BRP E300DCZSCS Manuals

Manuals and User Guides for BRP E300DCZSCS. We have 1 BRP E300DCZSCS manual available for free PDF download: Service Manual

BRP E300DCZSCS Service Manual

BRP E300DCZSCS Service Manual (396 pages)

Evinrude E-TEC series 250, 300 HP 90 V6 (3.4L)

Brand: BRP | Category: Outboard Motor | Size: 21.13 MB

Table of Contents

Table of Contents

4
Special Tools 1

15
- Diagnostic Tools
  16
- Special Tools
  16
- Universal Tools
  16
- Electrical / Ignition Tools
  18
- Fuel /Oil System Tools
  19
- Powerhead Tools
  19
- Gearcase Tools
  20
- Trim and Tilt Tools
  23
- Shop Aids
  24
Installation and Predelivery

27
- Boat Rigging
  
  28
  - Remote Controls
    28
  - Battery Installation
    29
  - Battery Switches and Multiple Batteries
    30
  - Auxiliary Battery Charging
    32
  - Fuel System Requirements
    35
  - Oiling System Set-Up
    37
  - Cable and Hose Installation
    40
- Outboard Installation
  
  44
  - Hull Preparation
    44
  - Transom Measuring and Drilling
    46
  - Lifting the Outboard
    49
  - Steering Systems
    49
  - Outboard Mounting
    51
- Outboard Rigging
  
  52
  - Cable, Hose, and Wire Routing
    52
  - Control Cable Installation
    53
  - Electrical Harness Connections
    55
  - Water Pressure Gauge
    55
  - Canbus Connections
    56
- Fuel and Oil Priming
  
  58
  - Fuel Requirements
    58
  - Fuel System Priming
    59
  - Oil Requirements
    59
  - Oil Injection Rate
    60
  - Break-In Oiling
    61
  - Oil Supply Priming
    61
- Before Start-Up
  
  63
- Running Checks
  
  64
  - Engine Monitoring System
    64
  - Fuel System
    64
  - Emergency Stop / Key Switch
    64
  - Start-In-Gear Prevention
    64
  - Tachometer Pulse Setting
    65
  - Water Pump Overboard Indicator
    65
  - Break-In
    65
- Propellers
  
  66
  - Propeller Selection
    66
  - Propeller Hardware Installation
    67
- Final Adjustments
  
  68
  - Tilt Limit Switch Adjustment
    68
  - Trim Sending Unit Adjustment
    69
  - Trim Tab Adjustment
    70
  - Dual-Outboard Alignment
    71
- Notes
  
  72
Maintenance

73
- Inspection and Maintenance Schedule
  
  74
- Anti-Corrosion Protection
  
  75
  - Sacrificial Anodes
    75
  - Testing Procedure - Continuity
    75
  - Metallic Component Protection
    75
  - Exterior Finishes
    75
- Cooling System
  
  76
  - Flushing
    76
  - Water Intake Screens
    77
  - Additional Maintenance
    77
- Lubrication
  
  78
  - Steering System
    78
  - Swivel Bracket and Trailering Bracket
    78
  - Tilt Tube
    78
  - Throttle and Shift Linkage
    79
  - Propeller Shaft
    79
  - Gearcase Lubricant
    79
  - Trim and Tilt
    81
- Battery and Battery Connections
  
  82
- Fuel and Oil Systems
  
  82
  - Fuel Filter
    82
  - Oil Filters and Oil Reservoir
    83
  - Air Silencer
    83
  - Hoses and Connections
    83
- Spark Plugs
  
  84
  - Indexing
    84
- Exhaust Pressure Fitting
  
  85
  - Operation Test
    85
  - Cleaning
    85
- Storage
  
  86
  - Fuel System Treatment
    86
  - Internal Engine Treatment
    86
  - Additional Recommendations
    87
- Pre-Season Service
  
  87
  - Outboard Mounting Bolts
    87
  - Gearcase Lubricant
    87
  - Battery(S)
    87
  - Power Trim and Tilt
    87
  - Operational Checks
    87
- Submerged Engines
  
