Ignition Electric Starter Servicing Electric Starter Servicing TPS Calibration Use Evinrude Diagnostics software to tell the Starter Removal EMM what throttle position sensor voltage is when the throttle plates begin to open. IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on Set TPS Calibration after replacing or adjusting the powerhead.
Page 122: Connector Servicing
Electrical and Ignition Connector Servicing Connector Servicing Tighten the bolts to a final torque of 168 to 192 in. lbs. (19.0 to 21.0 N·m) using the reverse sequence: Deutsch Connectors • Front IMPORTANT: • Electrical Grease is recommend- Lower • ed.
Page 123 Electrical and Ignition Connector Servicing Use needle-nose pliers to remove wedge from Terminal Installation 3-pin receptacle. Push terminal through seal until it locks into place. Fill connector with Electrical Grease to 1/32 in. (0.8 mm) below ledge or end of plug. 1.
Page 124: Amp Connectors
Electrical and Ignition Connector Servicing AMP Connectors tab and pull on wire to remove from connector housing. 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. Superseal 1.5 Disconnect Lift latch.
Page 125 Electrical and Ignition Connector Servicing Crimping Terminals Terminal Removal Crimping Superseal 1.5 terminals requires AMP Open lock mechanism and remove terminal from Crimp Tool with dies, P/N 777281. connector housing. 1. Terminal 002452 1. Latch 002453 2. Seal 2. Lock mechanism Super Seal Terminal Installation The J1-A and J1-B connectors of the EMM are...
Page 126: Packard Connectors
Electrical and Ignition Connector Servicing Connect Terminal Installation Push connector until seated in plug. Close latch Align terminal with connector housing and push completely. terminal with seal into connector housing until seated. 1. J2 connector 002120 2. Latch (closed) 1. Latch 002456 2.
Page 127 Electrical and Ignition Connector Servicing Insert a thin tool into the connector above the ter- minal to release tab. 1. Tab DRC5940a Terminal Installation Install wire gasket on wires and feed wires through the correct terminal position of the con- nector housing.
Page 128 Electrical and Ignition Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 129 Fuel System Fuel System Table of Contents Service Chart ..............130 Fuel System Hose Routing .
Page 130: Service Chart
Fuel System Service Chart Service Chart 2-Cylinder Models: Injectors, Vapor Separator, Fuel Pump Tighten in 3 stages 5 ft. lbs. (7 N·m) 10 ft. lbs. (14 N·m) 24-36 in. lbs. (2.7-4 N·m) 24-26 Ft. lbs. (33-35 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in.
Page 131 Fuel System Service Chart 2-Cylinder Models: Reed Plate Assembly and Throttle Body 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) IMPORTANT: Do NOT lubricate TPS 10-14 in. lbs (1.1-1.6 n·m) to throttle shaft surface. 10-14 in. lbs (1.1-1.6 n·m) 10-18 in.
Page 132 Fuel System Service Chart 3-Cylinder Models: Injectors, Vapor Separator, Fuel Pump Tighten in 3 stages 5 ft. lbs. (7 N·m) 24-36 in. lbs. 10 ft. lbs. (2.7-4 N·m) (14 N·m) 24-26 Ft. lbs. (33-35 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in.
Page 133 Fuel System Service Chart 3-Cylinder Models: Reed Plate Assembly and Throttle Body 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) IMPORTANT: Do NOT lubricate TPS to throttle shaft surface. 10-14 in. lbs (1.1-1.6 n·m) 10-14 in. lbs (1.1-1.6 n·m) 10-18 in.
Page 134: Fuel System Hose Routing
Fuel System Fuel System Hose Routing Fuel System Hose Routing 2-Cylinder Models Fuel Supply Fuel Return 010502 1. Fuel supply from boat fuel system 7. Electric fuel circulation pump (20 to 30 psi) 2. Fuel lift pump (2 to 8 psi) 8.
Page 135 Fuel System Fuel System Hose Routing 3-Cylinder Models Fuel Supply Fuel Return 010503 1. Fuel supply from boat fuel system 7. Electric fuel circulation pump (20 to 30 psi) 2. Fuel lift pump (2 to 8 psi) 8. Fuel supply manifold 3.
Page 136: Fuel System Circuit Diagrams
Fuel System Fuel System Circuit Diagrams Fuel System Circuit Diagrams 2-Cylinder Models J1-A J1-B 6 5 4 3 2 1 010345 1. Stator 5. Capacitor 9. GREEN (Cylinder #2) 2. EMM 6. WHITE/RED (55 V) 10. BROWN 3. Fuel injector 7.
Page 137 Fuel System Fuel System Circuit Diagrams 3-Cylinder Models J1-A J1-B 6 5 4 3 2 1 010346 1.Stator 5. Capacitor 9. PURPLE (Cylinder #2) 2. EMM 6. WHITE/RED (55 V) 10. GREEN (Cylinder #3) 3. Fuel injector 7. BLACK ground wires 11.
Page 138: Fuel System Requirements
Fuel System Fuel System Requirements Fuel System Require- Portable Fuel Tanks ments WARNING If engine is equipped with a quick-disconnect Regulations and Guidelines fuel hose, you MUST disconnect the fuel hose from the engine and the fuel tank to pre- Vessel manufacturer, and/or installer of an EPA vent fuel leaks: certified outboard, must meet minimum specifica-...
Page 139: Fuel Requirements
Fuel System Fuel System Requirements Fuel Requirements or fuel leakage are found. Inspect at least annu- ally. WARNING IMPORTANT: Always use fresh gasoline. Gaso- Gasoline is extremely flammable and highly line will oxidize, resulting in loss of octane and vol- explosive under certain conditions.
Page 140: Components
Fuel System Components Components Vacuum from the fuel lift pump pulls fuel from the fuel tank. Once fuel reaches the pump, internal pump pressure forces the fuel from the pump The fuel system includes the following compo- through the fuel filter and into the vapor separator. nents: •...
Page 141: 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 142: Fuel Manifolds
Fuel System Components Fuel Flow Compensation and disconnecting the pump’s internal coil to ground. NOTICE Fuel injectors MUST NOT be moved from one cylinder to another. EMM programming is associated with the cylinder location of each injector. Installing an injector on the wrong cylinder can result in powerhead failure.
Page 143: Fuel System Priming
Fuel System Fuel System Priming Fuel System Priming All Models WARNING Vent Line Clamp Failure to check for fuel leaks could allow a Federal Regulations require that all outboards leak to go undetected, resulting in fire or with a fuel vapor separator must be shipped with a explosion and may cause personal injury or vent line clamp installed.
Page 144: Fuel System Tests
Fuel System Fuel System Tests IMPORTANT: Fuel System Tests If outboard does not run, prime fuel system and crank outboard; check circulation pump operation; check fuel system pressure. WARNING Results: Use caution when working on any pressur- ized fuel system. Wear safety glasses and Normal pressure: work in a well ventilated area.
Page 145: Vapor Separator Vent Check
Fuel System Fuel System Tests Apply oil to valve and connect pressure pump and Loosen oil tank assembly to provide access to fuel hose to the fuel return fitting of vapor separator. manifolds. Refer to Oil Tank Assembly on p. 175. Apply pressure to check regulator operation.
Page 146: Circulation Pump Resistance Test
Fuel System Fuel System Tests Use a digital multimeter to measure the injector Circulation Pump Resistance Test coil resistance. Disconnect the battery cables at the battery. Fuel Injector Coil Resistance Use a digital multimeter with appropriate adapter 2 to 3 Ω @ 72°F (22°C) leads to measure the fuel pump circuit and coil resistance.
Page 147: Lift Pump Vacuum Test
Fuel System Fuel System Tests Results: START outboard and run at FULL THROTTLE for at least two minutes. Monitor clear vinyl hose for Normal pressure: the presence of air. Air bubbles indicate a faulty • Perform the Lift Pump Vacuum Test on p. 147. hose, connection, or fuel tank pick-up.
Page 148: Anti-Siphon Valve Test
Fuel System Fuel Component Servicing Anti-Siphon Valve Test Fuel Component Servic- Remove anti-siphon valve from fuel tank. Install 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 149: Fuel Filter Service
Fuel System Fuel Component Servicing Pressure Gauge, P/N 5007100, to top test fitting Clean up any spilled fuel with shop towels. of fuel pump/vapor separator assembly. ENVIRONMENTAL NOTE Dispose of fuel contaminated towels in an envi- ronmentally responsible manner, or according to local regulations.
Page 150: Vapor Separator Service
Fuel System Fuel Component Servicing Disconnect the fuel lift pump pulse hose at the Connect the fuel hoses to the fuel filter. Secure crankcase fitting. with Oetiker clamps. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks. Connect battery cables.
Page 151: Fuel Manifold Service
