BRP E200DHLIN Manuals

Manuals and User Guides for BRP E200DHLIN. We have 1 BRP E200DHLIN manual available for free PDF download: Service Manual

BRP E200DHLIN Service Manual

BRP E200DHLIN Service Manual (416 pages)

Brand: BRP | Category: Outboard Motor | Size: 50.13 MB

Table of Contents

Ervice Anual Contents

4
Table of Contents

17
- Inspection and Maintenance Schedule
  18
- Control Cable Installation
  19
- Lifting the Outboard
  19
- Outboard Rigging Connections
  19
- Battery Cable Connections
  23
- Systemcheck Harness Connections
  23
- I-Command Network Connections
  24
- Icon Network Connections
  25
- Water Pressure Gauge
  26
- Battery and Battery Connections
  27
- Oetiker Clamp Servicing
  28
- Adjustments
  30
- Tilt Limit Switch Adjustment
  30
- Trim Sending Unit Adjustment
  31
- Trim Tab Adjustment
  32
- Dual-Outboard Alignment
  33
- Operational Checks
  34
- Cooling System
  35
- Engine Flushing
  36
- Running the Outboard Using a Hose and Flushing Adapter
  37
- Lubrication
  38
- Steering System
  38
- Swivel Bracket and Trailering Bracket
  38
- Throttle and Shift Linkage
  38
- Tilt Tube
  38
- Gearcase Lubricant
  39
- Propeller Shaft
  39
- Trim and Tilt
  41
- Indexing
  42
- Spark Plugs
  42
- Air Silencer
  43
- Fuel and Oil Systems
  43
- Fuel Filter
  43
- Hoses and Connections
  43
- Oil Filters and Oil Reservoir
  43
- Cleaning
  44
- Exhaust Pressure Fitting
  44
- Operation Test
  44
- Anti-Corrosion Protection
  45
- Storage
  46
- Pre-Season Service
  48
- Submerged Engines
  48
Engine Cover Service

51
- Latch Hook Installation
  52
- Upper Cover Cap Replacement
  52
- Upper Cover Service
  52
- Lower Cover Installation
  53
- Lower Cover Removal
  53
- Lower Cover Service
  53
- Latch Handle Installation
  54
- Trim Switch Installation
  54
Engine Management Module (Emm)

55
- Description
  56
- Emm Inputs and Outputs Diagram
  57
- 55 V Circuit Sensor
  58
- Emm Temperature Sensor
  58
- Internal Sensors
  58
- Barometric Pressure Sensor
  59
- Circuit Sensor
  59
- Exhaust Pressure Sensor
  59
- Air Temperature Sensor
  60
- Engine Temperature Sensor
  60
- External Sensors
  60
- Oil Pressure Sensor
  61
- Throttle Position Sensor
  61
- Crankshaft Position Sensor
  62
- Knock Sensor
  62
- Neutral/Shift Interrupt Switch
  62
- Engine Monitor and Warning Systems
  63
- Fault Code Creation and Storage
  63
- Idle Controller
  63
- Internal Emm Functions
  63
- Neutral Rpm Limiter
  63
- Rom Verification
  63
- Rpm Limiter
  63
- Start Assist Circuit (Sac)
  63
- Engine Monitor System
  64
- Shutdown Mode
  65
- Warning System
  65
- Communication
  66
- Diagnostic Software Functions
  66
- Static Information
  66
- Dynamic Information
  67
- Hard Faults
  67
- Persistent Faults
  67
- Static Tests
  67
- Stored Service Codes (Faults)
  67
- Dynamic Tests
  68
- Oil Control Settings
  69
- Fuel Injector Servicing
  70
- Ignition Timing
  70
- Tps Calibration
  70
- Reports
  71
- Software Replacement
  71
- Emm Servicing
  72
- Emm Transfer
  72
System Analysis