  88
Engine Cover Service

89
- Upper Cover Service
  90
  - Latch Hook Installation
    90
  - Upper Cover Cap Replacement
    90
- Lower Cover Service
  91
  - Lower Cover Removal
    91
  - Lower Cover Installation
    91
  - Latch Handle Installation
    92
  - Trim Switch Installation
    92
Engine Management Module (Emm)

93
- Description
  
  94
- Emm Inputs and Outputs Diagram
  
  95
- Internal Sensors
  
  96
  - Emm Temperature Sensor
    96
  - 55 V Circuit Sensor
    96
  - Barometric Pressure Sensor
    97
  - Exhaust Pressure Sensor
    97
- External Sensors
  
  97
  - Air Temperature Sensor
    97
  - Oil Pressure Sensor
    98
  - Throttle Position Sensor
    99
  - Crankshaft Position Sensor
    99
- Internal Emm Functions
  
  100
  - Start Assist Circuit (Sac)
    100
  - Rom Verification
    100
  - Idle Controller
    100
  - Rpm Limiter
    100
  - Shift Interrupt
    100
  - Engine Monitor and Warning Systems
    100
  - Fault Code Creation and Storage
    100
- Engine Monitoring System
  
  101
- Warning System
  
  102
- Shutdown Mode
  
  102
- Diagnostic Software Functions
  
  103
  - Communication
    103
  - Static Information
    103
  - Dynamic Information
    104
  - Stored Service Codes (Faults)
    104
  - Hard Faults
    104
  - Persistent Faults
    104
  - Static Tests
    104
  - Dynamic Tests
    105
  - Oil Control Settings
    106
  - Ignition Timing
    107
  - Tps Calibration
    107
  - Fuel Injector Servicing
    108
  - Reports
    108
  - Software Replacement
    109
  - Emm Transfer
    109
- Emm Servicing
  
  110
  - Removal
    110
  - Installation
    110
System Analysis

111
- Diagnostic Procedures
  
  112
  - Visual Inspections
    112
  - Operational Inspections
    112
  - Troubleshooting
    113
- Dynamic Tests
  
  114
  - Cylinder Drop Tests
    114
  - Fuel Control Adjustment
    114
  - Inductive Amp Meter Test
    114
- Emm Led Indicators
  
  115
  - Key on
    115
  - Starting
    115
  - Running
    116
- Ignition Output Tests
  
  117
  - Required Ignition Systems
    117
  - Wiring Inspection
    117
  - Crankshaft Position Sensor (Cps) Test
    118
  - System Voltage Test
    118
  - Ignition Voltage Test
    119
  - Static Ignition Test
    119
  - Running Ignition Tests
    120
  - Ignition Primary Circuit Resistance Test
    121
  - Ignition Coil Tests
    121
  - Capacitor Test
    122
- Fuel Delivery Tests
  
  122
  - Fuel Pump Static Test
    122
  - Fuel Injector Static Test
    123
  - Running Fuel System Tests
    123
Electrical and Ignition

125
- Service Chart
  126
- Dash Connections, Instrument Harness
  128
- Electrical Harness Connections
  129
- Fuse
  131
- Ground Circuits
  131
- Sensor Tests
  132
- Stator Tests
  134
  - Stator Resistance Tests
    134
  - Stator Voltage Output Test
    134
- Charging System Tests
  135
  - 12 V Charging Circuit
    135
  - Auxiliary Battery - Charge Wire
    136
  - 55 V Alternator Circuit
    136
- Electric Start Circuit
  137
- Electric Start Tests
  139
- Remote Control Switch Tests
  141
- Tilt/Trim Relay Test
  143
- Systemcheck Circuit Tests
  144
- Tachometer Circuit Tests
  146
- Flywheel and Stator Servicing
  147
  - Flywheel Removal
    147
  - Stator Service
    147
  - Flywheel Installation
    148
- Timing Adjustments
  149
  - Timing Pointer
    149
  - Timing Verification
    150
  - Tps Calibration
    150
- Electric Starter Servicing
  151
  - Starter Removal
    151
  - Starter Disassembly
    151
  - Starter Cleaning and Inspection
    154
  - Starter Assembly
    155
  - Starter Installation
    157
- Connector Servicing
  158
Fuel System