Fuel System Fuel Component Servicing lator of vapor separator on mounting stud and Remove clamps and disconnect the fuel manifolds secure with retainer clip. as follows: • Fuel supply manifold to circulation pump. • Fuel return manifold to vapor separator. 1.
Page 152: Fuel Injector Service
Fuel System Fuel Component Servicing Install retainer in the outer groove of the manifold Mark fuel injectors to show cylinder locations. fittings. Install and tighten screw to a torque of 24 to 36 in. lbs. (2.7 to 4 N·m). 1. Retainer 005342 2.
Page 153 Fuel System Fuel Component Servicing Remove fuel injector and insulator. Align the angled edges of both sides of the tool base with the edge of the fuel injector housing as Clean up any spilled fuel with shop towels. shown. ENVIRONMENTAL NOTE Dispose of fuel contaminated towels in an envi- ronmentally responsible manner, or according to local regulations.
Page 154 Fuel System Fuel Component Servicing Turn the puller nut until the fuel injector is Installation removed from the fuel injector housing. NOTICE All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure. Installation of a replacement injector requires that coefficient data for the new injector is uploaded to the EMM.
Page 155 Fuel System Fuel Component Servicing Select the Replace Injector button. Make sure the serial number displayed on the screen matches the serial number printed on the serial number label of the replacement injector. 1. “Replace Injector” button 008568A Use the drop down menu to navigate to the saved 1.
Page 156: Intake Manifold Service
Fuel System Fuel Component Servicing Install washers (one per screw) on injector retain- Intake Manifold Service ing screws. Install screws and washers through Removal mounting flange of injector and into cylinder head. Disconnect vapor separator vent hose, main bear- ing vent hose, air temperature sensor, crankshaft position sensor, and throttle position sensor.
Page 157 Fuel System Fuel Component Servicing Remove the reed valve retainer screws and check flatness in all directions. Surface must be remove the assembly. flat, ± 0.004 in. (0.10 mm). 002496 1. Straight-edge 002324 Use caution to prevent damaging reed valve Assembly assemblies.
Page 158 Fuel System Fuel Component Servicing on reed plate and install screws. Tighten screws Tighten the center screws first and expand out- to a torque of 25 to 35 in. lbs. (2.8 to 4.0 N·m). ward. Tighten in stages to a final torque of 60 to 120 in.
Page 159 Oiling System Oiling System Table of Contents Service Charts ............. . . 160 Oil Supply Diagrams .
Page 160: Service Charts
Oiling System Service Charts Service Charts 2-Cylinder Models 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 008058 A Triple-Guard Grease E Red Ultra Lock X see Service Manual B Gasket Sealing Compound F Blue Nut Lock...
Page 161 Oiling System Service Charts 3-Cylinder Models 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 008059 A Triple-Guard Grease E Red Ultra Lock X see Service Manual B Gasket Sealing Compound F Blue Nut Lock...
Page 162: Oil Supply Diagrams
Oiling System Oil Supply Diagrams Oil Supply Diagrams 2-Cylinder Models 008060 1. Oil Tank 4. Oil Distribution Manifold 2. Oil Pick-up/filter 5. Crankcase Oil Inlet (Port) 3. Oil Injection Pump 6. Cylinder Oil Inlet (Starboard)
Page 163 Oiling System Oil Supply Diagrams 3-Cylinder Models 008061 1. Oil Tank 4. Oil Distribution Manifold 2. Oil Pick-up/filter 5. Crankcase Oil Inlet (Port) 3. Oil Injection Pump 6. Cylinder Oil Inlet (Starboard)
Page 164: Oil Recirculation Diagrams
Oiling System Oil Recirculation Diagrams Oil Recirculation Diagrams 2-Cylinder Models Starboard view Port view 002483a 3-Cylinder Models Port view Starboard view 002223...
Page 165: Oiling System Circuit Diagram
Oiling System Oiling System Circuit Diagram Oiling System Circuit Diagram J1-A 6 5 4 3 2 1 J1-B 010347 1. Stator 7. 55 V to injection pump (WHITE / RED) 2. Main harness ground (BLACK) 8. Oil injection pump 3. Alternator grounds (BLACK) 9.
Page 166: Oil System Requirements
Oiling System Oil System Requirements Oil System Requirements Components The oiling system includes the following compo- NOTICE nents: Failure to follow these recommendations • Oil tank could void the outboard warranty if a lubrica- • Oil injection pump and manifold assembly tion-related failure occurs.
Page 167: Oil Injection Pump
Oiling System Components • Electrical Circuit (55 V) Oil distribution hoses The oil injector is powered by the 55 V electrical circuit. The EMM controls pump operation by rap- idly connecting and disconnecting the pump’s internal coil to ground. The EMM monitors the oil injection pump electri- cal circuit.
Page 168: Cylinder And Crankcase
Oiling System Components If outboard has been run for more than 3 hours 2-Cylinder Models with NO OIL faults (codes 34 & 117), the EMM Activates SHUTDOWN Stores service code 33 EMM LED 4: FLASHING Engine Monitor NO OIL display: FLASHING Cylinder and Crankcase The oil distribution manifold provides crankcase lubrication through oil distribution hoses and...
Page 169: Oil Control Settings
Oiling System Oil Control Settings Oil Control Settings Crankcase / Main Bearing Recirculation The movement of oil through the main bearings is controlled by internal passages, external fittings NOTICE and hoses, and check valves. Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil Lower to upper main bearing oil flow: ratio will result in increased engine wear and...
Page 170: Break-In Oiling
Oiling System Oil Control Settings • that have been programmed for the reduced oil Moderate applications injection ratio. This outboard has been programmed for ® ® the use of Evinrude /Johnson XD100™ outboard oil ONLY. ® ® Failure to use Evinrude /Johnson XD100™...
Page 171: Oil Supply Priming
Oiling System Oil Control Settings • Observe oil flow through all oil distribution hoses. Use the diagnostics software to start break-in Air must be purged during the priming procedure. oiling after a powerhead rebuild. 1. Oil distribution hoses 007997 Small bubbles are acceptable. Large bubbles must be eliminated through continued priming.
Page 172: Oiling System Tests
Oiling System Oiling System Tests Oiling System Tests Use the Oil Injector test of Evinrude Diagnostic software Static Test screen to activate the oil pump. 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 Tests IMPORTANT: Do NOT perform static tests using...
Page 173: Oil Injection Pump Resistance Test
Oiling System Oiling System Tests • Clean up any spilled oil with shop towels. Voltage at pin A should be approximately 55 V. • If voltage at pin A is within range, refer to Oil ENVIRONMENTAL NOTE Injection Pump Resistance Test on p. 173. Dispose of used oil or oil contaminated towels in •...
Page 174: Oil Injection Fittings Flow Test
Oiling System Oil Component Servicing Oil Injection Fittings Flow Test Oil Component Servicing Make sure the oil injection fittings of the cylinder WARNING and crankcase assembly allow fluid to move. To prevent accidental starting while servic- Remove oil distribution hose from oil distribution ing, disconnect the Crankshaft Position Sen- manifold.
Page 175: Oil Tank Assembly
Oiling System Oil Component Servicing Once hose is removed from the manifold, make 3-Cylinder Models sure hose support is in the end of the hose. 1. Screw 008071 1. Hose support 008070 Installation Cut Replacement Oil Hose, P/N 778708, to the correct length.
Page 176 Oiling System Oil Component Servicing 2-Cylinder Models Disconnect the electrical connector to the low oil switch. 1. Screw 008073 1. Low oil switch connector 008076 IMPORTANT: Note oil distribution hose routings before proceeding with disassembly. Remove oil distribution hoses from the manifold. Installation Position oil tank assembly on powerhead.
Page 177: Oil Injection Pump
Oiling System Oil Component Servicing Repair any oil leaks and kinked or misrouted Installation hoses. Install air silencer and engine covers. Apply a drop of outboard lubricant to a new oil pump o-ring. Install o-ring on oil pump flange. Oil Injection Pump Removal Remove oil distribution hoses from oil manifold.
Page 178 Oiling System Oil Component Servicing IMPORTANT: Be sure oil pick up assembly is po- sitioned in front of oil tank baffle to prevent inter- ference with the LOW OIL switch. 1. Oil pick up assembly 008183 2. Oil tank baffle All Models Install pump...
Page 179 Cooling System Cooling System Table of Contents Hose Routing and Water Flow Diagrams ......... 180 Components .
