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BRP E200DHLSEB, Service Manual

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BRP E200DHLSEB Service Manual Download Page 329

327

GEARCASE – COUNTER ROTATION

GEARCASE ASSEMBLY

13

GEARCASE ASSEMBLY

Water Intake Screens

Install water intake screens. Tighten screws to a
torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

Shift Housing, Gear, and 
Propeller Shaft Installation

Push shifter detent into farthest downward posi-
tion. Tip the rear of the gearcase slightly down-
ward to assist in the installation of the shaft
assembly. 

Be sure the thrust bearing and the thrust washer
are in the proper position. Insert the shaft assem-
bly fully into the gearcase while aligning shift
housing pin with hole in forward end of gearcase
housing.

Shift Rod Cover

Refer to 

Shift Rod Cover

 on p. 311

Pinion Gear and Driveshaft
Installation 

Refer to 

Pinion Gear and Driveshaft Installation

on p. 312.

Propeller Shaft Bearing 
Housing and Gear Installation – 
“M2” Type 

IMPORTANT:

The propeller shaft bearing hous-

ing on “M2” type gearcases is PRESSED into the
gearcase housing. 

Lightly apply 

Triple Guard Grease

 to new bearing

housing O-rings. Install O-rings in grooves in the
housing. Grease the machined side surfaces of
bearing housing.

Place bearing housing in gearcase. 

1.

Water intake screen

006886

1.

Pin

006929

1

1

006846

Summary of Contents for E200DHLSEB

Page 1: ...Main Menu...

Page 2: ......

Page 3: ...rademark 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 NMEA is a registere...

Page 4: ...AGEMENT MODULE EMM 93 6 SYSTEM ANALYSIS 111 7 ELECTRICAL AND IGNITION 125 8 FUEL SYSTEM 165 9 OILING SYSTEM 189 10 COOLING SYSTEM 207 11 POWERHEAD 217 12 MIDSECTION 259 13 GEARCASE 281 GEARCASE STANDA...

Page 5: ...E EMISSIONS INFORMATION 7 MANUFACTURER S RESPONSIBILITY 7 DEALER S RESPONSIBILITY 7 OWNER S RESPONSIBILITY 7 EPA EMISSION REGULATIONS 7 MODEL DESIGNATION 8 MODELS COVERED IN THIS MANUAL 9 IDENTIFYING...

Page 6: ...never rush or guess a service pro cedure Human error is caused by many factors carelessness fatigue overload preoccupation unfamiliarity with the product and drugs and alco hol use to name a few Damag...

Page 7: ...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 8: ...ect Current ABYC American Boat Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft posit...

Page 9: ...oard maintenance performed to maintain emission lev els within prescribed certification standards The owner operator is not to and should not allow anyone to modify the outboard in any manner that wou...

Page 10: ...R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex SE 2009 MODEL RUN or SUFFIX DESIGN FEATURES AP Advanced Propulsion B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injectio...

Page 11: ...ZSEB 3 3 L 30 WH 54 M2 E225DCZSEB 3 3 L 30 WH 54 M2 CR E250DPLSEB 3 3 L 20 BL 54 M2 E250DPXSEB 3 3 L 25 WH 54 M2 E250DCXSEB 3 3 L 25 WH 54 M2 CR E250DPZSEB 3 3 L 30 WH 54 M2 E250DCZSEB 3 3 L 30 WH 54...

Page 12: ...bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 1 6199 to 1 6204 in 41 15 to 41 16 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Cranks...

Page 13: ...WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 L2 Type Gearcase 200 HP 14 26 538 1 86 1 L2 Type Gearcase 225 HP 14 24 583 1 71 1 Refer to GEARCASE TYPES on p 285 Lubr...

Page 14: ...piston oversize dimension to standard bore Top Crankshaft Journal 1 6199 to 1 6204 in 41 15 to 41 16 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Crankshaft Journal 1 57...

Page 15: ...ation Label Champion QC8WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 L2 Type Gearcase 14 24 583 1 71 1 Refer to GEARCASE TYPES on p 285 Lubricant HPF XR Gearcase Lu...

Page 16: ...in all marketing areas All service technicians must be familiar with 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 8...

Page 17: ...TOOLS 15 1 SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS 16 UNIVERSAL TOOLS 16 ELECTRICAL IGNITION TOOLS 18 FUEL OIL SYSTEM TOOLS 19 POWERHEAD TOOLS 19 GEARCASE TOOLS 20 TRIM AND TILT TOOLS 23 SHOP...

Page 18: ...nterface cable P N 437955 45583 Universal Puller Set P N 378103 32885 Slide hammer P N 391008 CO1577 Small puller jaws P N 432131 23150 Lifting eye P N 321537 23701 Slide hammer P N 432128 15345 Large...

Page 19: ...er P N 390898 15356 Tilt tube nut wrench P N 342680 46879 Temperature gun P N 772018 45240 Puller Bridge 432127 23146 Tilt tube service kit P N 434523 33249 Fresh water flusher P N 500542 50110 Syring...

Page 20: ...imping pliers P N 322696 30387 Peak reading voltmeter P N 507972 49799 Stator Test Adapter P N 5006211 004222 Connector tool P N 342667 42004 Test probe kit P N 342677 45241 Tachometer timing light P...

Page 21: ...gauge 15 PSI P N 5006397 90 fitting P N 353322 004560 Injector test fitting kit P N 5005844 002465 Cylinder bore gauge P N 771310 45303 Piston stop tool P N 342679 Replacement tip P N 5006098 46543 Ro...

Page 22: ...1 Universal Driveshaft Shimming Tool P N 5005925 1 Lower Driveshaft Shimming Bolt S2 gearcase P N352878 002601 Gearcase filler P N 501882 49790 1 Universal Pinion Bearing Remover and installer kit P N...

Page 23: ...ocket P N 311875 23261 Prop shaft bearing housing remover puller P N 354060 006784 Gauging Head M2 Type Gearcases P N 5007749 006822 Bearing Installation Tool P N 339778 32519 Driveshaft Puller P N 39...

Page 24: ...starting tool P N 342216 40372 Driveshaft seal protector P N 318674 23692 Prop shaft bearing installer P N 339750 32880 Prop shaft housing seal installer P N 336311 32973 1 Pinion nut holder P N 33445...

Page 25: ...it for adapter tips P N 434729 27340 2 1 Trim tilt service kit P N 390010 33013 Tilt cylinder end cap remover P N 352932 for single piston tilt systems 005340 Tilt cylinder end cap remover P N 326485...

Page 26: ...Purpose Lubricant P N 777192 Oil XD100 P N 764357 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 764354 Anti Corrosion Spray P N 777193 Silicone spray P N 775630 Oil XD30 P N 764349 HPF...