75
- Diagnostic Procedures
  76
- Diagnostic Software Inspections
  76
- Visual Inspections
  76
- Operational Inspections
  77
- Troubleshooting
  78
- Cylinder Drop Tests
  79
- Dynamic Tests
  79
- Fuel Control Adjustment
  79
- Inductive Amp Meter Test
  79
- Emm Led Indicators
  80
- Key on
  80
- Starting
  80
- Running
  81
- Ignition Output Tests
  82
- Required Ignition Systems
  82
- Wiring Inspection
  82
- Crankshaft Position Sensor (Cps) Test
  83
- System Voltage Test
  83
- Static Ignition Test
  84
- Running Ignition Tests
  85
- Capacitor Test
  86
- Ignition Coil Tests
  86
- Ignition Control Circuit Tests
  86
- Fuel Delivery Tests
  87
- Fuel Injector Static Test
  87
- Fuel Pump Static Test
  87
- Running Fuel System Tests
  88
Electrical and Ignition

89
- Service Chart
  90
- Ignition System Circuit Diagram
  92
- Electrical Harness Connections
  93
- Fuse
  95
- Ground Circuits
  95
- Crankshaft Position Sensor (Cps) Test
  96
- Sensor Tests
  96
- Throttle Position Sensor (Tps) Test
  96
- Air Temperature Sensor (At) Test
  97
- Engine Temperature Sensor Test
  97
- Knock Sensor Test
  97
- Stator Resistance Tests
  98
- Stator Tests
  98
- Stator Voltage Output Test
  98
- 12 V Charging Circuit
  99
- Charging System Tests
  99
- 55 V Alternator Circuit
  100
- Auxiliary Battery Charge Wire
  100
- Electric Start Circuit
  101
- Electric Start Tests
  103
- Remote Control Switch Tests
  105
- Tilt/Trim Relay Test
  107
- Systemcheck Circuit Tests
  108
- Tachometer Circuit Tests
  110
- Flywheel and Stator Servicing
  111
- Flywheel Removal
  111
- Stator Service
  111
- Flywheel Installation
  112
- Ignition Coil Installation
  113
- Ignition Coil Removal
  113
- Ignition Coil Servicing
  113
- Timing Adjustments
  114
- Timing Pointer
  114
- Timing Verification
  115
- Tps Calibration
  115
- Electric Starter Servicing
  117
- Starter Disassembly
  117
- Starter Removal
  117
- Starter Cleaning and Inspection
  120
- Starter Assembly
  121
- Starter Installation
  123
- Connector Servicing
  124
Fuel System

129
- Service Chart
  130
- Fuel System Hose Routing
  133
- Fuel System Circuit Diagram
  134
- Fuel Flow Requirements
  135
- Fuel System Requirements
  135
- Portable Fuel Tanks
  135
- Regulations and Guidelines
  135
- Fuel Requirements
  136
- Components
  137
- Fuel Filter
  137
- Fuel Lift Pump
  137
- Vapor Separator
  137
- Fuel Circulation Pump
  138
- Fuel Injectors
  139
- Fuel Manifolds
  139
- Fuel System Priming
  140
- Priming the Fuel System
  140
- Vent Line Clamp
  140
- Fuel System Pressure Test
  141
- Fuel System Tests
  141
- Fuel Injector Pressure Test
  142
- Pressure Regulator Test
  142
- Vapor Separator Vent Check
  142
- Circulation Pump Resistance Test
  143
- Fuel Injector Resistance Test
  143
- Lift Pump Pressure Test
  143
- Lift Pump Diaphragm Test
  144
- Lift Pump Vacuum Test
  144
- Anti-Siphon Valve Test
  145
- Fuel Component Servicing
  145
- Relieving Fuel System Pressure
  145
- Fuel Filter Service
  146
- Fuel Lift Pump Service
  147
- Fuel Manifold Service
  148
- Vapor Separator Service
  148
- Fuel Injector Service
  149
- Intake Manifold Service
  153
Oiling System