Page 180: Hose Routing And Water Flow Diagrams
Cooling System Hose Routing and Water Flow Diagrams Hose Routing and Water Flow Diagrams 2-Cylinder Models 1.Water intake screens 2.Water pump 3.Exhaust housing 4.Cylinder block 5.Pressure relief valve 6.Thermostat 7.Water supply to EMM 8.Water supply, EMM to vapor separator 9.Overboard indicator, outgoing water from vapor separator 10.Exhaust Water Valve Outgoing water (warm/hot)
Page 181 Cooling System Hose Routing and Water Flow Diagrams 3-Cylinder Models 1.Water intake screens 2.Water pump 3.Water tube 4.Adapter housing 5.Cylinder block 6.Pressure relief valve 7.Thermostat 8.Water supply to EMM 9.Water supply, EMM to vapor separator 10.Overboard indicator, outgoing water from vapor separator. Outgoing water (warm/hot) Incoming water (cool) 001818...
Page 182: Components
Cooling System Components Components the water outlet. This hole provides cooling water for the tip of the exhaust passage. Be sure to use the correct parts when replacing the water pump. Water Pump and Intakes 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 183: Pressure Relief Valve
Cooling System Components • Thermostat Provides exhaust passages which connect to the gearcase. The thermostat controls water flow and operating temperature at lower speeds (below 1800 RPM). Overheating: A restricted or faulty thermostat typ- ically results in LOW SPEED overheating. Overcooling: Debris may prevent the thermostat from closing completely.
Page 184: Block Venting
Cooling System Components Block Venting Water Pressure Connection A fitting and hose connected to the top of the A fitting and hose for an accessory water pressure exhaust cover allows the constant movement of gauge can be connected at the top of the cylinder water and/or air from the block.
Page 185: Operation
Cooling System Operation Operation inder block. Water flows through the block to the exhaust housing and then out of the outboard. NOTICE At higher speeds, water pressure opens the pressure relief valve at approximately 1800 RPM. Restricted or inadequate water flow through Water flows through the valve to the cylinder head the outboard reduces cooling system perfor- and bypasses the thermostat.
Page 186: Engine Temperature Check
Cooling System Engine Temperature Check Engine Temperature Software Method Check Use Evinrude Diagnostics software to read tem- perature displays. IMPORTANT: The engine temperatures listed below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). CAUTION When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and disconnect the Crankshaft...
Page 187: Idle Operating Temperature Troubleshooting (Below Range)
Cooling System Engine Temperature Check IMPORTANT: If you get low or inaccurate read- Refer to Thermostat Servicing on p. 189. ings with a digital pyrometer, coat the probe loca- tion with Thermal Joint Compound, P/N 322170. Pressure Relief Valve Inspection The pressure relief valve should be closed at IDLE speed.
Page 188: Temperature Sender Servicing
Cooling System Temperature Sender Servicing Temperature Wait 10 minutes for trapped air to bleed from cav- ity. Thermal compound may seep past threads. Sender Servicing Retighten sensor. Removal Loosen sensor and remove by hand. Use care to avoid breaking threads. 008346 Clean sensor threads, sensor, and sensor cavity.
Page 189: Thermostat Servicing
Cooling System Thermostat Servicing Thermostat Installation on p. 214. Servicing Disassembly Remove the thermostat cover and O-ring from cyl- inder head. 1. Cylinder head seal 002445 Inspection Inspect all parts for cracks, heat damage, or signs of corrosion. Replace damaged parts. Clean debris from housing and parts.
Page 190: Pressure Relief Valve Servicing
Cooling System Pressure Relief Valve Servicing Pressure Relief Valve Inspection Servicing Inspect all parts for cracks, heat damage, or signs of corrosion. Replace damaged parts. Clean The pressure relief valve assembly should be ser- debris from housing and parts. viced at the same time as the thermostat. Disassembly Remove screws and cover from pressure valve assembly.
Page 191 Powerhead Powerhead Table of Contents Service Charts ............. . . 192 Piston Pin Retainer Tool .
Page 192: Service Charts
Powerhead Service Charts Service Charts 2-Cylinder Models 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16 N·m) 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) M, X Q, X 60-84 In. lbs. (7-9.5 N·m) 26-30 Ft. lbs. (35-41 N·m) 60-84 In.
Page 193 Powerhead Service Charts 2-Cylinder Models H, X 30-32 Ft. lbs. (41-43 N·m) 002284 A Triple-Guard Grease G Needle Bearing Grease X See Service Manual Procedure B Gasket Sealing Compound H Outboard Lubricant Y Extreme Pressure Grease D Moly Lube M RTV Sealant Z Thermal Joint Compound E Red Ultra Lock P Permatex No.
Page 194 Powerhead Service Charts 3-Cylinder Models 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16 N·m) 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) M, X Q, X 60-84 In. lbs. 60-84 In. lbs. (7-9.5 N·m) (7-9.5 N·m) 26-30 Ft. lbs. (35-41 N·m) 60-84 In.
Page 195 Powerhead Service Charts 3-Cylinder Models H, X 30-32 Ft. lbs. (41-43 N·m) 15-20 Ft. lbs. (20-27 N·m) 110-130 Ft. lbs. (149-176 N·m) 002282 A Triple-Guard Grease G Needle Bearing Grease X See Service Manual Procedure B Gasket Sealing Compound H Outboard Lubricant Y Extreme Pressure Grease D Moly Lube M RTV Sealant...
Page 196: Piston Pin Retainer Tool
Powerhead Piston Pin Retainer Tool Piston Pin Retainer Tool Use the drawing below to modify a pair of needle nose pliers to remove piston pin retaining rings. NOT to Scale 0.0625 in 1.5875 mm 0.03125 in 0.09375 in 0.79375 mm 2.38125 mm 0.03125 in 0.79375 mm...
Page 197: Compression Testing
Powerhead Compression Testing Compression Testing Powerhead Removal 2-Cylinder Models Start and run outboard until it achieves operating temperature, then shut OFF. WARNING Disconnect crankshaft position sensor (CPS) con- Protect against hazardous fuel spray. Before nector. Remove all spark plugs. starting any fuel system service, carefully relieve fuel system pressure.
Page 198 Powerhead Powerhead Removal Remove pin and washer from shift rod lever to All Models release the lower shift rod. NOTICE Be sure to use only the 1 1/8 in. (short) screws, P/N 398067, included with the tool to avoid damage to electronic components under the flywheel.
Page 199: 3-Cylinder Models
Powerhead Powerhead Removal 3-Cylinder Models Remove six retaining screws and exhaust relief muffler. WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Reliev- ing Fuel System Pressure on p. 168. Disconnect the Crankshaft Position Sensor (CPS) to prevent accidental starting while servicing.
Page 200: Powerhead Disassembly
Powerhead Powerhead Disassembly Remove the small powerhead screw at rear. Powerhead 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 electric starter. Refer to Starter Removal on p.
Page 201: Throttle Linkage Removal
Powerhead Powerhead Disassembly Throttle Linkage Removal Remove the cotter pin and washer holding the shift shaft (2-cylinder models). Remove throttle cam and throttle lever. 1. Shift lever screw 002250 2-Cylinder Models 002245 1. Throttle lever screw 2. Throttle return lever 1.
Page 202: Crankcase Disassembly
Powerhead Powerhead Disassembly IMPORTANT: Crankcase Disassembly Do not use a tapered punch or any other tool that could jam in or damage the ta- Remove screws and carefully pry off exhaust side per bore when removing the pin. water cover. Remove crankcase flange screws.
Page 203: Cylinder Head Removal
Powerhead Powerhead Disassembly Cylinder Head Removal Use Torquing Socket, P/N 331638, to loosen in stages the rod cap retaining screws. DO NOT Remove thermostat cover and thermostat assem- remove the screws. bly. Refer to Thermostat Servicing on p. 189. Loosen in stages and remove cylinder head screws.
Page 204: Crankshaft Removal
Powerhead Powerhead Disassembly necting rod. If necessary, use Wrist Pin Pressing WARNING Tool, P/N 326356, to remove the wrist pin bearing. Wear safety glasses to avoid injury. Use an appropriate ring expander to remove all piston rings from pistons. Discard the rings. 002047 Be careful not to lose any of the 28 needle bear- ings or the two wrist pin washers.
Page 205 Powerhead Powerhead Disassembly Remove the upper main bearing. Use a punch to remove the housing seal. Discard seal. 1. Upper oil seal 002034 2. Upper main bearing 1. Punch 002053 Remove the lower bearing seal housing. Inspect housing and replace if necessary. Remove the O-ring from crankshaft sleeve and inspect it.