Page 27: ...8298 Needle Bearing Grease P N 378642 Power Trim Tilt and Power Steering Fluid P N 775612 Black Neoprene Dip P N 909570 Starter Bendix Lube P N 337016 Biodegradeable TNT Fluid P N 763439 Electrical Gr...

Page 28: ...Sealing Compound P N 508235 Pipe Sealant with Teflon P N 910048 Locquic Primer P N 772032 Adhesive 847 P N 776964 Thermal Joint Compound P N 322170 Instant Bonding Adhesive P N 509955 1 Screw Lock P N...

Page 29: ...2 CONTROL CABLE INSTALLATION 53 ELECTRICAL HARNESS CONNECTIONS 55 WATER PRESSURE GAUGE 55 CANBUS CONNECTIONS 56 FUEL AND OIL PRIMING 58 FUEL REQUIREMENTS 58 FUEL SYSTEM PRIMING 59 OIL REQUIREMENTS 59...

Page 30: ...ontrols require separate key switches with a single emergency stop switch Engine Monitoring System IMPORTANT Outboards with remote controls must be equipped with an I Command system a SystemCheck gaug...

Page 31: ...exceeds the mini mum requirements Minimum 12 Volt Battery Recommenda tions Location and Preparation Proper installation will prevent battery movement while underway Secure all batteries in protected...

Page 32: ...ons with extended length battery cables require an increased wire size Refer to the following table IMPORTANT Inadequate battery cables can affect the performance of an outboard s high amperage start...

Page 33: ...Battery Charging on p 32 Battery Switch Requirements Battery switches must meet the following require ments The switch must be approved for marine use The switch should be a make before break design t...

Page 34: ...ery Charging Evinrude E TEC V4 V6 outboards are equipped with isolated battery charging capability The iso lated charge connection must only be used to charge a single 12 volt battery or two 12 volt b...

Page 35: ...N PRIMARY 1 S 000135rev1 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 One outboard Battery disconnect One outboard One primary starting battery one secondary battery SECONDARY PRIMARY S 1 2 OFF BOTH SECONDARY...

Page 36: ...Two outboards One primary starting battery for each outboard two isolated accessory batteries ACCESSORY PRIMARY 1 PRIMARY 2 S S 1 2 OFF BOTH 1 2 OFF BOTH 1 2 ACCESSORY PRIMARY 1 PRIMARY 2 1 2 S S 0000...

Page 37: ...talled fuel hoses should be as short and horizontal as possible Use corrosion resistant metal clamps on per manently installed fuel hoses Multi outboard applications require separate fuel tank pickups...

Page 38: ...ult in serious powerhead damage Outboard Fuel System Recommendations 0070 Typical Fuel Supply Configuration 1 Primer bulb 2 Water separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC...

Page 39: ...ft 7 6 m IMPORTANT Do not add hose to an existing oil supply hose If the oil tank requires a longer oil supply hose Oil supply hose between the primer bulb and outboard must be replaced with one cont...

Page 40: ...bracket Assemble cross bar onto hook rods install flat washers and lock nuts Tighten locknuts to securely hold tank 1 8 GALLON TANK Place rods into floor bracket and secure floor bracket with lag bolt...

Page 41: ...the required length of 1 in I D fill hose to route as directly and as vertically as possible Avoid inappropriate hose routings that could distort the fill tube or tank tube Refer to installation instr...

Page 42: ...r kit Cable and Wire Harness Routing Remote control cables wiring and hoses must follow a similar path into the lower motor covers Select the best routing for the specific application All cables wirin...

Page 43: ...onduit Electric primers or man ual primers may not require this consideration Route fuel hoses with enough slack to allow the primer bulb arrow to point up during use Install the primer bulb with the...

Page 44: ...clamping range of the clamp Oetiker Stainless Steel Stepless Clamps WARNING DO NOT re use Oetiker clamps Fuel leak age could contribute to a fire or explosion 1 Clamp identification numbers 000093 1...

Page 45: ...pless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accesso ries Catalog P N 787145 Position correct size clamp over hose Install hose on fitting Close clamp ear fully...

Page 46: ...Refer to ABYC Standards to determine the maximum horsepower capacity for boats with out certification labeling Mounting Surface Inspect transom surface before drilling mounting holes The transom shoul...

Page 47: ...of bottom strakes on dual outboard installations Transom Brackets and Jack Plates When mounting an outboard on boats equipped with transom brackets or jack plates refer to the manufacturer s recommend...

Page 48: ...ing Refer to boat manufacturer for recommendations If the standard spacing does not allow full steering travel in a particular installation it may be neces sary to increase the spacing IMPORTANT Some...

Page 49: ...If drill fixture is unavailable refer to Drilling and Hardware Diagrams on p 48 for measure ments Position drill fixture on top of transom or bracket and align indicator points with centerline The ind...

Page 50: ...2 327053 3 in 76 mm 3 1 2 Bolt Hole Locations 7 318273 Retainer 2 318573 3 1 2 in 89 mm 4 Outside of Transom 8 319886 Screw 4 313327 4 in 102 mm 9 307238 Washer 2 336676 4 1 2 in 114 mm 10 320248 Wash...

Page 51: ...e cable mechan ical steering systems can be used on single or dual outboard installations if an ABYC approved steering link is used Dual cable mechanical steering helps provide firm steering control a...

Page 52: ...ufacturer s recommendations and to Dual Outboard Centerlines on p 46 Drag Links Use the correct drag link to allow full steering travel Install cable wiper nut on tilt tube and connect drag link to t...

Page 53: ...ing height of the outboard Mounting Bolt Installation IMPORTANT Use a marine sealant rated for above or below waterline use RTV silicone is not approved for below waterline use Polyurethane sealants...

Page 54: ...ing diagram to ensure proper positioning of rigging components in grommet The main wiring harness battery cables oil tank sending unit harness and any CANbus cables should be routed along the same pat...

Page 55: ...e pliers to insert straight section of clip into linkage pin hole Push the clip towards the hole while lifting on the curved end with the pliers Be sure retainer clip fully engages the pin Lock the re...

Page 56: ...on throttle lever pin and install washer and retainer clip Adjust the throttle cable trunnion to align with the trunnion block Place the cable trunnion in the trunnion block IMPORTANT Move control ha...

Page 57: ...SURE all harnesses and wires are not pinched cannot contact flywheel and do not interfere with moving throttle or shift linkages Replace harness connector cover Water Pressure Gauge If a mechanical w...

Page 58: ...control Seal unused SystemCheck connector with 6 Pin Connector Seal P N 586076 If installing a Deutsch style I Command network connect the purple wire from the CANbus Ignition Harness to the CANbus n...

Page 59: ...ANbus oil level gauge is used an optional CANbus oil level sender must be installed in the oil tank Connect the oil level sensor harness to the boat CANbus network Use Evinrude Diagnostics software to...

Page 60: ...osits which can damage the outboard Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other f...

