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BRP E 250 L HO AG B, Service Manual

The BRP E 250 L HO AG B comes with a comprehensive Service Manual to assist users in maintaining and troubleshooting their equipment efficiently. This manual is available for free download from manualshive.com, providing users with valuable resources to maximize the performance and longevity of their product.

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67

Engine Cover and Frame Service

Frame Removal

3

Center Frame Removal

Use a #2 

Posi-drive

 screwdriver and remove the

three center frame screws.

Remove the oil fill cap.

Remove the throttle body and upper oil fill tube
clamps.

5008559_25

5008559_26

1.

Throttle body camp

2.

Oil fill tube clamp

009173

2

1

Summary of Contents for E 250 L HO AG B

Page 1: ...GM is a registered trademark of The General Motors Corporation Locquic and Loctite are registered trademarks of The Henkel Group Lubriplate is a registered trademark of Fiske Brothers Refining Company...

Page 2: ...stem 145 8 Oiling System 185 9 Cooling System 209 10 Evinrude ICON II Remote Control System 223 11 Powerhead 233 12 Exhaust Housing Adapter 283 13 Stern and Swivel 293 14 Gearcase 351 S Safety 415 T T...

Page 3: ...reviations 6 Standard Torque Specifications 7 Product Reference and Illustrations 7 Emission Related Installation Instructions 8 Manufacturer s Responsibility 8 Dealer s Responsibility 8 Owner s Respo...

Page 4: ...type strength and material Use of substandard parts could result in injury or product malfunction Always wear EYE PROTECTION AND APPRO PRIATE GLOVES when using power tools Unless otherwise specified...

Page 5: ...dly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery ca...

Page 6: ...ic Power Steering ETB Electronic Throttle Body ETC Electronic Throttle Controller EGT Exhaust Gas Temperature EMM Engine Management Module EPA Environmental Protection Agency ESC Electronic Shift Cont...

Page 7: ...ith nauti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No...

Page 8: ...e containing greater than ten volume percent ethanol is readily available the US EPA has issued a prohibition against the use of gasoline containing greater than 10 vol ethanol that applies to this en...

Page 9: ...or the control of air pollution from new watercraft marine spark ignition out boards This certification is contingent on certain adjustments being set to factory standards For this reason the factory...

Page 10: ...t versions continue through the alphabet as AG AH etc will not use letters from the word INTRODUCES to identify models DESIGN FEATURES C Counter Rotation D Evinrude E TEC G Graphite Paint H High Outpu...

Page 11: ...13 24 0 542 1 85 1 DPS 1 Standard Digital EST 2 E250Z_ _ _ 30 SLX 13 24 0 542 1 85 1 DPS 1 Standard Digital EST 2 E250XC_ _ _ 25 SLX Counter Rotation 13 24 0 542 1 85 1 Hydraulic Standard Digital EST...

Page 12: ...s 570 lbs 259 kg Lubricant Preferred Lubricant Acceptable Lubricant Evinrude XD100 Evinrude XD50 Synthetic TC W3 NMMA certified oil Capacity 2 0 gallons 7 5 liters Engine Type 74 V 6 Cylinder Loop Cha...

Page 13: ...Filters Inline Water Separating P N 357797 P N 502906 Fuel Additives 2 4 Fuel Conditioner Fuel System Cleaner Use of other additives may result in engine damage Electrical System Minimum Battery Requi...

Page 14: ...rd Rotation Counter Rotation Gearcase only 38 9 fl oz 1180 ml Gearcase vent hose and oil reservoir 45 6 fl oz 1350 ml Gearcase only 39 fl oz 1154 ml Gearcase vent hose and oil reservoir 44 7 fl oz 132...

Page 15: ...ks 39 Propellers 40 Adjustments 42 Engine Mounting Height and Jack Plate Adjustment 42 Fuel System Vacuum 43 Engine Water Pressure 43 Trim Tilt 43 Tilt Limit Setting 43 Trim Gauge Calibration 44 i Tri...

Page 16: ...tem check water pump indicator water pressure Displays gauges self test warning horn check operation Emergency cut off switch es and tether cord check operation Engine to transom mounting hardware re...

Page 17: ...tors with a solution of baking soda and water Use a wire brush or battery terminal tool to remove cor rosion buildup Rinse and clean all surfaces Connecting the Battery IMPORTANT Connect the battery p...

Page 18: ...y in the middle of the clamp ing range of the clamp Refer to Oetiker Clamp Chart on p 54 Clamp Installation A constant stress should be applied to close the ear clamps This method ensures a positive s...

Page 19: ...ges and fittings overboard water pressure indicator Water Intake Screens Inspect condition of water intake screens Clean or replace as needed Confirm function of overboard water pressure indi cator En...

Page 20: ...ion can minimize potential gearcase damage Remove propeller Refer to Propeller Hardware Installation on p 360 Inspect bushing and blade surfaces Replace damaged or worn propellers Clean propeller shaf...

Page 21: ...e same appearance To check for water contamination put lubricant into a clear container Allow the oil to settle for a minimum of one hour to determine if there is an abnormal amount of water in the oi...

Page 22: ...e vent hose on the reservoir upper fitting Install the starboard side panel Spark Plugs Spark plugs should be removed and examined periodically Replace worn fouled or damaged spark plugs Use only reco...

Page 23: ...e sure the spark plug lead is accessible Apply Ultra Lock to the threads of the coil mount ing bracket screw Install the washer and screw Tighten the screw to a torque of 84 to 106 in lbs 9 5 to 12 N...

Page 24: ...ic pressure reading and changes in exhaust pressure reading With key ON outboard NOT running make sure the barometric pressure reading reflects actual atmospheric conditions If barometric pressure rea...

Page 25: ...not eroding may not be properly grounded Anodes and the mount ing screws must be clean and tight for effective corrosion protection For best anode performance Replace all anodes that have eroded or d...

Page 26: ...t engage or crank the outboard 4 Move the lever to NEUTRAL and start the out board s 5 Run the outboards at idle for a minimum of three seconds 6 With the outboard s running attempt to start the outbo...

Page 27: ...nted surfaces as needed Coat outer painted surfaces with automotive wax Remove battery s from boat Store in a cool dry location Periodically charge battery s while stored Refer to manufacturer s maint...

Page 28: ...ater flows from overboard indicator Lifting The Outboard Release the rear latch to remove the top cap of the engine cover Use Lifting Fixture P N 357667 to lift the out board The centerline lifting ey...

Page 29: ...e are aligned front to back as shown Fasten appropriate chain hook to the centerline lifting eye of the tool Plug Installation Install the following plugs from the Owner s Kit 1 Apply Triple Guard gre...

Page 30: ...llation details if installing a new engine package Rigging Center Evinrude E TEC 74 V6 models utilize a central rigging center All buss cables hydraulic steering hoses fuel and oil hoses and related r...

Page 31: ...r turn Hose and cable lengths are measured from the cable entryway to the connection point in the rig ging center Refer to Rigging Center Hose and Cable Lengths on p 32 Route all steering hoses batter...

Page 32: ...3 Component inches mm 1 Starboard Steering Hose 10 5 267 2 Port Steering Hose 12 305 3 Battery Cables 21 5 546 4 NMEA 2000 Network 13 25 337 5 Control Network 12 305 6 Flush Hose 13 330 7 Remote Oil T...

Page 33: ...ing hoses through the rigging center as shown Take care NOT to kink the hoses during installation Hydraulic Hose Connections Connect the PORT hydraulic hose from the helm to the PORT hydraulic steerin...

Page 34: ...s on the out board Connect the electrical connector from the oil tank to the connector on the outboard 8 If installing optional auxiliary battery charging kit remove plug from outboard harness and dis...

Page 35: ...rboard Steering Hose 3 Port Steering Hose 4 Positive Battery Stud 5 Negative Battery Stud 6 NMEA 2000 Network Cable 7 Remote Control Network Cable 8 Engine Flushing Hose optional 9 Remote Oil Tank Ele...

Page 36: ...uration screen of Evinrude Diag nostics software v6 1 to set the water pressure transducer Connect the transducer lead to the engine wiring harness connector Install the rigging hose to the entry port...

Page 37: ...uld be to the port side of the cable entryway shown below Hoses and cables should NOT bind or be pulled taught when engine is in a full turn Install cover on cable entryway with four screws Make sure...

Page 38: ...of the correct lubricant for the outboard Refer to Rec ommended Lubricants on p 192 Trim and Tilt Fluid The trim and tilt system is filled tested and sealed at the factory It is NOT necessary to chec...

Page 39: ...he Evinrude welcome page When the start up sequence is complete the default dig ital display will appear ICON The ICON system self tests by sounding a beep The ICON tachometer and speedometer LCD scre...

Page 40: ...and quality may not be representative of actual in water use Break In Evinrude E TEC outboards require no break in When the outboard is delivered refer the cus tomer to the Oiling System information...

Page 41: ...erclockwise direction as viewed from the rear Propeller Hardware Installation IMPORTANT Evinrude E TEC G2 outboards REQUIRE Propeller Hub Kit P N 767683 and Nut Keeper Assembly P N 5008966 Apply Tripl...

Page 42: ...stments or repairs and retest before delivery When ready for delivery give all instruction sheets operating instructions and user guides provided with accessories to the owner Advise the owner of any...

Page 43: ...f clearance and turn the steering system lock to lock If the outboard contacts the boat s motor well when fully tilted set the tilt limit to reduce full tilt position To prevent damage to equipment pr...

Page 44: ...it contacts the motor well Trim Gauge Calibration Observe the trim gauge If needed use Evinrude Diagnostics software v 6 1 or higher to calibrate the upper and lower trim range of the gauge i Trim Evi...

Page 45: ...use the Configuration screen of Evinrude Diagnostics software v 6 1 or higher to change the power steering assist level Multiple Outboard Alignment Multiple outboards must be connected with a tie bar...

Page 46: ...erformance steering and cooling is found A common practice is to set up the outboards par allel or with a small amount of toe out and adjust inward until best results are achieved A typical set up wit...

Page 47: ...onnect oil supply hose and oil return hose from outboard Drain and clean all oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil sy...

Page 48: ...letely from the steering system if the engine is even slightly trimmed up 1 Remove the filler cap from the helm 2 Install the threaded end of the filler tube sup plied with helm into the helm 3 Fill t...

Page 49: ...owing from the bleed valve 8 Open the LOWER bleed valve one half turn Then turn the steering wheel clockwise Continue turning the steering wheel clock wise until there are no air bubbles present in th...

Page 50: ...18 Proceed to Steering System Checks on p 52 Single Station Multiple Engine Installations Filling and bleeding multiple engine installations is similar to single engine installations Follow the instru...

Page 51: ...fluid return lines of the purging unit to the two bleed valves of the steering system 3 Loosen both bleed valves one half turn Then turn the purge unit ON After air bubbles are no longer visible 4 Tur...

Page 52: ...lm check all PORT lines and fittings for leaks 3 Turn steering wheel to STARBOARD After engine is turned fully to STARBOARD apply enough force to the steering wheel to exceed the pressure relief valve...

Page 53: ...itional bleeding may be required Push the gearcase to port until the steering mechanism bumps the mechanical stop Then push steadily with increas ing force Repeat to starboard Definite resistance shou...

Page 54: ...440 352110 455 358005 515 357516 560 356360 410 349729 331 352335 346 351685 316 349759 301 346153 256 346152 241 352703 226 353516 I D P N 1 2 3 8 1 4 1 8 3 4 1 1 1 4 1 1 2 1 3 4 2 2 1 4 695 352868...