Page 206 Powerhead Powerhead Disassembly Remove the lower main bearing only if it needs to Remove center main bearings and split sleeves be replaced. Use external retaining ring pliers to for inspection. DO not mix parts. Note location of remove the lower bearing retaining ring. bearings for reassembly.
Page 207: Cylinder Block Cleaning
Powerhead Cylinder Block Cleaning Cylinder Block Cleaning sealant from the cylinder block, crankcase, cylin- der head, and water cover. IMPORTANT: Before inspecting or assembling powerhead, all internal components must be com- pletely clean and free of contaminants. Be careful to avoid damaging any machined surfaces. Remove any carbon accumulation from exhaust port areas.
Page 208: Powerhead Inspection
Powerhead Powerhead Inspection Powerhead Inspection would only be measured if the bearing was removed for another reason. For dimensions, refer to Refer to Service Specifi- cations on p. 12 and Service Specifications on p. 14. IMPORTANT: Before any inspection process can begin, all internal components must be com- pletely clean and free of contaminants.
Page 209 Powerhead Powerhead Inspection IMPORTANT: • Ring end gap increases approxi- The cylinder taper must not exceed 0.002 in. (0.05 mm). mately 0.003 in. (0.076 mm) for each 0.001 in. (0.025 mm) increase in cylinder bore diameter. DO NOT exceed cylinder oversize dimension. Use a machinist’s straightedge to check for proper ring clearance.
Page 210: Powerhead Assembly
Powerhead Powerhead Assembly Powerhead Assembly If the installer sticks on the sleeve after installa- tion, thread Slide Hammer, P/N 391008, into installer and pull it off. IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called IMPORTANT: Inspect sleeve after installation.
Page 211: Pistons And Connecting Rods
Powerhead Powerhead Assembly lower housing with extended lip facing down. Lubricate upper main bearing with outboard lubri- Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft. 1. Seal lip 002036 1. Upper main bearing 002033 Pack lip of upper oil seal with Moly Lube. Place seal on crankshaft with lip down and enclosed face up.
Page 212 Powerhead Powerhead Assembly will be located toward the top and starboard side the connecting rod. Align bearings with Wrist Pin of the block. Bearing Tool, P/N 336660. 1. Exhaust side of block 002049 1. 28 needle bearings 24903 2. Stamped markings 2.
Page 213 Powerhead Powerhead Assembly IMPORTANT: Use Wrist Pin Cone, P/N 318600, and Driver, Be sure gap of ring fits squarely P/N 318599, to install new wrist pin retaining rings around dowel pin. in each wrist pin hole. Gap of retaining ring faces up, away from notch in piston.
Page 214: Cylinder Head Installation
Powerhead Powerhead Assembly Cylinder Head Installation Apply a 1/16 in. (2 mm) bead of RTV Adhesive around each water passage on the block and cyl- Install a new thermostat seal in cylinder head with inder head as shown. side marked “TO CYL HEAD” facing toward ther- mostat.
Page 215: Crankshaft And Connecting Rod Installation
Powerhead Powerhead Assembly Following sequence stamped on cylinder head, Check that main bearing alignment dowel pins are tighten all screws in stages to a torque of 168 to seated in the block. 192 in. lbs. (19 to 21.7 N·m). 1. Gasket Sealing Compound 002262 2.
Page 216 Powerhead Powerhead Assembly IMPORTANT: Lubricate each crankpin and bearing assembly Be sure alignment dot on rod cap with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dots face fly- up to crankshaft and install bearing halves. wheel.
Page 217 Powerhead Powerhead Assembly Secure restraining jaw “C” and forcing jaw “D” to • Tighten the forcing screw to a torque of 14 to 16 frame. in. lbs. (1.6 to 1.8 N·m). Restraining Jaw “C” 21591 1. Forcing screw 005297 2. Adjustment stop 3.
Page 218: Crankcase Assembly
Powerhead Powerhead Assembly IMPORTANT: Test at least three corners of the rod and cap joint Gel-Seal II has a shelf life of at with a pick. Joint must be smooth with no step. least one year when stored at room temperature. Test the Gel-Seal II or replace it if the age of the tube cannot be determined.
Page 219 Powerhead Powerhead Assembly Start in the center and work outward in a spiral Note: 3-Cylinder models include a double-ended pattern. stud and use a lock washer under the J-clamp. 002254 2-Cylinder models 002242r 1. J-clamp Apply Nut Lock to crankcase flange screws. Install screws and tighten to a torque of 60 to 84 in.
Page 220: Shift Linkage Installation
Powerhead Powerhead Assembly Shift Linkage Installation and washer and tighten screw to a torque of 120 to 144 in. lbs. (13.5 to 16 N·m). Place the spring, guide, and ball of the shift detent assembly into the crankcase. Lubricate with Tri- ple-Guard grease.
Page 221: Final Powerhead Assembly
Powerhead Powerhead Assembly Install lever, screw, and washer on crankcase and and tighten screw to a torque of 120 to 144 in. lbs. hook spring on rib as shown. Tighten screw to a (13.5 to 16 N·m). torque of 120 to 144 in. lbs. (13.5 to 16 N·m). 2-Cylinder models 002245 1.
Page 222: Upper Mount Servicing (3-Cylinder)
Powerhead Upper Mount Servicing (3-cylinder) Upper Mount Servicing or Powerhead Views on p. 229. Install thermostat assembly. Refer to Thermostat (3-cylinder) Servicing on p. 189. Removal Install pressure valve assembly. Refer to Pres- sure Relief Valve Servicing on p. 190. WARNING Wear safety glasses to avoid injury.
Page 223 Powerhead Upper Mount Servicing (3-cylinder) Dislodge mount assemblies and remove. Apply Moly Lube to all sides of retainer and install between mounts. 002132 002133 Inspect mounts and replace if necessary. Install the retainer screw and tighten to a torque of IMPORTANT: The motor mount, washer, and 15 to 20 ft.
Page 224: Powerhead Installation
Powerhead Powerhead Installation Powerhead Installation Loosely install all powerhead screws before tight- ening: Powerhead Mounting – 2-Cylinder Models Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only. Install gasket on exhaust housing. To ensure proper sealing, mating surfaces must be clean and dry.
Page 225 Powerhead Powerhead Installation Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing. retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 1.
Page 226: Powerhead Mounting - 3-Cylinder Models
Powerhead Powerhead Installation Install recoil starter ratchet and housing on out- clockwise direction to align crankshaft and drive- board. Refer to Recoil Starter Installation on shaft splines. p. 323. 1. Alignment pin 002162 1. Starter housing screws (3) 002515 Apply Triple-Guard grease to the threads, and Install the lower engine covers.
Page 227 Powerhead Powerhead Installation IMPORTANT: • Retighten powerhead mounting Tighten the upper mount screws to a torque of 110 to 130 ft. lbs. (149 to 176 N·m). Make sure screws after outboard has been run at full operat- that screw heads are tight against steering arm. ing temperature and allowed to cool.
Page 228: Shift Linkage Adjustment
Powerhead Powerhead Installation Connect the power trim connectors. • Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N·m). 002152 Install the lower engine covers. Refer to Lower 1. Adjustment screws 002125 Cover Service on p. 56. 2.
Page 229: Powerhead Views
Powerhead Powerhead Views Powerhead Views 2-Cylinder Port – Hose Routings 006490 2-Cylinder Starboard – Hose Routings 006491...
Page 230 Powerhead Powerhead Views 2-Cylinder Port Dressed Powerhead 010510 2-Cylinder Starboard Dressed Powerhead 010508...
Page 231 Powerhead Powerhead Views 2-Cylinder Port Rope Start Models 008370 2-Cylinder Starboard Rope Start Models 008185...
Page 232 Powerhead Powerhead Views 2-Cylinder Front 008160...
Page 233 Powerhead Powerhead Views 2-Cylinder Rear 010509...
Page 234 Powerhead Powerhead Views 2-Cylinder Top 010511...
Page 235 Powerhead Powerhead Views 2-Cylinder Top, Rope Start Models 008186...
Page 236 Powerhead Powerhead Views 3-Cylinder Port – Hose Routings 006760 3-Cylinder Starboard – Hose Routings 006761...
Page 237 Powerhead Powerhead Views 3-Cylinder Port Dressed Powerhead 010514 3-Cylinder Starboard Dressed Powerhead 010516...
Page 238 Powerhead Powerhead Views 3-Cylinder Front 008166...
Page 239 Powerhead Powerhead Views 3-Cylinder Rear 010515...
Page 240 Powerhead Powerhead Views 3-Cylinder Top 010517...
Page 241 Midsection Midsection Table of Contents Service Charts ............. . . 242 Tilt Tube, 3-Cylinder Models .
Page 242: Service Charts