Page 61: ...aks Oil Requirements Evinrude Johnson XD100 XD50 or XD30 out board oils are recommended for use in Evinrude E TEC outboards If these oils are not available you must use a TC W3 certified oil Evinrude...

Page 62: ...onventional use runabouts cruisers Moderate applications Powerhead oil programming labels are provided to identify EMM oil programming Install the cor rect label to alert user to specific oil requirem...

Page 63: ...from the oil tank Once oil flow is observed connect the oil tank hose to the outboard s oil supply hose and secure with 14 5 mm Oetiker clamp Oil Distribution Manifold Priming Squeeze the oil primer b...

Page 64: ...ed through continued priming IMPORTANT All clear blue oil distribution hoses on the powerhead should fill with oil as the air is purged from the lines Repair any fuel or oil leaks The oiling system ca...

Page 65: ...OIL warning has been tested Refer to Oil Requirements on p 59 When starting the outboard for the first time refer to Oil Supply Priming on p 61 Trim and Tilt Fluid Make sure trim and tilt reservoir is...

Page 66: ...utboard OFF while control is in FORWARD Try to restart the outboard Outboard should not start Shift back to NEUTRAL and restart outboard Shift to REVERSE Turn outboard OFF while con trol is in REVERSE...

Page 67: ...reaches idle temperature Refer to specific SERVICE SPECIFICATIONS on p 10 Idle Speed Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the i...

Page 68: ...of boat applications water skiing to high speed performance boating In such cases it might be necessary to have a propeller for each situation Refer to the Evinrude Johnson Genuine Parts and Accessor...

Page 69: ...s 95 to 109 N m Without Keeper 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the propeller nut without keeper and propeller shaft are not aligned tighten the nut until they are in line Do...

Page 70: ...maximum tilt position Check the adjustment by tilting the outboard fully Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it con tacts the motor well To pre...

Page 71: ...ust the sending unit by pivoting it up or down Lower the outboard against the thrust rod to check adjustment Repeat adjustment if necessary After adjustment is correct tilt the outboard up tighten the...

Page 72: ...the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m Test the boat and if needed repeat the p...

Page 73: ...d alignments Each applica tion must be thoroughly tested until the ideal combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small...

Page 74: ...72 INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 75: ...79 TRIM AND TILT 81 BATTERY AND BATTERY CONNECTIONS 82 FUEL AND OIL SYSTEMS 82 FUEL FILTER 82 OIL FILTERS AND OIL RESERVOIR 83 AIR SILENCER 83 HOSES AND CONNECTIONS 83 SPARK PLUGS 84 INDEXING 84 EXHAU...

Page 76: ...Cooling system check water pump indicator water pressure 3 Anticorrosion anodes check condition 3 Gearcase check condition 3 Propeller check condition 3 Fuel and oil systems inspect and repair leaks...

Page 77: ...e boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no resistance If resistance is high check the following R...

Page 78: ...e ground drainage during the flushing procedures Keep water inlet pressure between 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 67 Place outboard...

Page 79: ...ion outboard in VERTICAL position DOWN long enough to allow the powerhead to drain com pletely Water Intake Screens Inspect condition of water intake screens Clean or replace as needed Confirm functio...

Page 80: ...acket with Triple Guard grease Apply grease until the grease begins to flow from the upper or lower swivel bracket areas Coat the pivot points of the trailering bracket with Triple Guard grease Tilt T...

Page 81: ...nt inspection can minimize potential gearcase damage Remove propeller Refer to Propeller Hardware Installation on p 67 Inspect bushing and blade surfaces Replace damaged or worn propellers Clean prope...

Page 82: ...the gearcase Refer to GEARCASE LEAK TEST on p 286 Overheated lubricant will have a black color and burned odor Internal gearcase inspection is recommended when lubricant is contaminated or shows signs...

Page 83: ...threads Install the fill plug and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the unit at least five complete cycles to purge all air from the system When cycling t...

Page 84: ...T secure battery cables with wing nuts Coat all connections with Triple Guard grease and insulate to prevent shorts or spark arcing FUEL AND OIL SYSTEMS Routine replacement of filters reduces the poss...

Page 85: ...free of water or other contaminants Air Silencer The air silencer on Evinrude outboards maximizes air flow while minimizing noise Routine cleaning of the air silencer is recom mended to remove any acc...

Page 86: ...ceramic of the spark plug in line with the OPEN side of the ground elec trode This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector Apply...

Page 87: ...for restric tion With key ON outboard NOT running the exhaust pressure sensor reading should be close to zero With the outboard running make sure the exhaust pressure reading changes with throttle se...

Page 88: ...onds the System Check lights will go off Move throttle to IDLE position SystemCheck lights will light again Wait another 15 seconds SystemCheck lights will go off At this point advance throttle to FUL...

Page 89: ...rage make sure it is reinstalled with factory specified hardware Refer to the INSTALLATION AND PREDELIVERY section for proper set up Outboard Mounting Bolts Check and re tighten outboard mounting bolt...

Page 90: ...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 91: ...SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 90 LATCH HOOK INSTALLATION 90 UPPER COVER CAP REPLACEMENT 90 LOWER COVER SERVICE 91 LOWER COVER REMOVAL 91 LOWER COVER INSTALLATION 91 LATCH HANDLE INSTA...

Page 92: ...to position on bracket Apply Ultra Lock to screw threads Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Upper Cover Cap Replacement Place new upper cap into position Tighten self tapping s...

Page 93: ...de cover slightly and disconnect trim tilt switch connector Then remove port and starboard covers Lower Cover Installation Install the lower engine covers and tighten all screws to a torque of 24 to 3...

Page 94: ...to screw threads Place spring washer and hook into position and tighten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on switch...

Page 95: ...SOR 3 4 L MODELS 99 INTERNAL EMM FUNCTIONS 100 START ASSIST CIRCUIT SAC 100 ROM VERIFICATION 100 IDLE CONTROLLER 100 RPM LIMITER 100 SHIFT INTERRUPT 100 ENGINE MONITOR AND WARNING SYSTEMS 100 FAULT CO...

Page 96: ...PM profile and engine hours Oiling ratios Shift interrupt function EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections can damage the EMM DO N...

Page 97: ...8 11 Engine Temperature Sensor s 12 Water in Fuel Sensor Fuel Filter 13 Trim Tilt Sending Unit 14 Water Pressure Sensor w adaptor harness 15 LED indicators 16 Fuel Pump high pressure 17 Starter Soleno...

Page 98: ...sor circuit fault is detected and the EMM 55 V Circuit Sensor Monitors 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...

Page 99: ...ides a 5 V DC signal for sensor cir cuits It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges Inputs that fall outside of the acceptable range create service cod...

Page 100: ...roblem is resolved and code is cleared To clear code use the diagnostic software program If the sensor reads out of the expected range or the sensor or circuit fails the EMM If the sensor circuit indi...