Page 55: ...ver Starboard Cover and Starboard Frame 57 Port Cover and Frame Front Cover and Frame 58 Rigging Center 59 Cover Removal 60 Cover Installation 62 Frame Removal 64 Starboard Port and Front Frame Remova...

Page 56: ...In lbs 10 to 12 N m 25 8 28 Ft lbs 35 38 N m 26 to 28 Ft lbs 35 to 38 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 62 to 79 In lbs 7 to 9 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2...

Page 57: ...and Starboard Frame X 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs...

Page 58: ...rvice Charts 58 Port Cover and Frame Front Cover and Frame 18 to 30 In lbs 2 to 3 N m X 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 18 to 30 In lbs 2 to 3 N m 0093...

Page 59: ...59 Engine Cover and Frame Service Service Charts 3 Rigging Center 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 18 to 30 In lbs 2 to 3 N m 009315...

Page 60: ...over Removal Lift up on rear latch to release Remove the top cover Remove one screw at the top of the rear cover Unscrew and remove the retainer Remove the rear cover 1 Rear Latch 5008559_04 5008559_0...

Page 61: ...rt and starboard side cover screws one quarter turn Remove the side covers Remove the four front cover screws Remove the front cover Port Side Shown screws enlarged to show detail 5008559_08 5009420_0...

Page 62: ...the screws 18 to 30 in lbs 2 to 3 N m Apply Silicone Spray P N 775630 onto a shop towel and liberally apply to the port and starboard rubber seals Install the port and starboard covers Tighten the po...

Page 63: ...ar cover Install one screw at the top of the rear cover Tighten the screw 18 to 30 in lbs 2 to 3 N m Install the retainer Install the top cover Push down on the rear of the top cover to secure the lat...

Page 64: ...gearcase oil reservoir Remove the 17 starboard frame screws Pull the starboard frame slightly away from the center frame Disconnect the trim and tilt switch connector Remove the two Deutsch connector...

Page 65: ...Removal 3 Remove the four starboard exhaust housing cover screws Remove the starboard exhaust housing cover Remove the six port frame screws Remove the port frame and port exhaust housing cover 50085...

Page 66: ...ort exhaust housing cover screws Remove the port exhaust housing cover Remove the six front cover screws Move the front cover away from the powerhead Remove the rigging grommets from the front cover R...

Page 67: ...Center Frame Removal Use a 2 Posi drive screwdriver and remove the three center frame screws Remove the oil fill cap Remove the throttle body and upper oil fill tube clamps 5008559_25 5008559_26 1 Th...

Page 68: ...eparator cooling hose 5 Vapor separator vent solenoid connector 6 Temperature sensor connector 7 Water in fuel sensor connector 8 Engine grounds 9 Trim sender connector 10 Trim switch connector 11 Wat...

Page 69: ...use box remove from bracket remove connector from back of box 6 Air temperature sensor connector 7 Engine grounds 8 Ignition coil connectors 3X 9 Shift actuator connector 10 Knock sensor connector 11...

Page 70: ...Frame Service Frame Removal 70 Disconnect the rear electrical connectors 1 Cylinder oil pump connector 2 Water valve connector 3 Crankshaft position sensor connector 4 Knock sensor connector starboar...

Page 71: ...unts Align the air duct extension opening with the cen ter frame opening Align the red tape marker on the port side of the harness to the upper ignition coil bracket as shown Secure the harness to eac...

Page 72: ...re sensor connector Ignition coil connectors 3X Fuel injector connectors 3X EMM cooling hose secure with one 15 7 mm Oetiker clamp Shift actuator connector Assemble all starboard side electrical conne...

Page 73: ...to tighten Failure to follow this procedure can dam age the threads of the center frame mounts Tighten the screws securely Install the oil fill cap Front Port and Starboard Frame Installation Place th...

Page 74: ...four screws to a torque of 18 to 30 in lbs 2 to 3 N m Install the port frame and lower port exhaust hous ing cover to the outboard Seat the frame into the groove of the exhaust grommet Tighten the six...

Page 75: ...the two Deutsch connectors to the bosses on inside of the starboard frame Place the starboard frame on the outboard Seat the frame in the groove of the exhaust grommet Assemble the 17 frame screws tig...

Page 76: ...Engine Cover and Frame Service Frame Installation 76 tighten Failure to follow this procedure can dam age the threads of the gearcase oil reservoir Tighten the screws securely 5008559_12A...

Page 77: ...ngine Temperature Sensor 81 Low Oil Level Switch 82 Oil Level Sensor 82 Crankshaft Position Sensor 83 Knock Sensor 83 Internal EMM Functions 83 ROM Verification 83 Start Assist Circuit SAC 83 Idle Con...

Page 78: ...ompensation Electronic throttle control Electronic shift control Dynamic Power Steering EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections ca...

Page 79: ...Engine and Control Systems EMM Inputs and Outputs Diagram 79 4 EMM Inputs and Outputs Diagram 009289...

Page 80: ...rs the EMM s 55 V alternator circuit If system voltage exceeds 57 volts the EMM If system voltage is less than 45 V between 500 and 1000 RPM or is less than 52 V above 1000 RPM the EMM 12 V Circuit Se...

Page 81: ...e at the plenum If the AT sensor temperature value is below 22 F 30 C the EMM If the AT sensor temperature value exceeds 158 F 70 C the EMM If the AT sensor circuit fails the EMM Exhaust Temperature S...

Page 82: ...been stopped and restarted If outboard has been run for more than 5 hours with NO OIL faults codes 34 36 or 117 the EMM Oil Level Sensor The oil level sensor monitors the oil level in the oil tank and...

Page 83: ...he EMM If the EMM detects the knock sensor circuit is OPEN the EMM Internal EMM Functions ROM Verification The EMM performs a self test of programming every time it is turned ON Fault code 15 indicate...

Page 84: ...2000 network as backup Sensor inputs and internal EMM controllers are used to control the operation of the outboard s shift and throttle functions Use Evinrude Diagnostics software to trouble shoot th...

Page 85: ...re greater than 1000 or less than 65535 the EMM The EMM monitors the ETC motor circuit If the EMM detects the ETC circuit is OPEN the EMM If the EMM detects excessive current draw the EMM The EMM moni...

Page 86: ...If the SPS voltage is less than 0 25 V the EMM If the SPS voltage is greater than 4 75 V the EMM If the shift actuator cannot achieve the com manded gear the EMM If the SPS position differs from the N...

Page 87: ...MM monitors the ESC motor circuit If the EMM detects the ESC motor circuit is OPEN the EMM If ESC motor current exceeds 8 A when moving into NEUTRAL the EMM Activates SHUTDOWN Stores fault code 199 En...

Page 88: ...codes System Self Test During engine start up pause with the key switch in the ON position Digital displays and gauges will self test as follows Evinrude ICON Touch 7 0 and 4 3 CTS The touch screen d...

Page 89: ...ernator 55 V below expected range 18 Alternator 55 V above expected range 25 EMM temperature above expected range 34 Crankcase oil pump OPEN circuit 36 Cylinder oil pump OPEN circuit 40 Cylinder head...

Page 90: ...cted Find and correct the problem that caused the fault BEFORE clearing the Occurred fault code Note Engine will re start after key switch is cycled as long as the fault is not active Diagnostic Softw...

Page 91: ...abnormal condition that occurs is known as a fault There are three types of faults Active Fault A fault that currently exists Active faults become occurred faults only if the out board is running Occu...

Page 92: ...software to initiate break in oil ing Break in is a predetermined oiling program that runs for two hours of outboard operation above 2000 RPM Ignition Timing Use the Timing Verification screen to che...

Page 93: ...to Oiling System Tests on p 198 Fuel Pumps Use the diagnostics software to test the fuel lift pump and fuel circulation pump circuits Refer to Fuel Pump Static Test on p 105 Dynamic Tests Dynamic tes...

Page 94: ...ment for each injector History and Reports Engine history and reports provide service records and can be used to document the running history of an outboard Reviewing this information can help identif...

Page 95: ...vailable to enhance the operation of an outboard Select from Update EMM to update engine management software Load Co processor firmware to update the EMM co processor Load Steering firmware to update...

Page 96: ...and installation of the EMM requires removal of the engine covers and frames See Engine Cover and Frame Service on p 55 After covers and frames are removed from the engine continue with the procedure...

Page 97: ...ine and Control Systems EMM Servicing 97 4 Remove EMM mounting screws 2X Rotate EMM away from frame as shown Disconnect J1 A J1 B J2 J3 and J4 connectors from EMM These two screws do not require remov...

Page 98: ...nd Control Systems EMM Servicing Remove EMM from frame Installation Align slots in bottom side of EMM case with isolator mounts on the frame Slide EMM into position Install J1 A J1 B and J2 J3 and J4...

Page 99: ...en screws 12 to 16 in lbs 1 5 to 2 N m Install exhaust pressure hose and water cooling hoses Secure each hose with one 15 7 mm Oetiker clamp P N 346786 After the EMM is installed onto the center frame...

Page 100: ...Engine and Control Systems Notes 100 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 101: ...Visual Inspections 102 Diagnostic Software Inspections 102 Operational Inspections 103 Troubleshooting 104 Static Tests 105 Ignition System Static Test 105 Fuel System Static Tests 105 Oil System Stat...

Page 102: ...p switch lanyard Diagnostic Software Inspections Before running the outboard use Evinrude Diag nostics software v 6 1 or higher to review informa tion saved in the EMM Correct any problems and clear a...

Page 103: ...eate a new report must be connected to communicating with the engine EMM Press Open Exports Folder to view saved reports Press Show Selected Report to view a report selected from the Engine History Re...

Page 104: ...f ignition test indicates steady spark refer to Fuel System Static Tests on p 105 Outboard runs low on power misfires Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS...

Page 105: ...Tests on p 123 Refer to Ignition Coil Tests on p 123 Steady spark on all cylinders Refer to Running Ignition Tests on p 122 and Dynamic Tests on p 108 Fuel System Static Tests Fuel Pump Static Test U...

Page 106: ...tance Test on p 167 All injectors actuate Refer to Running Fuel System Tests on p 160 Oil System Static Tests Crankcase Oil Pump Static Test IMPORTANT Static tests operate the oil pumps with 30 V on t...

Page 107: ...MM control function for the oil pump Use an inductive timing light to monitor current flow through the ground circuit blue wire at the oil pump connector pin B Results If the light flashes the EMM and...

Page 108: ...e cylinder being dropped or A digital multimeter to check voltage changes on electrical circuits IMPORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to ma...

Page 109: ...118 Exhaust Temperature Circuit EGT Test 118 Knock Sensor Test 119 Knock Sensor Circuit Test 119 Ignition System 120 Required Systems 120 Ignition System Circuit Diagram 121 Wiring Inspection 122 Ign...

Page 110: ...30 in lbs 2 to 3 N m Z 12 to 18 in lbs 2 to 3 N m L 12 to 18 in lbs 2 to 3 N m 35 to 60 in lbs 4 to 6 N m 84 to 106 in lbs 10 to 12 N m 84 to 106 in lbs 10 to 12 N m 22 to 30 in lbs 2 5 to 3 N m 35 t...

Page 111: ...lbs 10 to 12 N m I X 84 to 106 In lbs 10 to 12 N m B 140 to 160 Ft lbs 190 to 217 N m 60 to 84 In lbs 7 to 10 N m 15 to 17 Ft lbs 20 to 23 N m 15 to 17 Ft lbs 20 to 23 N m 84 to 106 In lbs 10 to 12 N...