Midsection Service Charts Service Charts Exhaust Housing, 2-Cylinder Models 24-26 Ft. lbs. 18-20 Ft. lbs. (32.5-35 N·m) (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 in. lbs (7-9.5 N·m) 18-20 ft. lbs (24.5-27 N·m) 16-18 ft. lbs (22-24.5 N·m) 004304 A Triple-Guard Grease F Blue Nut Lock Q Gel Seal II...
Page 243 Midsection Service Charts Exhaust Housing, 3-Cylinder Models 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. lbs. 60-84 In. lbs. (24.5-27 N·m) (7-9.5 N·m) 150-180 In. lbs. (17-20 N·m) 002210 A Triple-Guard Grease...
Page 244 Midsection Service Charts Stern Bracket, 2-Cylinder – Power Tilt IMPORTANT: Use Triple-Guard grease on all pivot points. 45-50 Ft. lbs. 10-16 In. lbs. (61-68 N·m) (1-2 N·m) 144-168 In. lbs. (16-19 N·m) 45-50 Ft. lbs. (61-68 N·m) 010308 A Triple-Guard Grease F Blue Nut Lock Y Extreme Pressure Grease B Gasket Sealing Compound...
Page 245 Midsection Service Charts Stern Bracket, 3-Cylinder Power Trim & Tilt IMPORTANT: Use Triple-Guard grease 60-84 In. lbs. on all pivot points. (7-9.5 N·m) 110-130 Ft. lbs. (149-176 N·m) 40-50 In. lbs. (4.5-5.5 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 28-30 Ft. lbs. (38-41 N·m) 45-50 Ft.
Page 246 Midsection Service Charts Stern Bracket, 40 HP Manual Tilt IMPORTANT: Use Triple-Guard grease on all pivot points. 144-168 In. lbs. (16-19 N·m) 40-45 Ft. lbs. (54-61 N·m) 144-168 In. lbs. (16-19 N·m) 40-45 Ft. lbs. (54-61 N·m) 144-168 In. lbs. (16-19 N·m) 010310 A Triple-Guard Grease...
Page 247 Midsection Service Charts Tiller Handle (Long) 18-20 Ft. lbs. (24.5-27 N·m) 36-48 In. lbs. 24-36 In. lbs. (4-5.4 N·m) (2.7-4 N·m) 18-20 Ft. lbs. (24.5-27 N·m) 20-30 In. lbs. (2.3-3.4 N·m) 36-40 Ft. lbs. (49-54 N·m) 18-20 Ft. lbs. (24.5-27 N·m) 60-84 In.
Page 248: 3-Cylinder Models
Midsection Tilt Tube, 3-Cylinder Models Tilt Tube, Remove the nut from the starboard side. 3-Cylinder Models The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist. 30747 Pull the locking tabs on the tilt limit cam loose from Thread the spacer from Tilt Tube Service Kit,...
Page 249 Midsection Tilt Tube, 3-Cylinder Models Thread Slide Hammer, P/N 432128, into the Make sure the lock tab is in correct position. adapter until at least 2 in. (51 mm) of thread are engaged. 1. Lock tab 30742 Install the starboard locknut. 30744 Tighten starboard tilt tube nut to a torque of 45 to Pull tilt tube from stern bracket with the slide ham-...
Page 250: Exhaust Housing, 2-Cylinder Models
Midsection Exhaust Housing, 2-Cylinder Models Exhaust Housing, Check condition of the lower front mount and two lower side mounts. 2-Cylinder Models The exhaust housing contains no serviceable internal parts. The exhaust water valve and the exhaust relief muffler can both be serviced without removing the exhaust housing.
Page 251: Exhaust Water Valve (40 H.o. /60 Hp 2-Cylinder Models)
Midsection Exhaust Housing, 2-Cylinder Models Remove the exhaust housing. Check that all water passages are clear. Exhaust Housing 005069 1. Fitting, water passage 004300 Exhaust Water Valve Install hoses to fittings on exhaust housing. (60 HP 2-Cylinder Models) Place water valve and bracket in position. Apply Nut Lock to screws, install and tighten 60 to Disconnect water valve electrical connector.
Page 252: Exhaust Housing Installation
Midsection Exhaust Housing, 2-Cylinder Models Apply Gasket Sealing Compound to cover gasket Place lower thrust washer on the steering shaft and install cover. and place the lower front mount into position. Apply Nut Lock to cover screws and tighten to a torque of 60 to 84 in.
Page 253: Exhaust Housing, 3-Cylinder Models
Midsection Exhaust Housing, 3-Cylinder Models Exhaust Housing, Remove the exhaust housing. 3-Cylinder Models Exhaust Housing Removal Before removing the exhaust housing: • Remove the gearcase. Refer to Gearcase Removal and Installation on p. 46. • Remove the powerhead. Refer to Powerhead Removal on p.
Page 254: Exhaust Housing Installation
Midsection Exhaust Housing, 3-Cylinder Models Install the mount covers. Apply Nut Lock to Install gearcase. Refer to Gearcase Removal screws, install washers and screws, and tighten to and Installation on p. 46. a torque of 150 to 180 in. lbs. (17 to 20 N·m). Install powerhead.
Page 255: Cleaning And Inspection
Midsection Exhaust Housing, 3-Cylinder Models Remove the three upper screws and three lower Remove the four screws securing the exhaust screws securing the inner exhaust housing to the megaphone to the adapter housing. adapter housing. 1. Adapter to megaphone screws 001976 2.
Page 256: Exhaust Housing Assembly
Midsection Exhaust Housing, 3-Cylinder Models IMPORTANT: A distorted exhaust housing will Place a new grommet on the water tube and coat cause the upper driveshaft splines to wear exces- the outside edge with Adhesive 847. sively and will damage the crankshaft splines. 1.
Page 257 Midsection Exhaust Housing, 3-Cylinder Models and three upper screws and tighten to a torque of Cleaning Solvent. Apply Gel-Seal II sealant to the 60 to 84 in. lbs. (7 to 9.5 N·m). adapter flange of the exhaust housing. 1. Lower inner exhaust housing screws 001974 001983 Place the adapter/inner exhaust housing into the...
Page 258: Stern Bracket, 2-Cylinder Models With Power Tilt
Midsection Stern Bracket, 2-Cylinder Models with Power Tilt Stern Bracket, Use an appropriate tool to pry the lower seal from the swivel bracket. 2-Cylinder Models with Power Tilt Stern Bracket Disassembly Remove the bumpers from the upper mount retaining screws. Remove the screws, upper mount, and ground lead from the bracket.
Page 259: Stern Bracket Assembly
Midsection Stern Bracket, 2-Cylinder Models with Power Tilt Check the condition of the anode. Replace the Position the swivel bracket between the stern anode if it has been reduced to two-thirds its origi- brackets. Place a thrust washer between each of nal size.
Page 260: Stern Bracket, 3-Cylinder Models
Midsection Stern Bracket, 3-Cylinder Models sure to place the ground lead under the starboard Stern Bracket, screw. 3-Cylinder Models Stern Bracket Disassembly Before servicing the stern bracket: • Remove gearcase. Refer Gearcase Removal and Installation on p. 46. • Remove powerhead. Refer to Powerhead Removal on p.
Page 261 Midsection Stern Bracket, 3-Cylinder Models Remove the steering shaft and thrust washer. It Remove the anode. may be necessary to tap the steering shaft out using a wood dowel and mallet. 1. Anode 30762 Remove the swivel bracket. Inspect and, if neces- 30735 sary, replace the tilt tube bushings.
Page 262: Stern Bracket Assembly
Midsection Stern Bracket, 3-Cylinder Models Remove the tilt limit switch and retainer from the Remove the two trim rod rollers from the swivel swivel bracket. bracket. 1. Trim rod roller 30754 Remove the tilt support and bushing from the 1. Tilt limit switch 30758 swivel bracket and inspect the detent roller and 2.
Page 263 Midsection Stern Bracket, 3-Cylinder Models bushing to a torque of 28 to 30 ft. lbs. (38 to 41 Install the trail lock and bushings in the swivel N·m). bracket. Tighten to a torque of 216 to 240 in. lbs. (25 to 27 N·m). 30752 1.
Page 264 Midsection Stern Bracket, 3-Cylinder Models Install the tilt limit switch and retainer on the swivel • Coat the bushings and seal lips with Triple- bracket. Tighten screws to a torque of 40 to 50 in. Guard grease. lbs. (4.5 to 5.5 N·m). 010312 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.
Page 265: Stern Bracket, 2-Cylinder Manual Tilt
Midsection Stern Bracket, 2-Cylinder Manual Tilt Stern Bracket, Install the steering shaft keeper. Apply Locquic Primer and Nut Lock to the splines of the steering 2-Cylinder Manual Tilt shaft and lower mount bracket. Clamp Screw Service Inspect clamp screw assemblies). Replace swivel plate and retainer if bent or loose.
Page 266 Midsection Stern Bracket, 2-Cylinder Manual Tilt Slide the pivot shaft and upper thrust washer out is flush with the inside surface of the casting, of the swivel bracket. remove the steering friction thrust ring. 1. Upper thrust washer COA2956 1. Steering friction screw COA2959 Use an appropriate tool to pry the upper and lower seals from the swivel bracket.
Page 267 Midsection Stern Bracket, 2-Cylinder Manual Tilt Drive the steering friction bushing up and out of Place the tilt/run lever in the RUN position. the swivel bracket. Loosen the bellcrank setscrew. COA2974 1. Bellcrank setscrew COA2976 Remove the thrust rod from the stern brackets. Remove the tilt/run lever, port stop link, and bush- Remove one tilt tube nut, and remove tilt tube ing from the swivel bracket.