Page 101: ...speed generate a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 instances the EMM Approximate air gap between CPS and flywheel encod...

Page 102: ...e of EMM programming prevents engine damage due to excessive RPM At 6250 RPM fuel and ignition to the cylinders is shut off Normal engine operation resumes when engine RPM returns to the specified ran...

Page 103: ...EMM Refer to the EMM Service Code Chart at the back of this manual for a complete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position The horn...

Page 104: ...hat could allow fuel and or vapor to enter the engine through the air intake Check for internal fuel leakage from a leaking injector or vapor separator vent hose Recovery To recover from shutdown mode...

Page 105: ...puter s serial port The EMM must turn ON before it will communicate with the computer Power is normally supplied to the EMM when the key switch is ON Switched B 12 V enters the EMM at pin 21 purple of...

Page 106: ...and operating hours of first and last occurrences Hard Faults A hard fault is a service code that currently exists Hard faults become stored faults only if the out board is running Persistent Faults...

Page 107: ...he NO OIL circuit of the Engine Monitoring system Check Engine This test is used to check the CHECK ENGINE circuit of the Engine Monitoring system Tachometer This test is used to check operation of th...

Page 108: ...jection rate This set ting REQUIRES the use of Evinrude XD100 out board lubricant and is not recommended for all applications Use the XD100 setting for Conventional use runabouts cruisers Moderate app...

Page 109: ...rankshaft replacement Flywheel removal or replacement CPS replacement EMM replacement EMM software replacement IMPORTANT Make sure the timing pointer is set and the outboard reaches operating tempera...

Page 110: ...the Replace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Fuel Injector Installation on p 184 Reports Engine reports provide service records and...

Page 111: ...r to the instructions provided with the program IMPORTANT Software replacement requires the use of Bootstrap Tool P N 586551 EMM Transfer EMM Transfer is used to save engine history data when the EMM...

Page 112: ...screws Lift EMM away and to the starboard side Installation Align slots in starboard side of EMM case with iso lator mounts on cylinder block Slide EMM into position Install two EMM retaining screws T...

Page 113: ...TIVE AMP METER TEST 115 EMM LED INDICATORS 116 KEY ON 116 STARTING 116 RUNNING 117 IGNITION OUTPUT TESTS 118 REQUIRED IGNITION SYSTEMS 118 WIRING INSPECTION 118 CRANKSHAFT POSITION SENSOR CPS TEST 119...

Page 114: ...identified by the appearance of the spark plugs Check the fuse and the emergency stop switch lanyard Diagnostic Software Inspections Before running the outboard use Evinrude Diag nostics software to...

Page 115: ...ond The newest record is first on the list As each new record is added the oldest record is removed The Engine Identity Report provides a snap shot of current engine and sensor conditions From the Ide...

Page 116: ...EMM LED INDICA TORS on p 116 Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS volt ages System voltage should be steady and TPS voltage should be between 0 2 and 4 85...

Page 117: ...PORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to maintain a constant IDLE speed The Dynamic Tests screen includes a function to tem porarily disable t...

Page 118: ...CRANK POSITION OKAY input from CPS EMM powered ON For NO LIGHT check for Code 16 CPS intermittent loss of sync LED 3 SENSORS OKAY 5 V For NO LIGHT check for Code 12 TPS circuit fault Code 13 TPS belo...

Page 119: ...ylinder excessive knock Code 5 No 5 cylinder excessive knock Code 6 No 6 cylinder excessive knock Code 7 PORT Knock sensor circuit fault Code 8 STBD Knock sensor circuit fault Code 12 TPS circuit faul...

Page 120: ...voltage from EMM white red provides 55 VDC to the oil injection pump the fuel injec tors and the ignition module of EMM Capacitor Connected to 55 V circuit white red to stabilize current on 55 V circ...

Page 121: ...oftware Monitor screen to check system voltage Results KEY ON not running 30 V 2 system volt age is GOOD KEY ON not running less than 30 V 2 check 12 V power to EMM Repair connection or wiring Possibl...

Page 122: ...installed Connect timing light pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test and observe timing light strobe for consistent flash IMPORTANT You may need...

Page 123: ...ge and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 123 Check for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace spa...

Page 124: ...iagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil tests available Before replacing an ignition coil be sure 55 V is supplied to the white red wire of the i...

Page 125: ...r to check continuity between pin 2 of fuel pump connector and ground Refer to Circulation Pump Resistance Test on p 176 If the pump runs Refer to Fuel System Pressure Test on p 174 Refer to Running F...

Page 126: ...ed by the EMM The Dynamic Tests screen allows the control signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always check the o...

Page 127: ...S 136 12 V CHARGING CIRCUIT 136 AUXILIARY BATTERY CHARGE WIRE 137 55 V ALTERNATOR CIRCUIT 137 ELECTRIC START CIRCUIT 138 ELECTRIC START TESTS 140 REMOTE CONTROL SWITCH TESTS 142 TILT TRIM RELAY TEST 1...

Page 128: ...m 30 42 In lbs 3 5 4 7 N m F F 30 42 In lbs 3 5 4 7 N m F J 30 42 In lbs 3 5 N m 60 84 In lbs 7 9 5 N m 30 42 In lbs 3 5 N m Apply to inner flywheel taper 15 30 Ft lbs 20 41 N m T 10 16 In lbs 1 2 N m...

Page 129: ...le Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock N Starter Bendix Lube T Liquid Neoprene 004100 N 60 84 in lbs 7 9 5 N m 168 192 in lbs 19 21 5 N m...

Page 130: ...l Main harness ground 12 V from battery FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 7 2 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 1 2 3 4 5 6 7 8 9 1 2 3...

Page 131: ...ector Connect to a pre wired remote control or to a dash mounted key switch Black purple white tan wires Connect to the trim gauge 8 pin connector Connect to a 2 in System Check gauge or to a 3 1 2 in...

Page 132: ...iagnostic connector White 4 Ground water in fuel digital Black 5 Oil level switch Tan Black 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Bootstrap connector programming Blk Ora...

Page 133: ...linder 2 Orange Blue 20 Injector cylinder 4 Purple 21 Switched B 12V Purple 22 Injector ground Black 23 Oil solenoid Blue 24 vacant 25 Ignition cylinder 6 Orange Green 26 Ignition cylinder 1 Orange Bl...

Page 134: ...6 and 22 of the EMM J1 B connector and the main harness ground Sensor circuit grounds Check continuity between terminal pins 4 and 11 of the EMM J1 A connector and the appropriate sensor ground connec...

Page 135: ...ltimeter to measure sensor resis tance between the yellow and white wires The complete circuit can be tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mounted to throttle...

Page 136: ...rature sensor Use a digital multimeter to measure sensor resis tance Air Temperature Sensor AT Test Remove the electrical connector from the air tem perature sensor Use a digital multimeter to measure...