Page 112: ...ufacturing connector Red 3 Manufacturing connector White 4 Trim sender bond Dark Green 5 Manufacturing connector Black 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital Yellow White 8 Key S...

Page 113: ...Oil pump crankcase Blue 21 Switched B 12V wake up Purple Black 22 empty 23 Low oil switch Tan White 24 Fuel level upper Brown Orange 25 Ignition cylinder 5 Orange Green 26 Fuel level lower Brown Blue...

Page 114: ...sensor starboard Gray Red 15 Knock sensor port Gray Orange 16 Knock sensor digital ground Gray Black 17 empty 18 Ignition cylinder 6 Orange Green 19 Ignition cylinder 4 Orange Purple 20 Ignition cyli...

Page 115: ...onnections and continuity at the following locations Main battery ground terminal Check continuity between ground terminals at port and starboard main harness grounds Fuses The engine harness circuits...

Page 116: ...sistance Air Temperature Sensor Circuit Test Remove the electrical connector from the air tem perature sensor Use a digital multimeter with appropriate test probe leads to measure sensor circuit resis...

Page 117: ...no adjustment Air gap or clearance to flywheel is fixed at approximately 0 073 in 1 85 mm The acceptable clearance is 0 036 to 0 110 in 1 to 2 8 mm CPS Circuit Test Remove the electrical connector fro...

Page 118: ...the air tem perature sensor Use a digital multimeter with appropriate test probe leads to measure sensor resistance Exhaust Temperature Circuit EGT Test Remove the electrical connector from the exhaus...

Page 119: ...a torque of 14 to 16 ft lbs 19 to 22 N m Knock Sensor Circuit Test There are no tests for the knock sensor signal wires Use a digital multimeter with appropriate test probe leads to measure sensor gro...

Page 120: ...cuit 55 V Crankshaft Position Sensor Provides EMM with input Outboard cranking speed exceeds 75 RPM and a steady CPS signal is generated Alternator Output System Voltage System voltage from EMM white...

Page 121: ...Ignition System Circuit Diagram 1 1 2 6 4 5 5 7 8 9 3 5 3 9 3 1 Ignition Coils 2 EMM 3 55V Circuit 4 Capacitor 5 Grounds Negative 6 Crankshaft Position Sensor 7 Stator 8 Remote Control Private Networ...

Page 122: ...UNNING 55 V 2 system voltage is GOOD RUNNING less than 55 V 2 check stator out put to EMM Repair connection or wiring Possi ble faulty stator or EMM Refer to Stator Tests on p 125 IMPORTANT The EMM mu...

Page 123: ...ug lead provides conti nuity If all of the above tests are good and a cylinder does not have spark replace the ignition coil with a known good coil Ignition Circuit Tests Ignition 55V Circuit Voltage...

Page 124: ...d to the engine har ness connector wire listed in the table Connect the negative meter lead to engine ground Turn the key switch to the ON position Capacitor Test IMPORTANT Make sure the capacitor is...

Page 125: ...ty If meter reads continuity replace stator Stator Voltage Output Test Use a voltmeter to check the stator output voltage Set meter to read 110 VAC output Disconnect the CPS Disconnect the stator 6 pi...

Page 126: ...output is shown in the following graph Use Evinrude Diagnostics software to monitor bat tery voltage and GROSS charge current Use an inductive amp meter to monitor NET charge current at the battery Fl...

Page 127: ...should show a reduced output As the current draw decreases the battery voltage should stabilize at approximately 14 5 V If results vary check stator BEFORE replacing the EMM See Stator Tests on p 125...

Page 128: ...ectrical connector With outboard running at 1000 RPM voltage on white red wires should increase to 55 V Voltage readings at a specific speed RPM should be steady If there is any other reading refer to...

Page 129: ...Fuse Panel 5 Red Purple Wire Fused B 6 Fuse Starter Solenoid 7 Starter Relay 8 Red Yellow Wire Fused 12V to Remote Control 9 Black White Wire System Wake Up Signal 10 White Blue Wires CANbus Signals...

Page 130: ...te control Fuse Panel terminal 2D provides high current 12 V to the START RELAY Yellow red wires EMM J1 B connector terminal 11 Provides NEUTRAL signal from the shift actuator to the EMM EMM J1 B conn...

Page 131: ...the starter center frame and at the battery Connect the positive meter lead to the start S terminal on the starter Connect the negative meter lead to the ground terminal on the starter housing Crank t...

Page 132: ...r damaged cables or connections Tilt Trim Relay Test The tilt and trim TNT module contains the cir cuitry and relays required for power trim and tilt operation The tilt and trim switch provides B inpu...

Page 133: ...f alternator output can help determine the flywheel s condition Refer to Charging System Tests on p 126 Flywheel Removal Removal and installation requires removal of the engine covers and frames See C...

Page 134: ...uller to the flywheel with three puller screws Hold the puller body with a wrench and tighten the pressing screw until the flywheel releases Turn the center screw and lift the flywheel off of the cran...

Page 135: ...o install stator position stator on cylinder block Apply Nut Lock to screw threads Install screws and tighten in crossing pattern to a torque of 24 to 36 in lbs 3 to 4 N m Ignition Coil Servicing Igni...

Page 136: ...from the center frame air duct and flywheel Remove the spark plugs Use Flywheel Nut Socket P N 357715 to rotate the flywheel clockwise past the 28 ATDC mark on the flywheel Install the Piston Stop To...

Page 137: ...tacts the tool Record the degrees BTDC on the flywheel The timing pointer is correctly centered when the piston contacts the tool at the Step 5 result at both the ATDC and BTDC positions 8 Rotate the...

Page 138: ...ter frame Refer to Plug Installation on p 29 Electric Starter Servicing Starter Removal IMPORTANT Do not clean the starter drive while the starter motor and drive are installed on the powerhead The cl...

Page 139: ...s with No Ox Grease P N 768230 Connector Servicing DEUTSCH Connectors IMPORTANT Dielectric Grease P N 503243 is recommended Incorrect grease application can cause electrical or warning system problems...

Page 140: ...nsulation crimp area Capture all wire strands in crimp leave no loose strands Crimp wire securely Do not solder Crimp insulation in 14 16 gauge notch of crimping pliers AMP Connectors IMPORTANT Always...

Page 141: ...ary Lock Installer P N 777079 to seat device in connector Crimping Terminals Crimping Superseal 1 5 terminals requires AMP Crimp Tool with dies P N 777281 SUPER SEAL The J1 A J1 B and J3 connectors of...

Page 142: ...of the EMM are AMP Power Timer Series connectors Disconnect Use a screw driver to open latch Pull connector from plug Connect Push connector until seated in plug Close latch completely Terminal Remov...

Page 143: ...by releas ing the tab and then pushing the terminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gaske...

Page 144: ...Electrical and Ignition Notes 144 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 145: ...ns and Guidelines 153 Permanent Fuel Tanks 153 Portable Fuel Tanks 153 Fuel Flow Requirements 153 Fuel Requirements 154 Components 155 Mechanical Fuel Lift Pump AGA Newer 155 Fuel Pump Vapor Separator...

Page 146: ...ottle Body E 35 to 60 In lbs 4 to 6 N m 35 to 60 In lbs 4 to 6 N m F 30 to 42 in lbs 4 to 5 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 009305 E Red U...

Page 147: ...por Separator Fuel Filter and Fuel Rails 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 009586 Hand tighten until seal contacts filter housing Then tighten a...

Page 148: ...Fuel Filter and Fuel Rails 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 009667 Early Models AGA Newer Models Late Models Hand tighten until seal contacts f...

Page 149: ...lbs 10 to 12 N m H 60 to 84 In lbs 7 to 10 N m 120 In lbs 14 N m 24 to 26 Ft lbs 33 to 35 N m 1 2 3 A 84 to 106 In lbs 10 to 12 N m S H H H A X 009307 A Triple Guard Grease H Outboard Engine Lubricant...

Page 150: ...pply hose to water separating fuel filter Water separating fuel filter 10 micron Electric fuel circulation pump Fuel supply rail green connector 10 11 12 13 14 15 16 17 Fuel injector s Fuel return rai...

Page 151: ...c fuel lift pump Fuel supply hose to water separating fuel filter Water separating fuel filter 10 micron 11 12 13 14 15 16 17 18 19 20 Electric fuel circulation pump Fuel supply rail green connector F...

Page 152: ...19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 2 1 1 3 5 2 1 2 1 2 1 2 4 6 2 1 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 1...

Page 153: ...a leak occurs in the fuel distribution system Portable Fuel Tanks Fuel Flow Requirements NOTICE Do not use portable fuel tanks for outboards larger than 115 HP Inadequate fuel flow to high horsepower...

Page 154: ...use of unleaded gasoline containing alcohol above the percentage specified by local govern ment regulations is not recommended Use of a boat mounted water separating fuel filter such as Fuel Filter Ki...

Page 155: ...ise fuel pressure on AGA and newer outboard models Vapor separator assembly water cooled fuel reservoir to accumulate incoming fuel from the fuel lift pump and from the fuel return rail micro switches...

Page 156: ...ent fuel pressure in the fuel system See the Fuel System Flow Diagram AG Newer on p 151 Low Pressure Regulator A low pressure regulator maintains approximately 7 to 15 psi 48 to 103 kPa of fuel pressu...

Page 157: ...The EMM monitors the fuel circulation pump elec trical circuit If the circulation pump is disconnected open circuit the EMM If the circuit current is beyond the specified range short circuit the EMM F...

Page 158: ...in the housing of the water separating fuel filter Refer to Inspection and Maintenance Schedule on p 16 for service frequency Electrical Circuit The EMM monitors the water in fuel electrical cir cuit...

Page 159: ...cation on the outboard is identified by the EMM DO NOT install an injector without updating the compensa tion software Each service injector includes its fuel flow infor mation This software allows th...

Page 160: ...low or drops as RPM increases refer to Stator Volt age Output Test on p 125 Use an inductive timing light to monitor the injec tor control wire connector pin 2 for each injector WARNING Fuel vapors ar...

Page 161: ...all injector wires and consistent voltage readings EMM injector control function is good Use the diagnostics software Dynamic Fuel Test to isolate a faulty cylinder See Dynamic Tests on p 108 Refer to...

Page 162: ...ing and monitor the gauge for pressure reading Pressure should stabilize and gauge must not indicate less than 6 psi 41 kPa Results Normal pressure Perform the Fuel Lift Pump Vacuum Test on p 163 Make...

Page 163: ...ump Replace vapor separator assembly No pressure Check electrical circuit and ground connections for circulation pump If voltage is present and pump does not run repair connection or replace vapor sep...

Page 164: ...e returning to the EMM Circuit tests check the integrity of the main engine harness and EMM circuits using a diode test Con tinuity tests check the integrity of ground circuits and or the 55V circuit...

Page 165: ...c Fuel Lift Pump Resistance Test Disconnect the battery cables at the battery Remove the electrical connector from the fuel pump and vapor separator assembly Use a digital multimeter with appropriate...

Page 166: ...te the faulty component Check wiring and connections Repair or replace faulty wiring Use a digital multimeter with appropriate test probe leads to measure the resistance of the fuel pump and vapor sep...

Page 167: ...appropriate test probe leads to check the sig nal circuit Connect the negative meter lead to the wire listed in the table connect the positive meter lead to engine ground Results No reading OL or ind...