Page 268: Stern Bracket Assembly
Midsection Stern Bracket, 2-Cylinder Manual Tilt Remove the cotter pins from both reverse lock the springs. Push the pins through the springs and pins. Remove the reverse lock pins and springs. the reverse lock assembly. 1. Cotter pin COA2979 1. Reverse lock springs COA2981 2.
Page 269 Midsection Stern Bracket, 2-Cylinder Manual Tilt Install the bushing, the port stop link, and the Place the swivel bracket between the stern brack- tilt/run lever in the swivel bracket. The tilt/run lever ets. should be in the RUN position. Install the tilt tube through the following parts and install the tilt tube nuts loosely: •...
Page 270 Midsection Stern Bracket, 2-Cylinder Manual Tilt Install and tighten the nut to a torque of 144 to 168 Place the steering friction bushing in the swivel in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews. 1.
Page 271: Tilt Assist Cylinder
Midsection Stern Bracket, 2-Cylinder Manual Tilt Install new upper and lower seals in the swivel Tilt Assist Cylinder bracket with lips of seals facing away from the bracket. WARNING Support the outboard with a suitable hoist. Slide the upper thrust washer on the pivot shaft. Slide the pivot shaft through the swivel bracket.
Page 272: Tiller Handle Service - Standard
Midsection Tiller Handle Service – Standard Tiller Handle Service – Remove set screw from starboard stern bracket lower pivot pin access hole and use an appropri- Standard ate tool to remove lower pivot pin. Removal WARNING Disconnect the Crankshaft Position Sensor to prevent accidental starting of the engine while servicing.
Page 273: Disassembly
Midsection Tiller Handle Service – Standard Remove the electrical cover. Disassembly Loosen throttle friction control so there is no restriction on grip. IMPORTANT: Do not back screw out completely. Nut is under spring tension. 1. Electrical cover 002509 Disconnect the electrical harness coming from the tiller handle.
Page 274 Midsection Tiller Handle Service – Standard Remove the helix halves, rollers, and guides. Remove the throttle control plate. 1. Helix halves 007542 1. Throttle control plate 24287 2. Rollers 3. Guides Remove the throttle cable retaining clip. Pry the cable trunnion out of the steering handle and Pull the throttle pin out of the cable.
Page 275: Inspection
Midsection Tiller Handle Service – Standard Remove the plastic inner handle from the metal Install the metal outer handle over the plastic inner outer handle by driving the outer handle off with a handle and drive the outer handle into place. mallet and a punch.
Page 276 Midsection Tiller Handle Service – Standard Install the handle end of the throttle cable. Snap Push the throttle cable pin through the end of the the throttle cable trunnion into the recess in the throttle cable. handle. Install the retainer clip. 1.
Page 277: Installation
Midsection Tiller Handle Service – Standard Be sure the twist-grip's speed indicator line is Installation positioned with the speed range symbol on the handle. Snap the grip into place. CAUTION The steering handle nut must have a nylon patch for locking. Replace the nut if it has lost its locking feature.
Page 278: Throttle Cable Adjustment
Midsection Tiller Handle Service – Standard Install electrical cover. Secure electrical harness with tie strap. 1. Electrical cover 002509 1. Cable anchor 006526 2. Boss 3. Cable retainer Throttle Cable Adjustment 4. Tie strap Place throttle cable in position. Use Ball Socket Installer tool, P/N 342225, to snap throttle cable connector onto throttle lever.
Page 279: Tiller Handle Service - Long Handle
Midsection Tiller Handle Service – Long Handle Tiller Handle Service – Remove the electrical cover. Long Handle Removal WARNING Disconnect the Crankshaft Position Sensor to prevent accidental starting of the engine while servicing. Use Ball Socket Remover tool, P/N 342226, to unsnap the throttle cable clip from the throttle 1.
Page 280: Disassembly
Midsection Tiller Handle Service – Long Handle Remove the screws attaching tiller bracket to Remove stop switch cover screws, unplug stop steering arm. Remove tiller bracket and handle. switch electrical connector and remove stop switch assembly. 1. Screws 006361 006713 Disassembly Disconnect trim switch connector.
Page 281 Midsection Tiller Handle Service – Long Handle Remove the helix halves, rollers, and guides. Remove the throttle cable retaining clip. Pry the cable trunnion out of the steering handle and remove cable. 1. Helix halves COA2674 2. Rollers 3. Guides Pull the throttle pin out of the cable.
Page 282 Midsection Tiller Handle Service – Long Handle Use an appropriate tool to carefully pry up on the Remove cotter pin from shift handle pin. Remove inner handle retaining tab. shift cable. 1. Inner handle retainer tab 006679 1. Cotter pin 006708 Use a wooden dowel and a soft mallet to remove Remove shift handle screw and washer.
Page 283: Inspection
Midsection Tiller Handle Service – Long Handle Remove the shift pin if necessary. Coat detent ball, spring and guide with Triple- Guard grease and install into shift handle. Place one washer on shift handle mounting boss. 1. Shift pin 006716 Inspection 1.
Page 284 Midsection Tiller Handle Service – Long Handle Install shift cable on shift pin with a new cotter pin. Secure tab of the inner handle into the outer han- dle. Tab must be flush with the back of the flange and top of tab must be flush with top of flange. 1.
Page 285 Midsection Tiller Handle Service – Long Handle Install the throttle control plate on outer handle. ing. If wire guide is forced into place, it WILL dam- age trim switch wiring. 1. Throttle friction control 006671 1. Inner tiller handle 006684 2.
Page 286 Midsection Tiller Handle Service – Long Handle Install the handle end of the throttle cable. Snap Lubricate end of the pin, guides, rollers, helix the throttle cable trunnion into the recess in the halves, and inner handle guide slot with Moly handle.
Page 287: Installation
Midsection Tiller Handle Service – Long Handle Carefully pull trim switch wires through inner tiller Install bottom cover of tiller handle with seven handle as twist grip assembly is installed. screws. 1. Trim switch wiring 006677 1. Cover screw 006566 Install trim switch connector.
Page 288: Control Cable Installation
Midsection Tiller Handle Service – Long Handle into steering arm and tighten to a torque of 18 to Install the electrical cover. 20 ft.lbs. (24.5 to 27 N·m). 1. Electrical cover 002084 1. Screws 006361 Use tie strap to secure harness to throttle body Install locknuts on screws on top of steering arm.
Page 289 Midsection Tiller Handle Service – Long Handle anchor pocket. Adjust the trunnion nut so the cas- Throttle Cable Adjustment ing fits onto the shift lever pin. Place throttle cable in position. Use Ball Socket Installer tool, P/N 342225, to snap throttle cable connector onto throttle lever.
Page 290 Midsection Tiller Handle Service – Long Handle Install washer, cable anchor, and cable anchor screw on throttle body boss. Tighten screw securely. 1. Cable anchor 006745 2. Boss 3. Cable retainer 4. Tie strap 1. Throttle lever stop 005114 1. Turn anchor four turns toward cable end. 006564 IMPORTANT: Rotate twist grip.
Page 291 Trim and Tilt Trim and Tilt Table of Contents Service Charts ............. . . 292 System Description .
Page 292: Service Charts
Trim and Tilt Service Charts Service Charts 2-Cylinder Models 30 to 50 in. lbs. (4 to 5.6 N·m) 60 to 85 ft. lbs. (82 to 115 N·m) 45 to 55 in. lbs. (5 to 6 N·m) 60 to 85 ft. lbs. 45 to 55 in.
Page 293 Trim and Tilt Service Charts 3-Cylinder Models 30 to 50 In. lbs. (4 to 5.6 N·m) 60 to 85 ft. lbs. (82 to 115 N·m) 45 to 55 In. lbs. (5 to 6 N·m) 60 to 85 ft. lbs. 45 to 55 In. lbs. (82 to 115 N·m) (5 to 6 N·m) 84 to 106 in.
Page 294: System Description
Trim and Tilt System Description System Description 45 to 55 in. lbs. (5 to 6 N·m) before normal opera- tion can be resumed. The power trim/tilt hydraulic system is completely contained between the outboard's stern brackets. The system consists of: •...
Page 295: Routine Inspections
Trim and Tilt Routine Inspections Routine Inspections 3-Cylinder Models Use the trailering bracket to support the outboard General when trailering in the tilted position. This bracket protects the hydraulic system from damage. Check for external signs of fluid leakage. Correct causes as necessary.
Page 296: Troubleshooting