Page 137: ...to read 1 ohm or less To check for a grounded winding connect one meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no continuity If meter reads...

Page 138: ...01 and various other amp meters should be available through local tool suppliers Reconnect the battery cables Following the manufacturer s directions connect the variable load tester carbon pile acros...

Page 139: ...creases If there is no increase turn the key switch to OFF and test red black wire between the EMM and auxiliary battery connection Continuity indicates faulty output from EMM Check 12 V alternator ou...

Page 140: ...8 9 J2 J1 A J1 B M A S C M B 1 2 3 4 5 6 2 5 3 4 1 6 A B FUSE B A 004112 NEG 8 13 15 9 5 10 9 1 2 3 4 6 11 12 13 16 3 14 17 7 POS 1 Marine battery 10 26 pin J1 B EMM connector 2 RED wire POS 11 34 pin...

Page 141: ...Contains the following circuits Red purple output wire from fuse provides 12 V to instrument harness Purple wire provides switched 12 V to solenoid terminal A and EMM Yellow red wire provides switched...

Page 142: ...ter positive cable terminal and the other lead on the battery positive cable terminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to...

Page 143: ...for this test Use an inductive ammeter or connect a 0 to 100 amp ammeter in series with a heavy jumper between the battery positive terminal and the starter positive terminal Fluke model 334 or 336 Sn...

Page 144: ...terminal S Meter should indicate continuity IMPORTANT The choke function or terminal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or continuity light to test the continui...

Page 145: ...lts are incorrect Emergency Stop Switch Test This switch can be part of the key switch or installed as a separate switch Either style con nects the M terminals of the key switch The emergency stop swi...

Page 146: ...0 are considered normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure red and...

Page 147: ...turn on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the key switch ON Test for battery voltage between instrument harness terminal 1 purple wire a...

Page 148: ...ire of the SystemCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and th...

Page 149: ...n yellow wire of the Sys temCheck connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits TACHOMETER CIRCUIT TESTS Check voltage at the battery...

Page 150: ...37 and the center hole of the crankshaft Assemble the following components from Univer sal Puller Set P N 378103 Body P N 307636 Screw P N 307637 Handle P N 307638 Three screws P N 309492 Three washer...

Page 151: ...taper of the flywheel IMPORTANT DO NOT over apply Nut Lock on flywheel taper This prevents Nut Lock from migrating into upper seal of crankshaft Align the flywheel keyway and install the flywheel Coa...

Page 152: ...acket with four screws Tighten screws to a torque of 60 to 84 in lb 7 to 9 5 N m Install spark plug leads with ground screw Tighten screw securely Ignition Coil Installation Connect ignition coil elec...

Page 153: ...to position the piston firmly against the tool Mark the flywheel directly across from the pointer Label this mark A Rotate the flywheel clockwise until the piston contacts the tool Mark the flywheel...

Page 154: ...MPORTANT Make sure the timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS CALIBRATION Use Evinrude Diagnostics software to tell the EMM what...

Page 155: ...o the starter bearings and commutator Disconnect the battery cables at the battery Remove the starter positive cable from post on starter Remove the four frame and bracket mounting screws Lift and rem...

Page 156: ...ring under the spacer Remove the retaining ring spacer and spring from pinion shaft Remove pinion and plastic weather cover from pinion shaft Remove the driven gear and thrust washer Using No 2 exter...

Page 157: ...e with a rubber mallet to loosen it Find the insulator cap end of the shaft or inside the end cap Inspect and replace if necessary Note the alignment marks by the positive terminal stud Hold the armat...

Page 158: ...maged windings Clean off any carbon deposits or foreign matter which could contribute to failure of wind ings Check permanent magnets Make sure they strongly attract any steel or iron object held insi...

Page 159: ...ushes could damage the starter or cause reverse rotation Apply Moly Lube to the armature bushing Install the thrust washer and armature Align the starter frame and make sure the long alignment mark ma...

Page 160: ...the retaining ring flat side up with No 2 external retaining ring pliers Lightly coat the gear housing bearing with Moly Lube Lightly coat the driven gear with Triple Guard grease Install the thrust...

Page 161: ...t Lock to the thru bolts Install the nuts and tighten to a torque of 50 to 65 in lbs 5 6 to 7 3 N m To test the assembly and operation of the starter refer to No Load Current Draw Test on p 141 Starte...

Page 162: ...tly pull on wire Terminal Installation Push terminal through seal until it locks into place Fill connector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push wedge in until latch...

Page 163: ...ctor housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push con nector and seal into housing until seated Align...

Page 164: ...seated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 connector of the EMM is a AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull connector from...

Page 165: ...inals Disconnect Lift latch s Remove connector Connect Confirm the seal is in place Push connector onto housing until latched Terminal Removal A tab on the back side of the terminal engages a shoulder...

Page 166: ...and then pulled back into connector housing until lock ing tab engages and terminal is seated Crimping Terminals Strip insulation back 3 16 in 5 mm Position end of wire strands in terminal past the w...

Page 167: ...SURE REGULATOR TEST 175 VAPOR SEPARATOR VENT CHECK 175 FUEL INJECTOR PRESSURE TEST 175 FUEL INJECTOR RESISTANCE TEST 176 CIRCULATION PUMP RESISTANCE TEST 176 LIFT PUMP PRESSURE TEST 176 LIFT PUMP VACU...

Page 168: ...tighten to seal contact then 1 2 1 turn 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m L 100 110 In lbs 11 12 N m P Lower screw only L L L A Triple Guard Grease B Gasket Sealin...

Page 169: ...8 11 N m F 96 120 in lbs 11 13 5 N m 10 18 in lbs 1 2 N m 60 84 in lbs 7 9 5 N m C F K B B A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G...

Page 170: ...ly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Engine Lubricant S STP Oil Treatment 004101 R R R R R R R R R R R R R R R S S S S S S S S S S S S S S S R R 60 84 in lbs 6 8...

Page 171: ...or separator Vent hose to throttle body 8 9 10 11 12 13 14 Electric fuel circulation pump 20 to 35 psi Fuel supply manifold Fuel injector s Fuel return manifold Pressure regulator high pressure Test f...

Page 172: ...gh pressure fuel pump Fuel filter water separator 007109 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 1 3 5 2 4 6 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 2 3...

Page 173: ...forces the fuel from the pump through the fuel filter and into the vapor separator Fuel Filter The water separating fuel filter protects the vapor separator and the high pressure components of the fue...

Page 174: ...vapor separator decreases the fuel level begins to increase An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps maintain consi...

Page 175: ...e injector by serial number The EMM is programmed to compensate for vari ations in fuel flow Each injector and its location on the outboard is identified by the EMM DO NOT install an injector without...