157
- Service Chart
  158
- Oiling System Circuit Diagram
  159
- Oil Supply Diagrams
  160
- Oil Recirculation Diagrams
  164
- Components
  166
- Oil System Requirements
  166
- Oil Tank Assembly
  166
- Recommended Lubricants
  166
- Electrical Circuit (55 V)
  167
- Oil Injection Pump
  167
- Oil Pressure Sensor
  167
- Electrical Circuit (12 V)
  168
- Low Oil Warning
  168
- NO OIL Warning
  168
- Rear Oil Manifold (3.3 L Models)
  168
- Rear Oil Pump (3.4 L Models)
  168
- Cylinder and Crankcase
  169
- Oil Recirculation System
  169
- Oil Control Settings
  170
- Oil Injection Rate
  170
- Break-In Oiling
  171
- Oil Hose Priming
  172
- Oil Pump Priming
  172
- Oil Supply Priming
  172
- Oil Injection Pump Static Test
  175
- Oil Injection Pump Voltage Tests
  175
- Oiling System Tests
  175
- Oil Injection Pump Circuit Resistance Test
  176
- Cylinder Oil Pump Voltage Tests
  177
- Cylinder Oil Pump Resistance Test
  178
- Oil Supply Vacuum Test
  178
- Low Oil Sending Unit Test
  179
- Oil Injection Fittings Flow Test
  179
- Oil Injection Pump Function Test
  179
- Oil Component Servicing
  180
- Oil Distribution Hoses
  180
- Oil Injection Pump
  181
- Rear Oil Pump
  182
Cooling System

185
- Hose Routing and Water Flow Diagram 3.3 L
  186
- Hose Routing and Water Flow Diagram 3.4 L
  187
- Adapter Housing
  188
- Components
  188
- Water Pump and Intakes
  188
- Water Supply Tube
  188
- Block Venting
  189
- Pressure Relief Valve
  189
- Thermostats
  189
- Cylinder Block / Cylinder Head Cooling
  190
- Operation
  190
- Emm and Vapor Separator Cooling
  191
- Engine Temperature Check
  191
- Idle Operating Temperature Troubleshooting (below Range)
  192
- Pyrometer Method
  192
- Software Method
  192
- Assembly
  194
- Disassembly
  194
- Inspection
  194
- Installation
  194
- Removal
  194
- Temperature Sender Servicing
  194
- Thermostat Servicing
  194
- Assembly
  195
- Disassembly
  195
- Inspection
  195
- Pressure Relief Valve Servicing
  195
Evinrude Icon Remote Control System

197
- Service Chart
  198
- Components
  199
- Electronic Servo Module (Esm)
  199
- Shift Actuator
  199
- Icon System Failsafe Mode
  200
- Throttle Actuator
  200
- Electronic Servo Module (Esm)
  201
- Icon Component Servicing
  201
- Shift Actuator
  204
- Throttle Actuator
  206
- Calibrate Actuator Stroke
  209
- Icon System Settings
  209
- Set Engine Identity (Instance)
  209
- Icon Remote Control System Troubleshooting Chart
  212
- Icon Remote Control System Fault Messages
  214
Powerhead

217
- Service Chart
  218
- Compression Testing
  220
- Powerhead Removal
  221
- Powerhead Disassembly
  223
- Shift Linkage Removal
  223
- Systems Removal
  223
- Throttle Linkage Removal
  223
- Crankcase Disassembly
  224
- Connecting Rods and Pistons
  225
- Cylinder Head Removal
  225
- Crankshaft Removal
  226
- Cylinder Block Cleaning
  229
- Crankshaft
  230
- Cylinder Head
  230
- Powerhead Inspection
  230
- Cylinder Bore
  231
- Piston Rings
  231
- Pistons
  231
- Bearings
  232
- Crankshaft Assembly
  232
- Powerhead Assembly
  232
- Pistons and Connecting Rods
  235
- Cylinder Head Installation
  236
- Crankshaft and Connecting Rods
  237
- Crankcase Assembly
  240
- Shift Linkage Installation
  241
- Final Powerhead Assembly
  242
- Throttle Linkage Installation
  242
- Powerhead Installation
  243
- Pre-Service Adjustments
  245
- Port Hose Routings - 3.3 L Models
  246
- Powerhead Views
  246
- Starboard Hose Routings - 3.3 L Models
  247
- Port Hose Routings - 3.4 L Models
  248
- Starboard Hose Routings - 3.4 L Models
  249
- Port - 3.3 L Models
  250
- Starboard - 3.3 L Models
  251
- Port - 3.4 L Models
  252
- Starboard - 3.4 L Models
  253
- Front - 3.3 L Models
  254
- Front - 3.4 L Models
  255
- Rear - 3.3 L Models
  256
- Rear - 3.4 L Models
  257
- Top
  258
- Starboard - Icon Models
  259
Midsection