Trim and Tilt Troubleshooting Troubleshooting Electrical Circuit Tests Use the following guidelines to check a single pis- Relay Testing ton trim/tilt unit that is not working correctly. When the trim-UP button is pressed, the UP relay is energized and connects the blue trim motor wire Cylinder Leakdown: to the battery positive (+) terminal.
Page 297: Trim And Tilt Motor No Load Test
Trim and Tilt Electrical Circuit Tests Connect a 0 to 100 A DC ammeter in series Test results include three basic possibilities: between the battery side of the starter solenoid A. Low current draw – Check for: and the red lead to the trim/tilt relay module. •...
Page 298: Trim Gauge Test
Trim and Tilt Electrical Circuit Tests The motor shaft must rotate clockwise, as viewed • If results are different, replace the trim gauge. from the pump end, when positive (+) is applied to • If results agree, refer to Trim Sender Test. the blue lead, and negative (–) is connected to green lead.
Page 299: Trim And Tilt Replacement
Trim and Tilt Trim and Tilt Replacement Trim and Tilt Replace- • If results are different, replace trim sender. ment Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector. 010331 000686 Remove the terminals from the connector by using a suitable tool to depress the tab.
Page 300 Trim and Tilt Trim and Tilt Replacement Separate the trim/tilt unit wires in the braided tube Remove one of the locknuts from the angle adjust- to permit removal through the hole in the stern ment rod. Remove the rod from the stern brack- bracket.
Page 301 Trim and Tilt Trim and Tilt Replacement Use a punch to remove the upper pin. Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw. 25065 Retract the tilt cylinder rod. 1.
Page 302 Trim and Tilt Trim and Tilt Replacement Lubricate the angle adjustment rod with Triple- Install external snap rings on lower pin with sharp Guard grease. Install the rod. Tighten the locknuts edge of ring facing out. to a torque of 20 to 25 ft. lbs. (27 to 34 N·m). 25077 18941 Loosen the manual release valve if necessary and...
Page 303: Trim And Tilt Service
Trim and Tilt Trim and Tilt Service Trim and Tilt Service All Models Place trim/tilt wires in braided tube and install Thoroughly clean the unit before disassembling. through hole in the stern bracket. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from con- taminating internal parts.
Page 304 Trim and Tilt Trim and Tilt Service Screw the manual release valve in. Remove the Slowly remove the manual release valve. There retaining ring using a small pick or screwdriver. may be pressure behind the valve—wear safety Discard the retaining ring. glasses.
Page 305: Piston Seal And End Cap
Trim and Tilt Trim and Tilt Service Inspect the manual release valve. Discard the O- Install new retaining ring in groove. rings on the housing. 1. Retaining ring 002534 007108 Piston Seal and End Cap Oil O-rings and install them on the manual release Trim and Tilt Seal Tool Kit, P/N 5008918, is valve.
Page 306 Trim and Tilt Trim and Tilt Service Use end cap spanner wrench, P/N 352932, to Note: Use spanner wrench, P/N T-552, to remove remove the end cap from the trim and tilt assem- fastener from piston of trim and tilt assembly, bly.
Page 307 Trim and Tilt Trim and Tilt Service Use piston spanner wrench, P/N T-553, to remove 2-Cylinder Models the piston from the rod of trim and tilt assembly, Install a new o-ring into the piston. Refer to Ser- P/N 5007776. vice Charts on p. 292. 1.
Page 308 Trim and Tilt Trim and Tilt Service Apply red Ultra Lock to the threaded portion of the Tighten fasteners to specified torque, Service rod, piston and fasteners. Install the piston on the Charts on p. 292. rod. 008828 008826 Apply trim/tilt fluid to the inside diameter of the Use piston spanner wrench, P/N T-553, to install resizing fixture.
Page 309 Trim and Tilt Trim and Tilt Service chart. Part number is stamped on the bottom of Place the loading mandrel, on the piston. Make the housing of trim and tilt assemblies. sure the edge of the loading mandrel is flush with the top edge of the seal groove in the piston.
Page 310 Trim and Tilt Trim and Tilt Service Place the seal on the loading mandrel. Lift the resizing fixture up over the piston as shown. 1. Seal 008833 1. Resizing fixture 008835 Slowly move the seal pusher down the mandrel. Use the seal pusher to slide the seal into the Lift resizing fixture over the seal while observing groove of the piston.
Page 311: Trim Motor
Trim and Tilt Trim and Tilt Service Leave the resizing fixture in place for at least five cylinder could cause difficulty purging air from the minutes. trim and tilt assembly. 1. Bottom of the resizing fixture flush with the piston 008837 008839 2.
Page 312 Trim and Tilt Trim and Tilt Service Removal Installation Remove the four large motor flange retaining IMPORTANT – 3-Cylinder models: Use only screws. Remove the motor and discard O-ring, Evinrude/Johnson Biodegradable TNT Fluid to fill screws, and washers. the hydraulic system. Install drive coupler in pump assembly.
Page 313 Trim and Tilt Trim and Tilt Service Fill the oil reservoir up to the fill plug with the cor- rect fluid. Install the fill plug. 2-Cylinder Models 007646 1. Fill location 3-Cylinder Models – Use only Evinrude/Johnson 004278 Biodegradable TNT Fluid 1.
Page 314 Trim and Tilt Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 315 Manual Starter Manual Starter Table of Contents Service Chart ..............316 Recoil Starter Removal .
Page 316: Service Chart
Manual Starter Service Chart Service Chart 60 to 84 in lbs. (7 to 9.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) 96 to 120 in lbs. (11 to 13.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) 003724 E Red Ultra Lock F Blue Nut Lock...
Page 317: Recoil Starter Removal
Manual Starter Recoil Starter Removal Recoil Starter Removal Recoil Starter Disassem- WARNING Turn the key switch OFF, and disconnect the WARNING Crankshaft Position Sensor (CPS), to prevent Wear safety glasses while disassembling and accidental starting while servicing. assembling manual starters because of rewind spring tension.
Page 318 Manual Starter Recoil Starter Disassembly Remove the nut from the starter pawl retaining Use a screwdriver to pry open the pulley lock ring, screw. and remove ring from the starter. 1. Nut 007855 1. Lock ring COA1368 Remove the starter pawl retaining screw, washer, Remove the friction plates and friction plate spring and starter pawl plate with plate return spring from washer.
Page 319: Recoil Starter Cleaning And Inspection
Manual Starter Recoil Starter Cleaning and Inspection Recoil Starter Cleaning Recoil Starter Assembly and Inspection WARNING Wear safety glasses while disassembling and Wash metal components in solvent and dry with assembling manual starters because of compressed air. rewind spring tension. Inspect the rewind spring for broken end loops and weak tension.
Page 320 Manual Starter Recoil Starter Assembly crank and pin assembly to the starter winder base holes in the spring winder base to transfer the with the crank retainer screw. rewind spring into the starter housing. CO3591 1. Outer loop CO3584 2. Pin Rotate the crank and pin assembly in the direction Apply Triple-Guard grease or Lubriplate 777 to the shown on the tool.
Page 321 Manual Starter Recoil Starter Assembly Place the friction plate spring washer between the on the boss of the pulley. Position the starter pawl two friction plates on the pulley hub. Secure the plate on the pulley. friction plate and friction plate spring washer with the pulley lock ring.
Page 322 Manual Starter Recoil Starter Assembly Install the rope guide and pulley support to the Threading Tool, P/N 378774, thread the starter starter housing. Tighten the screws securely. rope through the handle. 1. Rope guide 007854 COA1373 2. Pulley support Press the starter rope into the channel of the rope If removed, install the starter handle bracket to the anchor, with end of starter rope firmly against end starter housing.
Page 323: Recoil Starter Installation
Manual Starter Recoil Starter Installation Recoil Starter Installation Apply Nut Lock to the threads of starter ratchet screws. Install washers and ratchet on flywheel. Tighten screws to a torque of 120 to 144 in. lbs. (13.5 to 16 N·m). 006654 Place the starter assembly onto the outboard.
Page 324 Manual Starter Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 325 Safety Safety Table of Contents Marine Products and the Safety of People Who Use Them ......S–327 Outboard Shift Systems and Safety .