Page 176: ...p 177 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying adequate fuel to vapor separa...

Page 177: ...lace vapor separator if the venting of fuel is continuous Fuel Injector Pressure Test This test requires Injector Test Fitting kit P N 5005844 Disconnect the battery cables at the battery Relieve fuel...

Page 178: ...g tested Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter to measure the fuel pump circuit and coil resistance Lift Pump Pressure Test Install a 0...

Page 179: ...s to prevent fuel or air leaks IMPORTANT Do not use fuel primer bulb man ual fuel primer or electric fuel pump primer to restart outboard A positive pressure in the fuel supply could damage some vacuu...

Page 180: ...art and run at IDLE for 5 seconds and STOP out board If outboard does NOT run crank for 10 seconds Disconnect the battery cables at the battery Wrap a shop towel completely around the pres sure test v...

Page 181: ...water If water is present identify the source and correct the problem Take additional fuel samples and drain fuel tank s if necessary Installation Lubricate filter seal with outboard lubricant and po...

Page 182: ...an assembly Installation Place fuel pump bracket with rubber isolator mounts in front of the throttle body Apply Nut Lock to screws and install screws into throttle body Tighten screws to a torque of...

Page 183: ...unts Installation Installation is the reverse of removal Pay close attention when performing the following addi tional tasks Install all hoses and manifolds to original locations and secure with appro...

Page 184: ...ANT Fuel injectors must be installed in the correct cylinder locations Use Evinrude Diag nostics Software to make sure that EMM program ming matches injector positioning The Injector Coefficients scre...

Page 185: ...e injector from mounting cup Thread adaptor and stud into face of injector Hold mounting cup securely Work slide hammer to separate injector from mount housing Remove adaptor from injector Remove crus...

Page 186: ...ght coat of Triple Guard grease Install washers one per screw on injec tor retaining screws Install screws and washers through mounting flange of injector and into cylin der head Tighten screws in sta...

Page 187: ...d reed valve assem blies must be cleaned before reassembly DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning Remove the reed valve retainer screws and remove the assembl...

Page 188: ...to a torque of 30 to 42 in lbs 3 5 to 4 7 N m Installation Place reed plate assembly on cylinder crankcase Apply Nut Lock to screws Install all screws Tighten the center screws first and expand out wa...

Page 189: ...to throttle shaft surface Install oil fuel pump bracket Tighten screws 30 to 42 in lbs 3 5 to 4 7 N m Position clamps as shown Refer to TPS CALIBRATION on p 152 1 Throttle linkage 2 TPS electrical con...

Page 190: ...188 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 191: ...G 197 NO OIL WARNING 197 CYLINDER AND CRANKCASE 197 OIL RECIRCULATION SYSTEM 198 OIL CONTROL SETTINGS 199 OIL PRIMING 199 OILING RATES 199 BREAK IN OILING 199 OILING SYSTEM TESTS 200 OIL INJECTION PUM...

Page 192: ...nson Refer to the Operator s Guide for Oil Requirements P N 351520 TCW3RL OIL XD 30 XD 50 Yellow XD 100 Blue IMPORTANT This outboard has been programmed for the use of Evinrude Johnson XD100 outboard...

Page 193: ...30 31 32 33 34 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 2 J1 A J1 B J2 3 8 4 3 4 1 4 5 6 7 004110 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8 9 1...

Page 194: ...fold 6 8 3 1 2 3 4 5 6 7 1 2 3 4 5 6 1 Cylinder 1 2 Cylinder 2 3 Cylinder 3 4 Cylinder 4 5 Cylinder 5 6 Cylinder 6 1 Cylinder 1 2 Cylinder 2 3 Cylinder 3 4 Cylinder 4 5 Cylinder 5 6 Cylinder 6 7 Rear...

Page 195: ...OILING SYSTEM OIL SUPPLY DIAGRAMS 193 9 3 3 L models 006870 Rear View 6 4 5 3 Top View 1 2...

Page 196: ...194 OILING SYSTEM OIL SUPPLY DIAGRAMS 3 4 L models 007256 Starboard View Port View...

Page 197: ...OILING SYSTEM OIL RECIRCULATION DIAGRAMS 195 9 OIL RECIRCULATION DIAGRAMS 004111a 2 4 6 1 3 5...

Page 198: ...bracket and hardware Protective cover 1 8 gallon tank only Primer bulb and supply hose Oil Injection Pump The oil injection pump is an electric 55 V actua tor style pump It draws oil from the oil tank...

Page 199: ...on the Engine Monitor LOW OIL display when the oil level falls below one quarter capacity An optional oil tank sending unit kit is available to display actual oil level through an I Command net work...

Page 200: ...ad oil drain passages connect the lowest point of the intake port area of the cylin der block to external check valves External hoses connect these check valves to a hose fitting pressed into the top...

Page 201: ...outboard is first installed Whenever the oil supply to the oil lift pump is disconnected or disrupted Whenever an oiling system component is removed or replaced Refer to Oil Supply Priming on p 61 Oi...

Page 202: ...nfirmed Use an inductive timing light to monitor current flow through the ground circuit blue wire at the oil tank connector pin 2 If the light flashes the EMM and oil injection cir cuits are not at f...

Page 203: ...mponent and retest For a higher than expected reading test resis tance of the injection pump If injection pump resistance reading is within range injection pump winding is good Isolate faulty compo ne...

Page 204: ...ults Oil flows from distribution hose compare to oil flow at other distribution hoses If one or more hoses fail to discharge oil check for a kinked or restricted hose before replacing the oil injectio...

Page 205: ...to rear manifold hose does not use a hose support IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully inserted into manifold Insertion depth is 5...

Page 206: ...fold Remove oil distribution hoses from the crankcase fittings Remove oil injection pump clamp screw Remove the oil injection pump assembly IMPORTANT The oil injection pump and mani fold is an assembl...

Page 207: ...hose before reconnecting hose to oil pump Reconnect oil supply hose to the inlet fitting of oil pump Fasten with Oetiker clamp Make sure oiling system is primed Check oil flow through oil distribution...

Page 208: ...206 OILING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 209: ...210 OPERATION 211 CYLINDER BLOCK CYLINDER HEAD COOLING 211 EMM AND VAPOR SEPARATOR COOLING 212 ENGINE TEMPERATURE CHECK 212 SOFTWARE METHOD 213 PYROMETER METHOD 213 IDLE OPERATING TEMPERATURE TROUBLES...

Page 210: ...w off valve to starboard cylinder head 9 2 7 5 4 11 8 10 12 3 7 8 5 Port Rear Hose Routing Water Flow Diagram 200 250HP 90 V6 Evinrude E TEC 5 Outgoing water warm hot Incoming Water cool 6 004109 6 RE...

Page 211: ...t HIGHER speeds Refer to WATER PUMP SERVICE on p 290 for water pump servicing Water Supply Tube The water pump outlet connects with the water supply tube located in the outboard s midsection Grommets...