Page 168: ...y presence of water If water is present identify the source and correct the problem Take additional fuel samples and drain fuel tank s if necessary WARNING Gasoline is extremely flammable and highly e...

Page 169: ...sensor probe Hand tighten until seal contacts filter housing Then tighten and additional one half to one turn Remove the hose pinching pliers from the fuel hose Connect the battery cables at the batte...

Page 170: ...cables at the battery Remove the engine top front and rear covers Remove the starboard side panel Remove the starboard frame Refer to Engine Cover and Frame Service on p 55 Use a 2 Posi drive screwdr...

Page 171: ...ntainer to catch the fuel from the vapor separator A full assembly can hold over 32 oz 1 L of fuel Take the assembly to a work bench or other suit able work surface Carefully remove Oetiker clamps fro...

Page 172: ...nstall the cen ter frame screws IMPORTANT Turn self tapping screws counter clockwise to start the threads and clockwise to tighten Failure to follow this procedure can dam age the threads of the cente...

Page 173: ...ver and Frame Service on p 55 Unlock and remove the quick connectors from the fuel pump vapor separator assembly Use shop towels to wipe up any spilled fuel Unlock the quick connectors from the fuel i...

Page 174: ...ws IMPORTANT Turn self tapping screws counter clockwise to start the threads and clockwise to tighten Failure to follow this procedure can dam age the threads of the center frame mounts Next install t...

Page 175: ...ly then loosen the lower screw sev eral turns do NOT remove the lower screw 2 MIDDLE injector remove BOTH screws 3 TOP injector remove the lower screw com pletely then loosen the upper screw several t...

Page 176: ...mounting cup Turn the nut of the fuel injector puller counter clockwise several turns Place the fuel injector puller on the fuel injector housing Align the angled edges of both sides of the tool base...

Page 177: ...iles to EMM Use the Evinrude Diagnostics software v 6 1 or higher Settings screen to upload the coefficient file to the EMM Select the Injectors tab From the View Injector window select the cylinder f...

Page 178: ...e of 84 to 106 in lbs 10 to 12 N m Align the injectors with the fuel tubes and press together until fully seated The following items and their mating surfaces must be cleaned before reassembly Injecto...

Page 179: ...172 Connect the electrical connectors to the fuel injec tors Install the ignition coils Position the ignition coil bracket assemblies onto each injector Install the ignition coil bracket washers reta...

Page 180: ...ver to install the cen ter frame screws IMPORTANT Turn self tapping screws counter clockwise to start the threads and clockwise to tighten Failure to follow this procedure can dam age the threads of t...

Page 181: ...ses from the reed plate assembly Remove 5 retaining screws from the reed plate assembly then remove the reed plate and gasket from the crankcase Disassembly All reed plate assembly and reed valve asse...

Page 182: ...004 in 0 10 mm Assembly Remove old adhesive from reed valve retaining screws Prime screw threads with Locquic Primer and let dry Apply Nut Lock to threads Position reed valve on reed plate and install...

Page 183: ...e a 2 Posi drive screwdriver to install the cen ter frame screws IMPORTANT Turn self tapping screws counter clockwise to start the threads and clockwise to tighten Failure to follow this procedure can...

Page 184: ...Fuel System Notes 184 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 185: ...k Assembly 192 Crankcase Oil Pump 193 Cylinder Oil Pump 193 Oil Level Sender 193 LOW OIL Switch 194 Oil Warning System 194 Cylinder and Crankcase 194 Oil Recirculation System 195 Break In Oiling 195 O...

Page 186: ...ervice Charts Service Charts Oil Tank Assembly 15 to 22 In lbs 2 to 3 N m 15 to 17 Ft lbs 20 to 23 N m 15 to 17 Ft lbs 20 to 23 N m 6 to 8 Ft lbs 8 to 10 N m 60 to 84 In lbs 7 to 9 N m 15 to 22 In lbs...

Page 187: ...Oiling System Service Charts 187 8 Cylinder Oil Pump Assembly 35 to 60 In lbs 4 to 6 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 009250...

Page 188: ...1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 A B 9 10 11 2 6 7 8 1 3 4 5 14 13 5 5 009247 12 1 2 3...

Page 189: ...eed plate 4 cylinder Oil inlet fitting to lower main bearing Oil outlet fitting from lower main bearing Check valve out reed plate 6 cylinder to lower main bearing Check valve from area in inside plen...

Page 190: ...9 10 11 12 13 14 15 Oil fill cap Remote oil fill hose Oil tank vent hose Oil tank assembly Crankcase oil pump LOW Oil switch Oil level sender Crankcase oil distribution hoses Crankcase oil fittings Oi...

Page 191: ...iagrams 191 8 200 225 250 HP 250 H O 300 HP Models Rear 1 4 6 3 5 2 009252 1 2 3 4 5 6 Oil tank assembly Oil hose assembly to cylinder oil pump Oil filter Cylinder oil pump Cylinder oil distribution h...

Page 192: ...1 3 liters P N 5008572 Oil Tank Pick up Kit P N 767686 for the 10 gal lon 37 8 liters capacity oil tank Components The oiling system consists of the following compo nents Oil tank Crankcase oil pump a...

Page 193: ...oil tank through a hose and filter assembly and supplies pressurized oil to the oil manifold The oil manifold distributes the oil supplied by the oil pump to the cylinder sleeves Electrical Circuit 5...

Page 194: ...sets after three oil pump pulse cycles when the outboard has been stopped and restarted If outboard has been run for more than 5 hours with NO OIL faults codes 34 117 the EMM Cylinder and Crankcase Th...

Page 195: ...5 a check valve and internal passage from the reed plate of cylinder number 6 The upper main bearing receives oil through a check valve and external hose from the reed plate of cylinder number 2 Lowe...

Page 196: ...Start the outboard 2 Use the Prime All button of the Tests screen to start the oil priming sequence IMPORTANT The outboard should be running during the priming procedure to avoid pumping too much oil...

Page 197: ...bubbles ARE present proceed to step 8 If air bubbles are NOT present the oil pump priming procedure is complete 8 Use the Cylinder Pump button of the Tests screen to prime the cylinder oil pump Obser...

Page 198: ...gital multimeter calibrated to a scale that reads 55 V DC to measure voltage between the oil pump electrical connector and engine ground Connect negative meter lead to ground Use an appropriate test p...

Page 199: ...cuit Tests on p 200 and Oil Pump Resis tance Test on p 201 No voltage reading should result in Code 34 Crankcase Oil Pump Open Circuit Refer to System Voltage Test on p 122 Cylinder Oil Pump The EMM c...

Page 200: ...ircuit Refer to Sys tem Voltage Test on p 122 Oil Pump Circuit Tests The oil pump circuit test can be performed on either the crankcase or cylinder oil pump IMPORTANT The complete oil pump electrical...

Page 201: ...or replace faulty wiring Oil Pump Resistance Test Disconnect the battery cables at the battery Dis connect the electrical connector from the oil pump Use a digital multimeter with appropriate test pro...

Page 202: ...f oil hose on the fitting Use a Syringe P N 346936 filled with isopropyl alcohol to force fluid through hose and fitting LOW OIL Switch Test Remove oil from the oil tank Turn the key switch ON The das...

Page 203: ...signal circuit Connect the BLACK meter lead to the wire listed in the table connect the RED meter lead to engine ground Results No reading OL or indicates an open circuit A reading of zero 0 indicate...

Page 204: ...oute oil distribution hoses from the oil manifold to the oil delivery fittings as they were before removal Refer to Oil Supply Diagrams on p 190 Connect oil hoses to crankcase oil fittings and fasten...

Page 205: ...ue of 15 to 17 ft lbs 20 to 23 N m Install the oil fill tube the remote oil fill hose and the oil vent hose on their fittings Secure the hoses with new Oetiker clamps Install the oil distribution hose...

Page 206: ...bricant to a new oil pump o ring Install o ring on oil pump flange Install oil pump retainer screws Tighten securely IMPORTANT Turn self tapping screws counter clock wise to start the threads and cloc...

Page 207: ...an assembly and cannot be serviced as in dividual components Installation Install the oil pump into the bracket Install the screw and tighten to a torque of 35 to 60 in lbs 4 to 6 N m Connect the elec...

Page 208: ...Oiling System Notes 208 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 209: ...ts 216 Water Pump and Intakes 216 Water Supply Tube 216 Exhaust Adapter 216 Pressure Relief Valve 216 Thermostats 217 Block Venting 217 Operation 217 Cylinder Block Cylinder Head Cooling 217 EMM and V...

Page 210: ...top of the exhaust manifolds allow any air to purge from the cooling system Air and water exiting the vents flow to the overboard indicator 11 Water dams 12 in the cylinder block 6 direct water to coo...

Page 211: ...ystem Water Flow and Hose Routing Diagrams 211 9 T T 1 23 4 5 1 1 1 1 1 1 14 21 17 8 9 10 11 20 12 6 13 16 18 2 7 22 3 24 19 1 21 009737 1 15 Incoming water cool Circulating water warm Outgoing water...

Page 212: ...dule exhaust cooling Water supply to EMM vapor separator Water to exhaust cooling Non DPS models Water to DPS module exhaust cooling Water from EMM vapor separator block vent to overboard indicator Wa...

Page 213: ...5 009256 1 2 3 4 5 6 7 Water from EMM to vapor separator Vapor separator Water from block vents Water from EMM vapor separator and block vents to overboard indicator Water from thermostats to exhaust...

Page 214: ...r from thermostats to exhaust adapter Water from cylinder heads to pressure relief valve Water from exhaust adapter rear to exhaust housing Water from block vents Water from EMM vapor separator Water...

Page 215: ...M vapor separator and DPS module Water supply to EMM vapor separator Water to exhaust cooling Non DPS models Water to DPS module exhaust cooling Water from EMM to vapor separator Block vent Water from...

Page 216: ...s with a water tube and hose assembly located in the outboard s mid section O rings seal the water tube to the water pump housing Hose clamps secure the water supply hose to the water tube and a fitti...

Page 217: ...through the overboard indicator Operation All models use a two stage cooling system design The cooling system is dependent on water pump pressure and controlled by thermostat and pressure valve opera...

Page 218: ...des 25 and 29 and the Engine Monitor warning system Refer to the EMM Fault Code Chart at the back of this manual for specific fault code information Cooling water from the EMM is routed to the water i...

Page 219: ...e thermostat housing and cylinder head Check temperature on both sides of powerhead Typical pyrometer readings at IDLE speed should be 140 F 10 F 60 C 6 C IMPORTANT If you get low or inaccurate read i...

Page 220: ...pinch ing off hoses and eliminating water flow to the pressure relief valve the pressure relief valve is leaking Clean or replace the pressure relief valve as needed If IDLE temperature is still belo...

Page 221: ...12 to 18 in lbs 1 35 to 2 0 N m Wait 10 min utes for trapped air to bleed from cavity Thermal compound may seep past threads Re tighten sensor Thermostat Servicing Disassembly Remove the thermostat co...

Page 222: ...ssure valve cover to the exhaust adapter Remove the pressure valve cover pressure valve assembly and o ring from the exhaust adapter Inspection Inspect all parts for cracks heat damage or signs of cor...

Page 223: ...twork 225 NMEA 2000 Network 225 Outboard EMM 225 Shift Actuator 225 Throttle Valve Assembly 226 System Settings and Diagnostics 226 Multiple Engine Instancing 226 Remote Control Configuration 229 Remo...