261
- Service Chart
  262
- Stern Bracket
  262
- Exhaust Housing - 3.3 L Models
  263
- Exhaust Housing - 3.4 L Models
  264
- Muffler
  265
- Removal
  266
- Tilt Tube
  266
- Installation
  267
- Exhaust Housing Removal
  268
- Exhaust Housing Service
  268
- Lower Mount Service
  268
- Exhaust Housing Installation
  269
- Exhaust Housing Disassembly - 3.3 L Models
  270
- Exhaust Housing Disassembly - 3.4 L Models
  271
- Cleaning and Inspection
  272
- Exhaust Housing Assembly - 3.3 L Models
  273
- Exhaust Housing Assembly - 3.4 L Models
  275
- Stern Bracket
  277
- Stern Bracket Disassembly
  277
- Stern Bracket Assembly
  279
- Exhaust Relief Muffler Assembly
  282
Gearcase

283
- Service Chart
  284
- Gearcase Types
  287
- Propeller Service
  288
- Gearcase Leak Test
  290
- Gearcase Removal and Installation
  291
- Water Pump Service
  294
- Shift Rod Adjustment
  297
- Gearcase - Standard Rotation
  298
- Gearcase Disassembly
  298
- Propeller Shaft Bearing Housing Removal
  299
- Pinion Gear and Driveshaft Removal
  300
- Driveshaft Service
  302
- Shift Housing, Gear, and Propeller Shaft Removal
  302
- Gearcase Housing Inspection
  303
- Pinion Bearing
  304
- Shifter, Bearing and Seal Servicing
  304
- Shift Housing
  305
- Driveshaft Bearing Housing
  309
- Propeller Shaft Bearing Housing Service
  310
- Driveshaft Shimming
  312
- Gearcase Assembly
  314
- Shift Housing, Gear, and Propeller Shaft Installation
  314
- Pinion Gear and Driveshaft Installation
  315
- Propeller Shaft Bearing Housing and Gear Installation - "L2" Type
  317
- Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
  318
- Final Assembly and Adjustment
  320
- Gearcase - Counter Rotation
  321
- Gearcase Disassembly
  321
- Propeller Shaft Bearing Housing Removal - "M2" Type
  321
- Gearcase Housing Inspection
  322
- Pinion Gear Removal and Driveshaft Servicing
  322
- Shift Housing, Gear and Propeller Shaft Removal
  322
- Shift Housing
  323
- Shifter, Bearing and Seal Servicing
  323
- Pinion Bearing
  326
- Propeller Shaft Bearing Housing and Forward Gear
  326
- Driveshaft Shimming
  329
- Gearcase Assembly
  331
- Pinion Gear and Driveshaft Installation
  331
- Propeller Shaft Bearing Housing and Gear Installation - "M2" Type
  331
- Shift Housing, Gear, and Propeller Shaft Installation
  331
- Final Assembly and Adjustment
  332
Trim and Tilt

333
- Service Chart
  334
- System Description
  335
- Modes of Operation
  336
- Trim-Out / Tilt-Up Mode
  336
- Tilt-Down / Trim-In Mode
  337
- Impact Relief
  338
- Shallow Water Drive Tilt Relief
  339
- Thermal Expansion Relief
  339
- Manual Release - up
  340
- Manual Release - down
  341
- General
  342
- Manual Release Valve
  342
- Reservoir Fluid
  342
- Routine Inspections
  342
- Stern Brackets
  342
- Troubleshooting
  342
- Pressure Leakdown Test
  343
- Service Procedures
  343
- Symptoms Chart
  343
- Electrical Circuit Tests
  346
- Relay Testing
  346
- Trim and Tilt Motor Current Draw Tests
  346
- Trim and Tilt Motor no Load Test
  347
- Trim Gauge Test
  348
- Trim Sender Test
  348
- Removal
  349
- Trim and Tilt Replacement
  349
- Installation
  350
- Disassembly
  351
- Trim and Tilt Service
  351
- Tilt Piston Removal
  354
- Tilt Piston Assembly
  355
- Tilt Piston Identification
  355
- Tilt Rod Assembly
  356
- Trim Rod Removal
  357
- Trim Rod Assembly
  358
- Manifold and Reservoir Installation
  359
- Trim Rod Installation
  360
- Motor Installation
  361
- Tilt Rod Installation
  361
Safety

365

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