163
- Service Chart
  
  164
- Fuel System Hose Routing
  
  167
- Fuel System Circuit Diagram
  
  168
- Components
  
  169
  - Fuel Lift Pump
    169
  - Fuel Filter
    169
  - Vapor Separator
    169
  - Fuel Circulation Pump
    170
  - Fuel Manifolds
    171
  - Fuel Injectors
    171
- Fuel System Tests
  
  172
  - Fuel System Pressure Test
    172
  - Pressure Regulator Test
    173
  - Vapor Separator Vent Check
    173
  - Fuel Injector Pressure Test
    173
  - Fuel Injector Resistance Test
    174
  - Circulation Pump Resistance Test
    174
  - Lift Pump Pressure Test
    174
  - Lift Pump Vacuum Test
    175
  - Lift Pump Diaphragm Test
    175
  - Anti-Siphon Valve Test
    176
- Fuel Component Servicing
  
  176
  - Relieving Fuel System Pressure
    176
  - Fuel Filter Service
    177
  - Fuel Lift Pump Service
    178
  - Vapor Separator Service
    179
  - Fuel Manifold Service
    179
  - Fuel Injector Service
    180
  - Intake Manifold Service
    183
  - Installation
    184
- Notes
  
  186
Oiling System

187
- Service Chart
  188
- Oiling System Circuit Diagram
  189
- Oil Supply Diagrams - V6
  190
- Oil Recirculation Diagrams - V6
  192
- Components
  193
  - Oil Tank Assembly
    193
  - Oil Injection Pump
    193
  - Oil Pressure Sensor
    193
  - Electrical Circuit (55 V)
    194
  - Low Oil Warning
    194
  - NO OIL Warning
    194
  - Cylinder and Crankcase
    194
  - Oil Recirculation System
    195
- Oil Control Settings
  196
  - Oil Priming
    196
  - Oiling Rates
    196
  - Break-In Oiling
    196
- Oiling System Tests
  197
  - Oil Injection Pump Static Test
    197
  - Oil Injection Pump Voltage Test
    197
  - Oil Injection Pump Circuit Resistance Test
    198
  - Oil Supply Vacuum Test
    198
  - Oil Injection Pump Function Test
    199
  - Oil Injection Fittings Flow Test
    199
  - Low Oil Sending Unit Test
    199
- Oil Component Servicing
  200
  - Oil Distribution Hoses
    200
  - Oil Injection Pump
    201
Cooling System

203
- Hose Routing and Water Flow Diagram
  
  204
- Components
  
  205
  - Water Pump and Intakes
    205
  - Water Supply Tube
    205
  - Adapter Housing
    205
  - Pressure Relief Valve
    205
  - Thermostats
    206
  - Block Venting
    206
- Operation
  
  206
  - Cylinder Block / Cylinder Head Cooling
    206
  - Emm and Vapor Separator Cooling
    207
- Engine Temperature Check
  
  208
  - Software Method
    208
  - Pyrometer Method
    208
  - Idle Operating Temperature Troubleshooting (below Range)
    209
- Thermostat Servicing
  
  210
  - Disassembly
    210
  - Inspection
    210
  - Assembly
    210
- Pressure Relief Valve Servicing
  
  211
  - Disassembly
    211
  - Inspection
    211
  - Assembly
    211
- Notes
  
  212
Powerhead

213
- Service Chart
  
  214
  - Taper Pin Tool
    216
- Powerhead Removal
  
  217
- Powerhead Disassembly
  
  219
  - General
    219
  - Throttle Linkage Removal
    219
  - Shift Linkage Removal
    219
  - Crankcase Disassembly
    220
  - Cylinder Head Removal
    221
  - Connecting Rods and Pistons
    221
  - Crankshaft Removal
    222
- Cylinder Block Cleaning
  
  225
- Powerhead Inspection
  
  226
  - Cylinder Head
    226
  - Crankshaft
    226
  - Cylinder Bore
    227
  - Pistons
    227
  - Piston Rings
    227
  - Bearings
    228
- Powerhead Assembly
  