Page 224: ...he operation of the outboard s shift and throttle functions Use Evinrude Diagnostics software to trouble shoot the sensors Refer to the Fault Code Chart for a complete list of all control system fault...

Page 225: ...tronic throt tle body assembly to the positions commanded by the remote control Also see Electronic Shift Controller on p 86 and Electronic Throttle Con troller on p 84 If the ICON II remote control c...

Page 226: ...iple Engine Instancing Multiple outboard installations require the transom position of each outboard be identified Engine identity is set and stored in the EMM of each outboard By default the EMM of a...

Page 227: ...rd 3 Then press the STOP button for outboard 3 If this installation has more than three outboards go to the step 6 If this is a triple outboard installa tion go to step 7 6 After setting the instance...

Page 228: ...ation select the total number of engines 6 Then select the engine s transom position from the available Engine Selection list 7 Close the Configuration screen Then close the Settings screen 8 From the...

Page 229: ...trol Identity Select the Identification button to view identifica tion information Fluid Level Configuration Select the Fluid Levels button to configure fuel or oil level sensors connected to the remo...

Page 230: ...ode The following conditions will cause the ICON II system to enter NEUTRAL idle mode Remote control lever sensor failure Foot throttle sensor failure Loss of communication with the EMM The EMM Remote...

Page 231: ...tion Response Indication Condition Code or Warning A conditional fault requiring remedial action to correct that does not affect normal operation Example Attempt to start outboard s with control lever...

Page 232: ...Evinrude ICON II Remote Control System Notes 232 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 233: ...tion 251 Powerhead Assembly 254 Crankshaft Assembly 254 Pistons and Connecting Rods 256 Installing Pistons 257 Cylinder Head Installation 258 Deck Cover Installation 259 Crankshaft and Connecting Rods...

Page 234: ...N m A 15 to 17 Ft lbs 20 to 23 N m A I X A X Z 12 to 18 In lbs 1 4 to 2 N m E 35 to 60 In lbs 4 to 6 N m 15 to 17 ft lbs 21 to 23 N m 47 to 49 ft lbs 64 to 66 N m 009270 A Triple Guard Grease E Red U...

Page 235: ...rhead Service Charts 235 11 Crankshaft and Pistons H H H D H H H X 63 to 69 Ft lbs 86 to 93 N m H B H B H D 009313 B Gasket Sealing Compound D Moly Lube H Outboard Lubricant X See Service Manual Proce...

Page 236: ...o 106 In lbs 10 to 12 N m 84 to 106 In lbs 10 to 12 N m 60 to 84 In lbs 7 to 9 N m L 84 to 106 In lbs 10 to 12 N m L 15 to 17 Ft lbs 21 to 23 N m X 11 5 to 13 5 Ft lbs 15 5 to 18 3 N m 28 to 30 Ft lbs...

Page 237: ...4 N m 84 to 106 In lbs 10 to 12 N m X 15 to 17 Ft lbs 21 to 23 N m X X X 84 to 106 In lbs 10 to 12 N m L 84 to 106 In lbs 10 to 12 N m L 15 to 17 Ft lbs 21 to 23 N m L 84 to 106 In lbs 10 to 12 N m L...

Page 238: ...238 Powerhead Service Charts Cylinder and Crankcase to Exhaust Adapter and Exhaust Housing X 22 to 24 ft lbs 30 to 32 N m 009272 X See Service Manual Text...

Page 239: ...ugs Powerhead Removal Procedure IMPORTANT Before removing the powerhead trim the engine to the vertical position Remove the top engine cover Then remove the 4 inch plug from the center frame Next remo...

Page 240: ...the electrical connectors from the fol lowing 4 Crankcase oil pump oil tank 5 Low oil switch oil tank 6 Oil level sender oil tank 7 Trim relay three Amp connectors and two 2 ring terminals 1 ground o...

Page 241: ...o adapter remove the hose from the Y fitting 4 21 0 mm Tee fitting thermostat hose to adapter remove the hose from adapter fitting 5 Tie strap Exhaust back pressure hose remove the hose from adapter f...

Page 242: ...d Removal Rear Remove the following hose clamps and hoses 1 10 5 mm Rear oil pump s hose s remove the supply hose from the oil pump 2 15 7 mm Tee fitting hose to overboard indica tor remove hose from...

Page 243: ...ropriate chain hook to the off set lifting eye Remove the 12 nuts and washers retaining the powerhead to the exhaust adapter and exhaust housing On the port side there are four nuts and washers on the...

Page 244: ...g and fuel rails and injectors Refer to Fuel Com ponent Servicing on p 168 IMPORTANT Mark injectors for cylinder location before removal All injectors must be installed in their original location Impr...

Page 245: ...aft with a rawhide or rubber mallet to loosen Carefully remove the crankcase from the cylinder block to avoid damaging the crankshaft seal rings Cylinder Head Removal Loosen in stages and remove 8 cyl...

Page 246: ...NOT remove the screws Use one hand to support the piston and remove the rod cap screws with your other hand Remove each piston and rod assembly IMPORTANT Identify all internal components so if reused...

Page 247: ...ing Tool P N 396747 to remove wrist pin Crankshaft Removal Carefully lift crankshaft straight up and remove from crankcase Remove upper seal from crankshaft Discard the seal A new upper seal must be i...

Page 248: ...eve and inspect it Replace the O ring if it is not in good condition Inspect the crankshaft sleeve and replace if nec essary To remove the sleeve use Slide Hammer P N 432128 and Large Puller Jaws P N...

Page 249: ...for an alter native method of removal Install a powerhead retaining nut fully onto the stud Then install a second nut and tighten it against the first Place a wrench on the first nut and turn counter...

Page 250: ...bers If cylinder walls are glazed from extended use use a rigid medium grit cylinder hone to resurface walls Use slow RPM for best oil retention and ring sealing When finished a cross hatch pattern of...

Page 251: ...vent corrosion Powerhead Inspection For dimensions refer to Service Specifications on p 12 Before any inspection process can begin all inter nal components must be completely clean and free of contami...

Page 252: ...re for an out of round oversize or tapered condition Be sure the gauge is perfectly square in the bore when measuring Measure each cylinder in at least two areas Each area should be measured twice The...

Page 253: ...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 Position piston ring...

Page 254: ...f the crankshaft Use Crankshaft Bearing Sleeve Installer P N 338649 to drive a new sleeve onto the crankshaft until the installer contacts the lower main bearing If the installer sticks on the sleeve...

Page 255: ...extended lip of the seal MUST face down Lubricate the seal lip with Triple Guard grease Install a new o ring on the lower housing Apply a thin coat of Gasket Sealing Compound to the o ring Apply a thi...

Page 256: ...rod with bearing into the pis ton IMPORTANT Make sure to hold the bearing installer in place to prevent bearing needles from falling out of place the alignment dots on the connecting rod are facing t...

Page 257: ...efer to Powerhead Inspection on p 251 IMPORTANT Be sure gap of ring fits squarely around dowel pin Coat pistons rings cylinder walls and ring com pressor with outboard lubricant Center connecting rod...

Page 258: ...ead as shown Make SURE the oil pas sages are NOT blocked Apply soapy water to water dams and insert into block Apply a thin bead of RTV around each of the water passages on the block and cylinder head...

Page 259: ...and Connecting Rods Check that main bearing alignment dowel pins are seated in the block Push all pistons to the top of cylinders Remove the numbered connecting rod caps and hold the connecting rods...

Page 260: ...ng rod Install rod cap screws finger tight NO MORE than 6 in lbs 1 N m maximum IMPORTANT Be sure alignment dot on rod cap matches dot on rod and that both dots face fly wheel Install Rod Cap Alignment...

Page 261: ...on necting rod Slide frame down until adjustment stop contacts the rod cap The groove lines on the jaws must be centered on the rod crankpin diameter Tighten the forcing screw to a torque of 23 in lbs...

Page 262: ...Thoroughly clean and degrease the mating flanges of the crankcase and cylinder block with a non petroleum based solvent such as isopropyl alcohol or acetone and let air dry IMPORTANT DO NOT allow sol...

Page 263: ...he stator and flywheel Refer to Flywheel and Stator Servicing on p 133 Install the rear oil pump and oil circulation hoses Refer to Oil Component Servicing on p 204 Install the cooling water hoses Ins...

Page 264: ...powerhead from the shipping container Use Engine Lifting Fixture P N 357667 to lift the powerhead Use the off set lifting eye to lift the powerhead IMPORTANT Carefully thread the lifting fixture into...

Page 265: ...ers and nuts to retain the pow erhead to the exhaust adapter and exhaust hous ing On the port side there are four washers and nuts on the exhaust adapter and four washers and nuts on the exhaust housi...

Page 266: ...ts in the sequence shown to a torque of 22 to 24 ft lbs 30 to 32 N m Wait 5 minutes then re tighten the nuts Use the same sequence and tighten to a torque of 22 to 24 ft lbs 30 to 32 N m Remove the li...

Page 267: ...11 Rear Install the following hoses and hose clamps 1 Install the supply hose to the oil pump secure with a new 10 5 mm Oetiker clamp 2 Install the overboard indicator to the tee fitting secure with a...

Page 268: ...xhaust adapter to the adapter fitting secure with a new 15 7 mm Oetiker clamp 4 The Y fitting to the exhaust adapter hose secure with a new 34 6 mm Oetiker clamp 5 The thermostat hose to the exhaust a...

Page 269: ...ose on to the center top frame secure with a new 51 5 mm Oetiker clamp 5 The oil tank vent hose on to the oil tank secure with a new 10 5 mm Oetiker clamp 6 The remote oil fill hose on to the oil tank...

Page 270: ...mets into the front frame then install the front frame Install the port and starboard frames Install the rear covers Connect all cables buss cables and hoses from the engine Then install the front cov...

Page 271: ...Powerhead Powerhead Views 271 11 Powerhead Views Starboard 009375...

Page 272: ...272 Powerhead Powerhead Views Port Non DPS Models 009406...

Page 273: ...Powerhead Powerhead Views 273 11 Port DPS Models 009374...

Page 274: ...274 Powerhead Powerhead Views Rear 200 225 250 HP Models 009407...

Page 275: ...Powerhead Powerhead Views 275 11 Rear 250 H O 300 HP Models 009376...

Page 276: ...276 Powerhead Powerhead Views Front Frame Removed 009379...

Page 277: ...Powerhead Powerhead Views 277 11 Front Frame Installed 009378...

Page 278: ...ow 009469 009469 5 1 4 2 4 3 1 Water Filter Block Outlet 2 Water Supply Hose to Exhaust Water Valve 3 Exhaust Water Valve 4 Water Tube and Fitting 5 Exhaust Water Fitting Starboard 6 Water Hose and Te...

Page 279: ...namic test of the water valve while the outboard is running Disconnect the water valve outlet hoses Start the outboard No water should flow from the hoses If water appears check for debris in valve as...

Page 280: ...ero 0 indicates an short circuit Isolate the faulty component Check wiring and connections Repair or replace faulty wiring Water Valve Resistance Test Disconnect the battery cables at the battery Dis...

Page 281: ...er fitting from the exhaust runner Installation is the reverse of removal Apply Pipe Thread Sealing Compound P N 764806 or equiv alent to the threads of the exhaust water fittings Tighten water fittin...

Page 282: ...282 Powerhead Notes Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 283: ...ter and Muffler 285 Exhaust Housing Service 286 Exhaust Housing Removal 286 Cleaning and Inspection 286 Exhaust Housing Installation 287 Exhaust Adapter Removal 287 Exhaust Adapter Installation 289 Ex...