Page 212: ...event the valve from closing completely Thermostats Thermostats control water flow and operating temperature at lower speeds below 1200 RPM Overheating A restricted or faulty thermostat typ ically res...

Page 213: ...Water flows through the block to the exhaust housing and then out of the outboard At higher speeds water pressure opens the pressure relief valve at approximately 1200 RPM Water flows through the valv...

Page 214: ...sing ENGINE TEMPERATURE CHECK IMPORTANT The engine temperatures listed below are based on an intake water temperature of 70 10 F 21 3 C Install correct test propeller and place outboard in a test tank...

Page 215: ...IDLE speed with pyrometer should be 143 F 15 F 62 C 8 C IMPORTANT If you get low or inaccurate read ings with a digital pyrometer coat the probe loca tion with Thermal Joint Compound P N 322170 Idle...

Page 216: ...f hoses and eliminating water flow to the cylinder heads pressure relief valve is leaking Replace pressure relief valve If IDLE temperature is still below operating range with hoses pinched off inspec...

Page 217: ...ped air to bleed from cav ity Thermal compound may seep past threads Retighten sensor THERMOSTAT SERVICING Disassembly Remove the thermostat cover and O ring from cyl inder head Remove spring thermost...

Page 218: ...ap from the hous ing Remove the pressure valve assembly Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly Ass...

Page 219: ...EARINGS 232 POWERHEAD ASSEMBLY 232 CRANKSHAFT 232 PISTONS AND CONNECTING RODS 235 CYLINDER HEAD INSTALLATION 236 CRANKSHAFT AND CONNECTING RODS 237 CRANKCASE ASSEMBLY 240 SHIFT LINKAGE INSTALLATION 24...

Page 220: ...84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m L 30 42 In lbs 3 5 5 N m L H H 84 108 In lbs 9 5 12 N m P X Q B X 120 144 In lbs 13 5 16 5 N m 120 144 In lbs 13 5 16 5 N m 144 168 In lbs 16 5 19 N m Apply...

Page 221: ...3 5 N m 96 120 In lbs 11 13 5 N m F A A B F B D 96 120 In lbs 11 13 5 N m F B B X A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle B...

Page 222: ...attachment into spark plug hole 14 mm threads While cranking outboard with starter note maxi mum pressure reading on gauge Repeat proce dure for each cylinder If engine shows a variation greater than...

Page 223: ...NG Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 178 To prevent accidental starting w...

Page 224: ...chain hook to eye of tool and support weight of powerhead with hoist On each side remove the powerhead retaining screws and nuts Remove the rear powerhead nut Use a suitable tool to carefully separate...

Page 225: ...Service on p 182 IMPORTANT Mark injectors for cylinder loca tion before removal All injectors must be installed in their original location Improper injector installa tion can result in powerhead fail...

Page 226: ...ch or any other tool that could jam in or damage the taper bore when removing the pin Remove crankcase flange screws Remove the upper crankcase head screws Remove the lower crankcase head screws IMPOR...

Page 227: ...crankshaft seal rings Cylinder Head Removal Loosen in stages and remove cylinder head retaining screws Remove the cylinder head Connecting Rods and Pistons Use a permanent marker to identify each con...

Page 228: ...all internal components so that if reused they can be reinstalled in their original positions Repeat steps for each remaining piston and con necting rod Use an appropriate ring expander to remove all...

Page 229: ...to remove the lower crankshaft seal Remove and discard two crankcase head O rings Remove the O ring from crankshaft sleeve and inspect it Replace the O ring if it is not in good condition Inspect the...

Page 230: ...DO NOT reuse it Use a bearing separator to support the bearing and press off the crankshaft Remove and inspect crankcase seal rings Iden tify each ring for installation in original location Remove cen...

Page 231: ...ket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block and crankcase Carefully remove any carbon accumulation from the tops and ring grooves of the pisto...

Page 232: ...page using a piece of bar stock or machinist s straightedge and a feeler gauge set Cylinder head warpage must not exceed 0 003 in 0 08 mm per inch of measurement Replace head if warpage exceeds this d...

Page 233: ...CIFICATIONS on p 10 The cylinder must not be oversized by more than 0 003 in 0 08 mm Pistons Visually inspect pistons for signs of abnormal wear scuffing cracks or burning Piston Rings For new ring se...

Page 234: ...rfectly clean and lightly coated with outboard lubricant IMPORTANT Use new wrist pin retaining rings gaskets seals and O rings during assembly Crankshaft Place bearing retainer plate flat side down on...

Page 235: ...be used if surface is damaged Use retaining ring pliers to install bearing retaining ring with sharp edge facing away from bearing Lubricate a new driveshaft O ring and lightly lubri cate crankshaft...

Page 236: ...N 383175 to align retainer plate with crankcase head Slide crankcase head onto crankshaft until seated around lower main bearing Install new seals on the four bearing retainer screws Apply Nut Lock t...

Page 237: ...on will be located toward the flywheel and opposite the exhaust port IMPORTANT It is also very important that the connecting rods are installed with the alignment dots facing up toward the flywheel Ap...

Page 238: ...rings could be misaligned Refer to CYLINDER BLOCK CLEANING on p 229 Coat pistons rings cylinder walls and ring com pressor with outboard lubricant Center connecting rod in piston and locate piston rin...

Page 239: ...eated in the block Push all pistons to the top of cylinders Remove the numbered connecting rod caps and hold the connecting rods to the outside with rubber bands Gently lower crankshaft into place Tur...

Page 240: ...rod cap screws with out Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent dam age to the connecting rod and crankshaft To maintain accurate torque values keep torque w...

Page 241: ...3 in lbs 2 5 N m IMPORTANT Make sure that frame is squarely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Torquing Socket P N 346187 to tighten rod cap s...

Page 242: ...l Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the tube cannot be determined Using old Gel Seal II could cause crankca...

Page 243: ...st two hours for Gel Seal II to cure before running outboard Shift Linkage Installation Lubricate shift linkage bosses at the base of the crankcase with Triple Guard grease Insert bush ings into bosse...

Page 244: ...Refer to PRES SURE RELIEF VALVE SERVICING on p 216 Install shift linkage Refer to Shift Linkage Instal lation on p 241 Install throttle linkage Refer to Throttle Linkage Installation on p 242 Install...

Page 245: ...crankshaft and driveshaft splines Apply Gasket Sealing Compound to the threads of all powerhead screws Loosely install all fasteners before tightening Tighten the 3 8 in diameter powerhead screws to...

Page 246: ...neutral Install water hoses and exhaust back pressure hose Route power trim harness through clamp and con nect to engine harness Install flywheel Refer to Flywheel Installation on p 149 1 Rear powerh...