  228
  - Crankshaft
    228
  - Pistons and Connecting Rods
    231
  - Cylinder Head Installation
    232
  - Crankshaft and Connecting Rods
    233
  - Crankcase Assembly
    236
  - Shift Linkage Installation
    237
  - Throttle Linkage Installation
    238
  - Final Powerhead Assembly
    238
- Powerhead Installation
  
  239
- Powerhead Views
  
  242
  - Port Hose Routings
    242
  - Starboard Hose Routings
    243
  - Port
    244
  - Starboard
    245
  - Front
    246
  - Rear
    247
  - Top
    248
Midsection

249
- Service Chart
  
  250
- Tilt Tube
  
  253
  - Removal
    253
  - Installation
    254
- Exhaust Housing
  
  255
  - Exhaust Housing Removal
    255
  - Exhaust Housing Disassembly
    256
  - Cleaning and Inspection
    257
  - Exhaust Housing Assembly
    257
  - Exhaust Housing Installation
    260
- Stern Bracket
  
  261
  - Removal
    261
  - Stern Bracket Disassembly
    261
  - Stern Bracket Assembly
    263
- Exhaust Relief Muffler Assembly
  
  266
Gearcase

267
- Service Chart
  
  268
- Gearcase Types
  
  271
- Propeller Service
  
  272
- Gearcase Leak Test
  
  272
- Gearcase Removal and Installation
  
  273
- Water Pump Service
  
  276
- Shift Rod Adjustment
  
  279
- Gearcase - Standard Rotation
  
  280
- Gearcase Disassembly
  
  280
- Gearcase Housing Inspection
  
  285
- Shifter, Bearing and Seal Servicing
  
  286
  - Shift Housing
    286
  - Pinion Bearing
    289
  - Driveshaft Bearing Housing Service
    290
  - Propeller Shaft Bearing Housing Service
    291
- Driveshaft Shimming
  
  294
- Gearcase Assembly
  
  295
- Gearcase - Counter Rotation
  
  302
- Gearcase Disassembly
  
  302
- Gearcase Housing Inspection
  
  303
- Shifter, Bearing and Seal Servicing
  
  304
  - Shift Housing
    304
  - Pinion Bearing
    307
  - Propeller Shaft Bearing Housing and Forward Gear
    307
- Driveshaft Shimming
  
  310
- Gearcase Assembly
  
  312
Trim and Tilt

315
- Service Chart
  
  316
- System Description
  
  317
  - Manual Adjustment
    317
  - Trailering Bracket and Tilt Support
    317
- Modes of Operation
  
  318
  - Trim-Out / Tilt-Up Mode
    318
  - Tilt-Down / Trim-In Mode
    319
  - Impact Relief
    320
  - Shallow Water Drive Tilt Relief
    321
  - Thermal Expansion Relief
    321
  - Manual Release - up
    322
  - Manual Release - down
    323
- Routine Inspections
  
  324
  - General
    324
  - Reservoir Fluid
    324
  - Manual Release Valve
    324
  - Stern Brackets
    324
- Troubleshooting
  
  324
  - Symptoms Chart
    325
  - Service Procedures
    325
  - Pressure Leakdown Test
    325
- Electrical Circuit Tests
  
  328
  - Relay Testing
    328
  - Trim and Tilt Motor Current Draw Tests
    328
  - Trim and Tilt Motor no Load Test
    329
  - Trim Gauge Test
    330
  - Trim Sender Test
    330
- Trim and Tilt Service
  
  331
  - Removal
    331
  - Installation
    332
  - Disassembly
    334
  - Tilt Piston Removal
    336
  - Tilt Piston Identification
    337
  - Tilt Piston Assembly
    338
  - Tilt Rod Assembly
    338
  - Trim Rod Removal
    340
  - Trim Rod Assembly
    341
  - Manifold and Reservoir Installation
    342
  - Trim Rod Installation
    343
  - Tilt Rod Installation
    343
  - Motor Installation
    344
- Adjustments
  
  345
- Notes
  
  346
Safety

347
- Marine Products and the Safety of People Who Use Them
  349
- Marine Products and the Safety of People Who Fix Them
  363
  - Handling Outboards
    363
  - Handling Lead/Acid Batteries
    367
  - Gasoline - Handle with Care
    368
  - Hazardous Products
    369
  - Safety Awareness Test
    370

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