Page 284: ...4 N m 24 to 26 Ft lbs 33 to 35 N m 28 to 30 Ft lbs 38 to 40 N m X L 15 to 17 Ft lbs 20 to 23 N m L 6 to 8 Ft lbs 8 to 10 N m 6 to 8 Ft lbs 8 to 10 N m 6 to 8 Ft lbs 8 to 10 N m 6 to 8 Ft lbs 8 to 10...

Page 285: ...9 Ft lbs 9 5 to 12 N m L 72 to 96 In lbs 8 to 11 N m L 72 to 96 In lbs 8 to 11 N m L 72 to 96 In lbs 8 to 11 N m L 18 to 20 Ft lbs 25 to 27 N m L 18 to 20 Ft lbs 25 to 27 N m L 72 to 96 In lbs 8 to 1...

Page 286: ...eriorated or damaged Before checking the exhaust housing for distor tion Remove the exhaust adapter Remove the gearcase retaining studs Thoroughly clean the top and bottom mating surfaces and remove a...

Page 287: ...tank assembly Refer to Oil Tank Installa tion starting on p 205 Exhaust Adapter Removal Remove the exhaust hosing and adapter from the swivel bracket Refer to Remove one hose clamp and two tie straps...

Page 288: ...the adapter and insert the exhaust pipe into the adapter Cooling Water Hose and Tube Remove the hose clamps to service the hose and tube assembly Installation is reverse of removal If fitting is remo...

Page 289: ...the casting Carefully install the foam gasket onto the adapter Next install the muffler and hose from the exhaust pipe Secure the muffler hose to the exhaust pipe with a new Oetiker clamp Then instal...

Page 290: ...he fitting Install the fitting and tighten to a torque of 72 In lbs 8 N m Check the index marks Correct indexing is achieved when one of the index marks is aligned with or up to 30 past the exhaust ba...

Page 291: ...dapter from the swivel bracket to service the lower mounts Remove the four screws and lower mount covers and inspect the lower mounts If replacement is necessary remove the two screws from the front o...

Page 292: ...lief grommet connect to a water hose A tee fitting distributes water to two hoses One hose supplies flushing water to the vapor separa tor EMM and DPS module and exits into the exhaust adapter A secon...

Page 293: ...ensor Circuits 305 CANbus Circuit 305 Steering Pressure Sensor Tests 305 Steering Position Sensor Test 306 Steering Position Sensor Service 306 DPS Module Service 307 DPS Module Removal 307 DPS Module...

Page 294: ...N m 84 to 120 In lbs 10 to 14 N m 36 to 60 In lbs 4 to 6 N m 84 to 106 In lbs 10 to 12 N m 15 to 23 Ft lbs 20 to 23 N m 15 to 23 Ft lbs 20 to 23 N m 180 to 204 In lbs 20 to 23 N m X 348 to 372 In lbs...

Page 295: ...e 84 to 106 In lbs 10 to 12 N m 15 to 23 Ft lbs 20 to 23 N m 15 to 23 Ft lbs 20 to 23 N m 84 to 120 In lbs 10 to 14 N m 36 to 60 In lbs 4 to 6 N m 36 to 60 In lbs 4 to 6 N m 36 to 60 In lbs 4 to 6 N m...

Page 296: ...o 120 In lbs 10 to 14 N m 84 to 120 In lbs 10 to 14 N m X 26 to 28 Ft lbs 36 to 38 N m 67 to 69 Ft lbs 90 to 94 N m X 59 to 70 Ft lbs 80 to 94 N m 79 to 96 In lbs 9 to 10 N m 40 to 42 Ft lbs 55 to 57...

Page 297: ...to 30 in lbs 2 5 to 3 N m 18 to 24 in lbs 2 to 2 7 N m 84 to 106 in lbs 9 5 to 12 N m 84 to 106 in lbs 9 5 to 12 N m 35 to 60 in lbs 4 to 6 7 N m 36 to 60 in lbs 4 to 6 7 N m 84 to 106 in lbs 9 5 to 1...

Page 298: ...ly 009431 X 18 to 20 Ft lbs 24 4 to 27 N m 60 to 84 In lbs 7 to 10 N m 60 to 84 In lbs 7 to 10 N m 60 to 84 In lbs 7 to 10 N m 60 to 84 In lbs 7 to 10 N m 84 to 108 In lbs 10 to 12 N m 4 3 6 5 1 2 E R...

Page 299: ...ressure Sensors 144 to 168 In lbs 17 to 19 N m 144 to 168 In lbs 17 to 19 N m 84 to 108 In lbs 10 to 12 N m 84 to 108 In lbs 10 to 12 N m 009748 E Red Ultra Lock X See Service Manual Text AA No Ox Gre...

Page 300: ...18 to 20 Ft lbs 24 4 to 27 N m 4 3 1 2 60 to 84 In lbs 7 to 10 N m 18 to 20 Ft lbs 24 4 to 27 N m 59 to 70 Ft lbs 80 to 94 N m 60 to 84 In lbs 7 to 10 N m 60 to 84 In lbs 7 to 10 N m 22 to 30 In lbs 2...

Page 301: ...pump pressure sensor signals the DPS module of an increase in hydraulic pressure beyond normal steering load The DPS module then turns OFF the DPS pump to maximize sys tem efficiency The DPS Module mo...

Page 302: ...f PTPS voltage is less than 0 12 V the EMM If PTPS voltage is greater than 4 6 V the EMM If STPS voltage is less than 0 12 V the EMM If STPS voltage is greater than 4 6 V the EMM If Steering Sensor ST...

Page 303: ...17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 5 4 2 6 7 8 9 1 3 10 DPS 2 DPS 1 009734 1 EMM 2 DPS Module 3 DPS Module to EMM Connections 4 Steering Position Sensor DPS 2 models only 5 Battery Post B suppl...

Page 304: ...er lead to engine ground Results Readings as listed in table indicate circuit is good No reading OL or indicates an open circuit A reading of zero 0 indicates an short circuit Replace faulty module NO...

Page 305: ...it resistance Connect the positive meter lead to the DPS Mod ule connector wire listed in the table Connect the negative meter lead to engine ground Results No reading OL or indicates an open circuit...

Page 306: ...el Steering Position Sensor Service Remove two screws from the sensor and two screws from the magnet Assembly is the reverse of disassembly Tighten all screws to a torque of 35 to 60 in lbs 4 to 6 7 N...

Page 307: ...PS module mounting screws and washers Remove the DPS module from the engine DPS Module Installation If installing the DPS module on an ABA engine model install the Connector and Seal Assembly P N 5873...

Page 308: ...ut board select the Software button then select the Load Steering Firmware button A pop up window will appear Select the correct software from the list Then follow the on screen prompts to install the...

Page 309: ...connects to the network select from the device list the Engine Controller EMM Then select the Power Steering button 1 Select Enable Calibration The power steering pump is disabled while in calibratio...

Page 310: ...select from the device list the Engine Controller EMM Then select the Power Steering button 1 Select Enable Calibration The power steering pump is disabled while in calibration mode 2 Press Reset Limi...

Page 311: ...ontroller EMM for the FIRST DPS outboard Then select the Power Steering button 1 Select Enable Calibration The power steering pump is disabled while in calibration mode 2 Press Reset Limits Then be SU...

Page 312: ...the device list the Engine Controller EMM for the SECOND DPS outboard Then select the Power Steering button 8 Repeat steps 1 through 7 for the SECOND DPS outboard After completing end points calibrat...

Page 313: ...st below Steering System Test Turn the steering wheel fully to PORT The power steering pump should run then shut OFF when the engine is turned fully to PORT Turn the steering wheel fully to STARBOARD...

Page 314: ...stern and swivel bracket in a clean work area Place oil absorbent mats or shop towels in a large pan Place the pan on a work bench and place the stern and swivel bracket in the pan A quantity of hydra...

Page 315: ...the DPS manifold and the four hex screws retaining the trim manifold The DPS and trim manifolds are removed as one assembly Carefully remove the manifold assembly from the outboard Use shop towels to...

Page 316: ...hich are 0 237 in 6 mm inside diameter x 0 103 in 2 6 mm thick The Trim and Tilt Manifold uses 4 Filters P N 356937 which are 0 875 in 22 4 mm long 1 Four DPS manifold o rings 2 Four trim manifold o r...

Page 317: ...wn Insert a new filter into the each swivel bracket oil passage for the trim and tilt circuit Continue to push the filter into the oil passage until the filter is just below the mating surface Place t...

Page 318: ...are to keep o rings in position Install the two cap screws and washers into the DPS manifold and the four hex screws into the trim manifold Tighten screws in the sequence shown to a torque of 18 to 20...

Page 319: ...ring Pressure Sensor Calibration AFA and Newer Models Only on p 309 Fill and bleed the trim and tilt system refer to Fill ing the Trim and Tilt System on p 332 Confirm the trim and tilt fluid level is...

Page 320: ...ilter Clean and dry all parts thoroughly Assembly Install a new filter into the manifold Apply a drop of Power Trim Tilt Fluid P N 767969 to the o rings of a new tube and o ring assembly Install the t...

Page 321: ...he top of the DPS mani fold Tighten the screws to a torque of 60 to 84 In lbs 7 to 10 N m Steering Pressure Sensors Remove the steering pressure sensors as required for replacement Install sensors and...

Page 322: ...DPS manifold is re installed on the out board Refer to Steering Pressure Sensor Calibration AFA and Newer Models Only on p 309 Electric Motor Remove the four screws and washers retaining the electric...

Page 323: ...me Outboard Removed from Boat If the outboard is removed from the boat remove the four screws retaining the plate to the stern brackets Then remove the plate Outboard Installed on Boat If the engine i...

Page 324: ...the manifold assembly is removed from the swivel bracket Remove the four hex screws retaining the trim manifold Carefully remove the manifold assembly from the outboard Use shop towels to wipe up spil...

Page 325: ...Filters P N 356937 which are 0 875 in 22 4 mm long 3 O rings P N 326956 which are 0 299 in 7 6 mm inside diameter x 0 103 in 2 6 mm thick 1 O ring P N 318372 which is 0 306 in 7 8 mm inside diameter x...

Page 326: ...racket Carefully place the manifold assembly into posi tion on the swivel bracket Take care to keep o rings in position on the swivel bracket Install the four hex screws into the trim manifold Tighten...

Page 327: ...er and Frame Service on p 55 Manifold Disassembly Service of the trim and tilt manifold requires removal from the outboard Refer to Trim Tilt Manifold Service on p 323 Separate the fluid reservoir fro...

Page 328: ...pply a drop of Power Trim Tilt Fluid P N 767969 to the o rings of a new tube and o ring assembly Install the tube and o rings into the manifold Align the screw bosses and fluid passage of the trim res...

Page 329: ...e the four screws and washers retaining the electric motor to the manifold housing Remove the electric motor o ring and coupler from the manifold housing Clean and dry all parts thoroughly Assembly is...

Page 330: ...e the trim rod end caps Remove end caps from both trim cylinders Slide the end caps towards the trim rollers NOTICE Service procedures of hydraulic trim and tilt systems MUST occur in a clean dust fre...

Page 331: ...rim rods 009579 1 Tube 009580 NOTICE Apply cleaning solvent to lint free shop tow els to clean hydraulic oil residue from all sur faces Do NOT spray cleaning solvent on the swivel bracket or into the...

Page 332: ...S models Use a CLEAN funnel and hose to add Power Trim Tilt Fluid P N 767969 to the reservoir Do NOT re install the filler cap at this time Turn the key switch ON Use the trim switch to cycle the trim...