Page 326 S–326...
Page 327: Marine Products And The Safety Of People Who Use Them
Safety Marine Products and the Safety of People Who Use Them 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 fol- low common shop safety practices.
Page 328: Outboard Shift Systems And Safety
Safety Marine Products and the Safety of People Who Use Them 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.
Page 329: Outboard Speed Control System And Safety
Safety Marine Products and the Safety of People Who Use Them 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 330: Outboard Steering Control System And Safety
Safety Marine Products and the Safety of People Who Use Them 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: •...
Page 331 Safety Marine Products and the Safety of People Who Use Them 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 •...
Page 332: Outboard Fuel, Electrical System, And Safety
Safety Marine Products and the Safety of People Who Use Them 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.
Page 333 Safety Marine Products and the Safety of People Who Use Them 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 •...
Page 334 Safety Marine Products and the Safety of People Who Use Them After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard Check for leaks under engine cover Whenever possible, remove hose from outboard and from tank.
Page 335: Outboard Mounting System And Safety
Safety Marine Products and the Safety of People Who Use Them 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...
Page 336: If Weakened, Parts Could Fail Later On The Water, When Not Expected
Safety Marine Products and the Safety of People Who Use Them If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only When rigging or fixing any boat, if transom looks weak, tell the owner.
Page 337: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety
Safety Marine Products and the Safety of People Who Use Them 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. •...
Page 338: Outboard Emergency Stop System And Safety
Safety Marine Products and the Safety of People Who Use Them 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? •...
Page 339 Safety Marine Products and the Safety of People Who Use Them 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.
Page 340: Summary
Safety Marine Products and the Safety of People Who Use Them Summary 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 “ ”...
Page 341: Marine Products And The Safety Of People Who Fix Them
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 342 Safety Marine Products and the Safety of People Who Fix Them 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.
Page 343 Safety Marine Products and the Safety of People Who Fix Them 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.
Page 344 Safety Marine Products and the Safety of People Who Fix Them 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.
Page 345: Handling Lead/Acid Batteries
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 346: Gasoline - Handle With Care
Safety Marine Products and the Safety of People Who Fix Them 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.
Page 347: Hazardous Products
Safety Marine Products and the Safety of People Who Fix Them 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 •...
Page 348: Safety Awareness Test
Safety Marine Products and the Safety of People Who Fix Them 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?
Page 349 Index Index Break-In EMM Programming 170, 228 Abbreviations 6 Oiling 170 Accessories Procedure 73 Battery Cable, P/N 584348 70 XD100 Outboard Oil Decal, P/N 352369 Capacitor Test 89 Adjustments Clamp Screw 265 Control Cable 21, 278, 288 Connecting Rods Shift Linkage 228 Installation on Crankshaft 216 Shift Rod 13, 15 Installation on Piston 211, 212...
Page 350 Index Cover Service 56 Timing Verification 73, 120 Crankcase TPS Calibration 74, 121 Assembly 218 Dual-Outboard Disassembly 202 Alignment 34 Crankshaft I-Command Settings 26 Assembly 210, 215 Disassembly 204 Inspection 208 Electrical Circuits Crankshaft Position Sensor EMM Pin Locations 98 Description 65 Fuse 100 Operation Test 86...
Page 351 Index Exhaust Housing Assembly 256 Gearcase Cleaning and Inspection 255 Installation 47 Installation 252, 254 Lubricant 13, 15, 40 Removal 250, 253 Removal 46 Exhaust Water Valve Grommet 21 Service 251 Tests 92, 113 Exterior Finish Protection 45 Honing 207 Hoses Grommet 21 Flushing, Cooling System 36, 37...
Page 352 Index Electrical Tests 172 Functional Test 173 LED Indicators 84 Oiling Rate 73, 169 Lower Cover Oiling System Installation 56 Components 166 Removal 56 Electrical Circuits 165 Lubrication Engine Lubricant 166 Engine Oil 166 Low Oil Switch 64 Gearcase 13, 15, 40 New Engine Set-Up 166 Propeller Shaft 40 Oil Distribution 162...
Page 353 Index Predelivery Checks 35 Lubrication 39 Pre-Season Service 52 Removal 201 Pressure Relief Valve Shift Rod Adjustment 13, 15 Assembly 190 Shutdown 68 Disassembly 190 No Oil 168 Inspection 190 Spark Plugs Priming Gap 13, 15, 43 Fuel System 143 Indexing 43 Propeller Safety 5 Maintenance Schedule 18...
Page 354 Index Swivel Bracket Lubrication 39 Installation 264 Removal 248, 258 Lubrication 39 Timing Adjustments Removal 261 Timing Verification 120 SystemCheck TPS Calibration 121 LOW OIL Warning Signal 167 Timing Pointer Adjustment 119 NO OIL Warning Signal 167 Tools Outboard Connections 23 Accessory Power Cable Kit, P/N 5008092 Tests 113, 114, 115 69, 76, 154...
Page 355 Index Rod Cap Alignment Fixture, P/N 396749 Test 298 Trim Tab Secondary Lock Installer, P/N 777079 124 Adjustment 33 Secondary Lock Tool, P/N 777078 124 Removal 46 Slide Hammer Adapter, P/N 340624 300 Troubleshooting Slide Hammer, P/N 391008 210, 300 Charging System Tests 104 Slide Hammer, P/N 432128 205, 249 Cylinder Drop Tests 83...
Page 356 Index Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other I–356...
Page 357 Trouble Check Chart Trouble Check Chart Table of Contents Outboard Will Not Start ........... . . T–358 Outboard Will Not Start .
Page 358: Outboard Will Not Start
Trouble Check Chart Outboard Will Not Start Outboard Will Not Start OBSERVATION POSSIBLE CAUSE PROCEDURE Outboard does not Battery switch not ON Check battery switch operation turn over Discharged battery Check battery, recharge or replace Battery cables and connectionsClean and tighten connections. Check for voltage drop in starter circuit.
Page 359 Trouble Check Chart Outboard Will Not Start Outboard Will Not Start OBSERVATION POSSIBLE CAUSE PROCEDURE Outboard turns over Stop circuit grounded Check wiring and emergency stop switch. Check 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...
Page 360: Outboard Hard To Start
Trouble Check Chart Outboard Hard to Start Outboard Hard to Start OBSERVATION POSSIBLE CAUSE PROCEDURE Outboard eventually Weak battery Check battery, recharge or replace starts, may or may Battery cables and connectionsClean and tighten connections, check voltage not run properly once drop on high amperage circuit started Starter or bendix/drive gears...
Page 361: Outboard Will Not Shut Off
Trouble Check Chart Outboard Will Not Shut Off Outboard Will Not Shut Off OBSERVATION POSSIBLE CAUSE PROCEDURE Outboard starts and Key switch or wire harness Check key switch and ground to key switch, refer runs, normal perfor- ground to System Analysis and Electrical and Ignition mance while running Stop circuit wiring Check EMM LED indicators.
Page 362: Outboard Starts, Low Maximum Rpm
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 Setup or rigging Incorrect propeller Refer to specifications, check recommended change WOT RPM;...
Page 363: Outboard Surges, Runs Rough
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 May be erratic or Incorrect, fouled, or worn spark Replace spark plugs inconsistent plugs Water in fuel system Check water separator/fuel filter, sample fuel from fuel return manifold test port Contaminated or poor fuel...
Page 364 Trouble Check Chart Notes Notes Technician’s Notes Related Documents Bulletins Instruction Sheets Other T-364...

BRP E-TEC EVINRUDE Manual

Service Manual

Routine Service

Engine Cover Service

Engine Management Module (Emm)

System Analysis

Electrical and Ignition

Fuel System

Oiling System

Cooling System

Powerhead

Midsection

Quick Links

Chapters

Troubleshooting

Related Manuals for BRP E-TEC EVINRUDE

Summary of Contents for BRP E-TEC EVINRUDE