Page 333: ...ghten it securely Do NOT over tighten the cap Clean up spilled fluid with shop towels DPS Models Trim the outboard UP until the center of the roller shaft is 6 3 8 inches 162 mm from the end of the tr...

Page 334: ...p spilled fluid with shop towels Use a clean shop towel to remove wax pencil ref erence marks made on the outboard Stern Swivel Bracket Removal IMPORTANT Trim the engine to the vertical po sition BEFO...

Page 335: ...trim motor and trim sender Pull the harnesses back to the stern and swivel bracket If equipped disconnect the electrical connectors from the DPS module Note the routing of the harnesses for the DPS m...

Page 336: ...g eye is aligned to the REAR of the engine Use the off set lifting eye to support the engine Fasten an appropriate chain hook to the off set lift ing eye Remove the four lower mount bolts Remove the t...

Page 337: ...ces Apply marine sealer under hex heads of bolts on the mounting plates and to the bolt shanks Install the stern and swivel assembly with the four mounting bolts Install all washers and nuts Tighten m...

Page 338: ...ine Con nect the electrical connectors Install the rigging center with four screws Tighten screws to a torque of 84 to 106 in lbs 10 to 12 N m Install the front frame starboard and port frames and rea...

Page 339: ...loosen the manual release valve and tilt the swivel bracket up slightly Close the manual release valve Make sure the trim rollers are NOT touching the ramps If the trim rollers are touching the ramps...

Page 340: ...e stern bracket cover Remove the cover and large o ring Use a punch and hammer to bend the locking tab from the spanner nut slot Use Spanner Socket P N 359225 to remove the spanner nut Remove the lock...

Page 341: ...t The screw will be tightened later Apply a light coating of Triple Guard Grease into the o ring groove on the inside of the stern bracket Install the o ring into the groove Place the thrust washer on...

Page 342: ...gned with a locking tab on the washer Use a suitable tool to bend the locking tab into the spanner nut Install the large o ring and cover Install the two screws and o rings to secure the stern bracket...

Page 343: ...o 23 ft lbs 20 to 23 N m Tighten the bottom screws to a torque of 30 to 60 in lbs 4 to 6 N m Install the spray plate cover with four screws Tighten the screws to a torque of 30 to 60 in lbs 4 to 6 N m...

Page 344: ...inal over the lower screw Install the washer and nut on the lower screw Tighten both screws to a torque of 22 to 30 in lbs 2 5 to 3 N m Apply No Ox Grease P N 768230 over the ring terminal washer and...

Page 345: ...rom the steering shaft End Cap Removal Remove the steering arm from the steering shaft Refer to Steering Arm Removal on p 344 Remove the two screws retaining the steering position sensor and remove th...

Page 346: ...ings on the steer ing shaft Apply Triple Guard Grease to a new o ring and install the o ring in the groove in the end cap Install the end cap assembly and install the eight screws hand tight Use a T 4...

Page 347: ...sly made on the splined steering shaft and steering arm If installing a new service replacement part align the mounting surface of the steering arm with the mounting surface of the lower bracket After...

Page 348: ...g Install the three screws in the steering arm cover Tighten screws to a torque of 79 to 96 In lbs 9 to 10 N m Install the engine on the stern and swivel bracket assembly Refer to Installation on p 33...

Page 349: ...e splines on the steering shaft and lower bracket Inspect for any burrs especially in the area of snap ring groove on the shaft Carefully clean up any burrs with a small file Lower Bracket Installatio...

Page 350: ...y to port and fully to starboard IMPORTANT The bracket MUST turn an equal amount in both directions Remove and re align the bracket if steering is not equal Use a bent jaw retaining ring pliers to ins...

Page 351: ...ctuator Ground Circuit 369 Neutral Circuit 369 Shift Actuator Service 370 Shift Actuator Removal 370 Shift Actuator Installation 370 Shift Actuator Calibration 372 Gearcase Standard Rotation Gearcase...

Page 352: ...rward Gear Removal 397 Pinion Gear Removal and Driveshaft Servicing 399 Clutch Shaft and Reverse Gear Removal 399 Shift Housing Removal 401 Water Intake Screens 401 Shifter Bearing and Seal Servicing...

Page 353: ...Gearcase Service Charts 353 14 Service Charts Propeller Hardware 15 to 17 Ft lbs 20 to 23 N m 70 to 80 Ft lbs 95 to 105 N m 009314...

Page 354: ...14 N m A A E 15 to 17 Ft lbs 20 to 23 N m 10 to 14 In lbs 1 2 to 1 6 N m 18 to 24 In lbs 2 to 2 7 N m 18 to 24 In lbs 2 to 2 7 N m 60 to 84 in lbs 7 to 10 N m X 009311A A Triple Guard Grease B Gasket...

Page 355: ...to 17 Ft lbs 20 to 23 N m A 100 to 110 Ft lbs 136 to 149 N m G G D B B 144 to 168 In lbs 16 to 19 N m 60 to 84 In lbs 7 to 10 N m D A X 009311B A Triple Guard Grease B Gasket Sealing Compound D Moly L...

Page 356: ...r Shaft B 82 to 92 Ft lbs 111 to 125 N m X A A A A B A X 84 to 106 In lbs 10 to 12 N m X 2 to 4 in lbs 0 25 to 0 45 N m 009311C A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra...

Page 357: ...92 Ft lbs 111 to 125 N m X A A A A B A X 84 to 106 In lbs 10 to 12 N m X 2 to 4 in lbs 0 25 to 0 45 N m X 100 to 110 Ft lbs 136 to 149 N m 009312 A Triple Guard Grease B Gasket Sealing Compound D Moly...

Page 358: ...ing with retaining spanner nut and locking ring heavy duty standard rotation gear set pressed in forward bearing housing 13 24 542 Counter Rotation 25 in 30 in Front water inlets and straight leading...

Page 359: ...ttle operating range when the boat has a normal load Occasionally one propeller will not cover a wide range of boat applications water skiing to high speed performance boating In such cases it might b...

Page 360: ...with the propeller IMPORTANT After installation make sure out board is in NEUTRAL and carefully spin propeller Propeller must turn freely and should not spin off center If propeller appears to wobble...

Page 361: ...leakage apply oil around suspected seal If leak stops or oil is drawn in seal is defective Repeat test gearcase must hold minimum of 15 in vacuum 381 mm Hg Gearcase Removal and Installation Gearcase...

Page 362: ...Lube 5008933 10 CAUTION Gearcase lubricant may be under pressure and or hot if outboard was recently operated or if gearcase lubricant is above the Maxi mum level Wear safety glasses and take precaut...

Page 363: ...ator cable from the engine harness Route the oil hose and shift actuator cable through the opening at the front of the exhaust housing The oil hose is routed to starboard the actuator cable to port 14...

Page 364: ...ighten gearcase nuts with a torque wrench could lead to gearcase dam age or loss resulting in loss of control and possible personal injury Nut torque should be checked regularly especially in high spe...

Page 365: ...ling a new gearcase or shift actuator Install the frames and covers Refer to Engine Cover and Frame Service on p 55 Water Pump Service Disassembly Remove the four impeller housing screws Slide the wat...

Page 366: ...his groove is blocked by adhesive the pump will lose its prime and will not pump water Install the o ring in the impeller housing Lightly coat the exterior rim of the impeller cup with Triple Guard gr...

Page 367: ...is the leading edge in clockwise rotation Slide the water pump down the driveshaft Align impeller slot with the impeller key Rotate the driveshaft to engage the key with the impeller and slide water p...

Page 368: ...ift rod MUST be in the up position to install the shift actuator Remove the tool from the gearcase Alternate Adjustment Method If the Shift Rod Installer P N 358162 is not avail able this alternate me...

Page 369: ...ring Shift Actuator Ground Circuit Use a digital multimeter with appropriate test probe leads to measure the ground circuit resis tance Connect the positive meter lead to the engine harness connector...

Page 370: ...actuator seal and discard it Remove all old gasket sealing compound from the shift actuator and gearcase housing Shift Actuator Installation 1 Screws 009317 009318 1 1 2 1 Seal 009319 1 Gearcase hous...

Page 371: ...o the ON position Do NOT start the engine 6 Shift the remote control into NEUTRAL After verifying the shift actuator is in NEUTRAL turn the key switch to the OFF position Then dis connect the shift ac...

Page 372: ...the plug in the top of the shift actuator Tighten the plug to a torque of 60 to 84 in lbs 7 to 9 5 N m Shift Actuator Calibration Calibrate the shift actuator 1 If the gearcase is removed from the out...

Page 373: ...askets Remove the propeller and mounting hardware Drain and inspect oil as described in Gearcase Lubricant on p 20 Remove gearcase as described in Gearcase Removal on p 361 Remove water pump as descri...

Page 374: ...aring housing of SLX Type gearcases is PRESSED into gearcase housing Use two flat blade screwdrivers to remove the ventilation ring from the gearcase Insert the blade of a small screwdriver into one o...

Page 375: ...removed BEFORE beginning this procedure Place the Adapter P N 354178 on the gearcase followed by the Puller P N 354177 Then install the Puller Stud P N 358294 onto the propeller shaft until seated In...

Page 376: ...arcase The bearing housing shims thrust bearing and thrust washer will come out with the driveshaft If driveshaft cannot be removed refer to Locked Driveshaft Removal Remove the pinion gear from the g...

Page 377: ...ft bore If the pinion bearing is being removed the oil pump can be removed with the pinion bearing using the pinion bearing removal procedure See Pinion Bearing Removal on p 380 If the pinion bearing...

Page 378: ...e the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out Use the tool to remove the shift rod from the detent lever Use Propeller Shaft Bearing Housing Pul...

Page 379: ...moved remove the forward gear thrust bearing and thrust washer Shift Housing Removal Use Puller Tool P N 358520 with Puller Jaws P N 432129 and Puller Wrench P N 334359 to remove the shifter housing A...

Page 380: ...g and Seal Servicing Pinion Bearing Removal Assemble the following components of the Pinion Bearing Remover and Installer P N 5005927 in the gearcase as follows Use a 7 8 in wrench to hold the remover...

Page 381: ...Whenever a gearcase is disas sembled the pinion bearing should be checked to ensure that it has been installed with the lettering facing up Insert the tool with the bearing into the gearcase Drive th...

Page 382: ...housing Remove the detent ball and spring Remove needle bearings from bearing housing for cleaning and inspection WARNING Wear safety glasses to avoid injury 1 Shift lever pin 009556 1 Shift lever pi...

Page 383: ...shown Depress the ball and spring with a suitable tool Then push the shifter detent is past the ball and remove the tool Rotate the shifter detent 90 to position the detent to engage the ball in the...

Page 384: ...thrust bearing and thrust washer into the shift housing assembly Verify the assembly of the shift shaft cradle and shift lever Align holes in the clutch dog with slot in the pro peller shaft Install t...

Page 385: ...ign the plate across the top of the gearcase so the threaded rod pulls the bushing straight as the nut is tightened 5 Tighten the nut with a wrench until the bushing is removed from the bore of the ge...

Page 386: ...ean the bearing housing in solvent to remove sealer from the seal bore and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of...

Page 387: ...d the inner seal If necessary use an electric heat gun to warm the housing to aid in seal removal Rear Seal Removal Late Models Late models use a retaining ring to improve seal retention Insert the bl...

Page 388: ...bearing housing Turn the screw driver to move the end of the retaining ring from its retaining groove Use a curved pick to work the snap ring up from the retaining groove Remove the snap ring Remove b...

Page 389: ...Tools P N 358167 front bearing P N 358168 rear bearing Counter Rotation housing Bearing Installation Tool P N 432401 front bearing P N 358168 rear bearing Rear Bearing Retaining Ring Installation Late...

Page 390: ...back to back in bearing housing Seal Installation Tool P N 358169 Install inner seal with lip facing toward the bearing housing then outer seal with lip facing away from the bearing housing Apply Trip...

Page 391: ...oving the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 100 to 110 ft lbs 136 to 149 N m IMPORTANT The original pinion nut may be used...

Page 392: ...from 0 020 in 0 508 mm to determine the cor rect shim thickness required Select the fewest number of shims to achieve the correct thickness Remove the driveshaft from the tool and add the required sh...

Page 393: ...to Gear case Press Fixture P N 354059 Place Forward Bearing Press Fixture P N 358163 over propeller shaft and into gearcase housing Align and level the gearcase assembly in the fix ture as shown Secur...

Page 394: ...ion gear into the gearcase Insert the driveshaft into the gearcase and through the pinion gear Be SURE the oil passage of the drive shaft bearing housing is facing FOR WARD or AFT Lightly coat the thr...

Page 395: ...ase to a new bear ing housing o ring Install o ring in the groove in the housing Grease both machined side surfaces of bearing housing Place the bearing housing into the gearcase Align the vertical ri...

Page 396: ...ing Apply Gasket Sealing Compound to threads of a new spanner nut Start the spanner nut by hand Then use Spanner Nut Wrench P N 358165 to tighten the spanner nut Tighten the spanner nut to a torque of...

Page 397: ...rotation CR gearcases use unique components and require different ser vice procedures Use care when working on count er rotation gearcases DO NOT interchange parts between standard and counter rotatio...

Page 398: ...ORTANT Make SURE the shift actuator is removed BEFORE beginning this procedure DO NOT use tools designed to push on the pro peller shaft Pushing force against the propeller shaft could damage the forw...

Page 399: ...rse Gear Removal Use Ball Detent Remover Installer P N 358519 remove the sleeve detent balls and spring from the clutch shaft Align the slots in the tool end with the small detent balls Push the tool...

Page 400: ...t obtain locally through the holes Place the puller plate over the puller rod and install the puller nut Hold the rod with a wrench and tighten the nut to remove the clutch shaft The reverse gear may...

Page 401: ...d bearing are serviced as an assembly If either are worn or dam aged replace the complete assembly If the reverse gear came out with the clutch shaft remove the cradle and gear from the clutch shaft I...

Page 402: ...hift lever Move shifter detent as needed to help ease removal of parts 1 Pin 009559 1 Shift lever pin 009556 1 1 1 Shift lever pin 2 Magnet 3 Cradle 4 Shift lever 5 Shifter detent 009518 NOTICE Discar...

Page 403: ...t the spring in the housing then the ball Insert shifter detent into the housing Position the NEUTRAL detent at a 90 angle as shown Depress the ball and spring with a suitable tool Then push the shift...

Page 404: ...bearing and thrust washer with Needle Bearing grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the gear bearing and washer into the bearing housing...

Page 405: ...Bearing Installation on p 380 Propeller Shaft Bearing Housing and Forward Gear Disassembly Remove and discard the bearing housing O ring Remove the anode and discard if more than two thirds deteriorat...

Page 406: ...eplace anode if it is reduced to two thirds of original size Tighten screws to a torque of 108 to 132 in lbs 12 to 15 N m Discard the bearing housing o ring Clean the housing and bearings in solvent a...

Page 407: ...389 in reading on the gauge 0 011 in shims required 1 400 in required dimension Apply Needle Bearing grease to the thrust bear ing Position bearing around shoulder on the pro peller shaft Apply Needl...

Page 408: ...bars are precision made and should be handled carefully The length of each bar is stamped near the part number This dimension is 0 020 in 0 508 mm shorter than the actual shimmed length of the drives...

Page 409: ...eck if variance is greater than 0 004 in 0 101 mm Check squareness of the pinion to the driveshaft Hold the shim gauge bar against the bearing housing between the screw holes while rotating just the d...

Page 410: ...Make sure the align ment pin on the shifter housing is aligned with the hole in forward end of gearcase housing Make sure the shifter detent will align with the shift rod bushing Look through the shi...

Page 411: ...leeve into the clutch shaft Install the spring and large detent ball into the clutch shaft Then place the two small detent balls into the clutch shaft Place the sleeve over the tool Use the tool to al...

Page 412: ...g O ring Install the O ring in the groove in the housing Grease the machined side sur faces of bearing housing Place the bearing housing into the gearcase Align the vertical ribs of the propeller shaf...

Page 413: ...sing Apply Gasket Sealing Compound to threads of a new spanner nut Start the spanner nut by hand Then use Spanner Nut Wrench P N 358165 to tighten the spanner nut Tighten the spanner nut to a torque o...

Page 414: ...down to snap the ventilation ring into place Final Assembly and Adjustment To complete gearcase assembly refer to Gearcase Leak Test on p 361 Water Pump Service on p 365 Shift Rod Adjustment on p 368...

Page 415: ...Electrical System and Safety 422 Outboard Mounting System and Safety 425 If weakened parts could fail later on the water when not expected 426 Outboard Hydraulic Tilt Trim Shock Absorption System and...

Page 416: ...S 416...

Page 417: ...e not had training related to common shop safety practices you should do so not only to protect yourself but also to protect the people around you It is impossible for this manual to cover every poten...

Page 418: ...IF NEUTRAL FORWARD REVERSE FORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted...

Page 419: ...UTRAL Operator must be able to STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How ca...

Page 420: ...arts here at the steering wheel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could b...

Page 421: ...that will not loosen rust or weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK ear...

Page 422: ...k What is most important Fuel leakage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is store...

Page 423: ...Metal Clamps Tie Straps Position as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark P...

Page 424: ...heck for leaks under engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is...

Page 425: ...must stay in position on boat s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits somethi...

Page 426: ...nsom is curved outboard may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken...

Page 427: ...rd must not trim in too far suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow w...

Page 428: ...ere at the clip and lanyard and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled f...

Page 429: ...or may drown and boat WILL run into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow wa...

Page 430: ...proper safety takes time Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damage...

Page 431: ...gravity Stand Clear It might hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly...

Page 432: ...ard to work on the outboard remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts l...

Page 433: ...ns and other boats Avoid exhaust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create...

Page 434: ...ng 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 Always shut off th...

Page 435: ...ty when connecting these larger leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged...

Page 436: ...hem if fumes are smelled Matches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors...

Page 437: ...hurt people READ How and where to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle labe...

Page 438: ...rstand that the service manual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you rec...

Page 439: ...Check wiring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendix...

Page 440: ...ng Check voltage at injectors Excessive fuel or oil engine flooded Check for leaking injectors leaking fuel or oil lift pump or leaking vapor separator vent refer to System Analysis Low or no 55 V alt...

Page 441: ...siphon valve and fuel pick up check for fuel system air leaks Low or no alternator output 55 V Check voltage on 55 V circuit refer to System Analysis and Electrical and Ignition Capacitor or 55 V cir...

Page 442: ...ternator output 55 V Check voltage on 55 V circuits refer to System Analysis and Electrical and Ignition Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to v and Electrical and...

Page 443: ...ck ignition refer to System Analysis and Electrical and Ignition Fuel injector electrical circuit or control function Check voltage at injectors refer to System Analysis Restricted or leaking fuel inj...

Page 444: ...leaks Restricted or leaking fuel injector s Check injectors refer to Fuel System Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring Check CPS air gap Low alterna...

Page 445: ...ging System Tests 126 Maintenance 17 Requirements 13 17 Storage 27 Bearing Connecting Rod 260 Crankshaft 254 255 Pinion Gear 380 Break In EMM Programming 195 264 Gearcase 397 414 Oiling 195 Procedure...

Page 446: ...nder Bore Honing 250 Inspection 252 Cylinder Head Inspection 251 Installation 258 Removal 245 D Deutsch Connector Servicing 139 Diagnostic Procedures Data Logging 104 Dynamic Tests 108 Ignition Tests...

Page 447: ...ircuits EMM Pin Locations 112 Fuse 115 Ground Circuits 115 Ground Tests 115 Start Circuit 129 Electrical Harness AMP Connectors 140 Connector Servicing 139 Deutsch Connectors 139 EMM J1 A Connector 11...

Page 448: ...Charts 284 Exhaust Pressure Fitting 24 Exhaust Temperature Sensor Circuit Test 118 Description 81 Resistance Test 118 Exhaust Water Valve Circuit Tests 279 Component Service 281 Dynamic Test 279 Exha...

Page 449: ...oubleshooting 160 Vacuum Test 163 Vapor Separator Service 170 Fuel Vapor Separator Cooling 156 Description 155 Installation 171 Removal 170 Fuses 115 G Gearcase Assembly Counter Rotation 410 Standard...

Page 450: ...Diagnostic Software Method 227 Manual Method 227 Intake Manifold Assembly 182 Disassembly 181 Inspection 182 Installation 182 Removal 180 i Trim 44 Operation 44 Trim tilt switch over ride 45 J Jack Pl...

Page 451: ...rical Tests 199 Installation 207 Removal 207 Oil Tank Servicing Oil Tank Installation 205 Oil Tank Removal 205 Oil Warning System LOW OIL Warning 194 NO OIL Warning 194 Oiling System Components 192 El...

Page 452: ...18 360 Propeller Shaft Installation Standard Rotation 392 Counter Rotation 412 Lubrication 20 Removal Standard Rotation 378 Counter Rotation 397 Propeller Shaft Bearing Housing Assembly Counter Rotati...

Page 453: ...295 Standard Rotation Propeller Shaft 356 Steering Arm End Cap and Lower Bracket 296 Stern Swivel Bracket Attachments 297 Stern and Swivel Bracket Assembly 294 Top Cover and Center Frame 56 Trim Tilt...

Page 454: ...stments Timing Lead P N 587316 137 Timing Pointer 136 Timing Verification 138 Tools Adapter P N 354178 375 398 Backing Plate P N 325867 376 Ball Detent Remover Installer P N 358519 399 411 Bearing Ins...

Page 455: ...374 396 398 413 Spanner Socket P N 359224 345 348 Spanner Socket P N 359225 340 342 Spanner Wrench P N 359080 330 332 Spanner Wrench P N 432400 405 408 Spanner Wrench P N 912084 330 332 348 350 Stato...

Page 456: ...7 Voltage Drop Test 131 W Warning System Activation 89 Description 89 Recovery 89 Recovery from shutdown mode 90 Water Intake Screens 19 Inspection 19 Installation 392 410 Removal 380 401 Water Pressu...

Page 457: ...roubleshooting Flow Charts 457 F Fault Code Tables DPS Troubleshooting Flow Charts Table of Contents Remote Control Fault Codes 1 Outboard Fault Codes 3 DPS 1 Troubleshooting Flow Chart 8 DPS 2 Troubl...

Page 458: ...Fault Code Tables DPS Troubleshooting Flow Charts Notes 458 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 459: ...II Start Stop Panels ICON II Concealed Side Mount Control Harness ICON II Single Binnacle Mount Control Harness ICON II Dual Binnacle Mount Control Harness Twin Outboards ICON II Dual Binnacle Mount...

Page 460: ...Diagrams Notes 460 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

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