Page 247: ...ng outboard to service Index all spark plugs Refer to Spark Plug Indexing on p 84 Adjust timing pointer and check engine timing Refer to TIMING ADJUSTMENTS on p 151 Use Evinrude Diagnostics software t...

Page 248: ...246 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings 3 3 L models 006951...

Page 249: ...POWERHEAD POWERHEAD VIEWS 247 11 Starboard Hose Routings 3 3 L models 006952...

Page 250: ...248 POWERHEAD POWERHEAD VIEWS Port Hose Routings 3 4 L models 007153...

Page 251: ...POWERHEAD POWERHEAD VIEWS 249 11 Starboard Hose Routings 3 4 L models 007154...

Page 252: ...250 POWERHEAD POWERHEAD VIEWS Port 3 3 L models 007139...

Page 253: ...POWERHEAD POWERHEAD VIEWS 251 11 Starboard 3 3 L models 007138...

Page 254: ...252 POWERHEAD POWERHEAD VIEWS Port 3 4 L models 007143...

Page 255: ...POWERHEAD POWERHEAD VIEWS 253 11 Starboard 3 4 L models 007144...

Page 256: ...254 POWERHEAD POWERHEAD VIEWS Front 3 3 L models 007140...

Page 257: ...POWERHEAD POWERHEAD VIEWS 255 11 Front 3 4 L models 007145...

Page 258: ...256 POWERHEAD POWERHEAD VIEWS Rear 3 3 L models 007141...

Page 259: ...POWERHEAD POWERHEAD VIEWS 257 11 Rear 3 4 L models 007142...

Page 260: ...258 POWERHEAD POWERHEAD VIEWS Top 007146...

Page 261: ...XHAUST HOUSING 266 EXHAUST HOUSING REMOVAL 266 EXHAUST HOUSING DISASSEMBLY 3 3 L MODELS 267 EXHAUST HOUSING DISASSEMBLY 3 4 L MODELS 268 CLEANING AND INSPECTION 269 EXHAUST HOUSING ASSEMBLY 3 3 L MODE...

Page 262: ...N m 216 240 In lbs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m...

Page 263: ...7 9 5 N m 60 84 In lbs 7 9 5 N m B F F F 144 168 In lbs 16 19 N m B B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P B C See Assembly Instructions B C C C See Assembly Instructions A C C 60 84...

Page 264: ...19 N m 18 20 Ft lbs 25 27 N m 60 84 In lbs 7 9 5 N m B F F 144 168 In lbs 16 5 19 N m B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P C A C C B L 60 84 In lbs 7 9 5 N m Q E A Triple Guard Grea...

Page 265: ...MIDSECTION SERVICE CHART 263 12 Muffler...

Page 266: ...r Remove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer from Tilt Tube Service Kit P N 434523 onto the starboard end of the tilt tube Remove steering ca...

Page 267: ...e a wood or leather mallet to tap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft lbs...

Page 268: ...Refer to POWER HEAD REMOVAL on p 221 Remove and discard four lower mount screws Remove the steering arm ground lead and screw Remove two upper mount screws Remove the exhaust housing Remove lower mou...

Page 269: ...ry up to remove it from the adapter housing Lift the adapter inner exhaust housing out of the exhaust housing Mark the water tube for correct reassembly loca tion Remove six inner exhaust housing scre...

Page 270: ...ous ing screws Remove three nuts at rear of the adapter Loosen and remove the upper mount plate screws and remove the mount plate Lubricate the upper mount with soapy water and pry up to remove it fro...

Page 271: ...l indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a distorted housing Replace it IMPORTANT A distorted exhaust housing will cause the upper driveshaft spli...

Page 272: ...f 60 to 84 in lbs 7 to 9 5 N m Apply Adhesive 847 to the bottom flange of the inner exhaust housing Install a new seal Apply Triple Guard grease to outer seal surface Install a new inner exhaust housi...

Page 273: ...g and adapter by placing two powerhead mounting screws through their holes Install four mount plate screws and washers and tighten to a torque of 22 to 24 ft lbs 30 to 33 N m Tighten the small adapter...

Page 274: ...the inner exhaust housing Clean and degrease the adapter housing and outer exhaust housing mating surfaces with Cleaning Solvent Apply Gel Seal II sealant to the adapter flange of the exhaust housing...

Page 275: ...d adapter by placing two powerhead mounting screws through their holes Install four mount plate screws and washers and tighten to a torque of 22 to 24 ft lbs 30 to 33 N m Tighten the small adapter to...

Page 276: ...Ultra Lock to upper mount screws and tighten to a torque of 64 to 72 ft lbs 87 to 98 N m Attach the ground lead and star washer to the steering arm s starboard side If necessary replace the exhaust ad...

Page 277: ...must be removed Refer to TRIM AND TILT on p 329 Stern Bracket Disassembly Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaft and thrust wash...

Page 278: ...he braided tube Remove the tilt limit switch and retainer from the swivel bracket Disconnect the trail lock spring and remove it from the swivel bracket Remove trail arm retainer Remove the trail lock...

Page 279: ...e proceeding make sure all components have been thoroughly cleaned Replace any seals that have been removed Inspect all thrust washers and bushings for evi dence of deterioration Install the detent ro...

Page 280: ...he tilt limit switch and retainer on the swivel bracket Tighten screws to a torque of 40 to 50 in lbs 4 5 to 5 5 N m Route the trim sender wires through the braided tube and install the sender unit in...

Page 281: ...ly Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket Align...

Page 282: ...mbly connects to the exhaust relief hoses from the adaptor housing assembly The overboard indicator and flush port in the exhaust relief grommet connect to the adaptor housing assembly with a hose Thi...

Page 283: ...E ASSEMBLY 310 SHIFT HOUSING GEAR AND PROPELLER SHAFT INSTALLATION 310 SHIFT ROD COVER 311 PINION GEAR AND DRIVESHAFT INSTALLATION 312 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION 313 FINAL A...

Page 284: ...bs 6 8 9 5 N m B B 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m B A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m B 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 27 N m A G A B B 108...

Page 285: ...40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m B 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 108 132 In lbs 12 15 N m A A E 18 20 Ft lbs 24 27 N m A G J 30 34 Ft lbs 41 46 N m...

Page 286: ...bs 61 68 N m B A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 60 84 in lbs 6 8 9 5 N m B 30 34 Ft lbs 41 46 N m C 70 80 Ft lbs...

Page 287: ...performance gearset V6 583 ratio is original equipment on 225HO 250 300 HP 14 26 538 and 14 24 583 90 V6 20 in 90 V6 25 in 90 V6 30 in M2 front water inlets and straight leading edge pressed in prope...

Page 288: ...hread pressure test gauge fitting and seal in lubricant level hole Pressurize 3 to 6 psi 21 to 42 kPa If pressure gauge indicates leakage submerge the gearcase in water to determine source of leak If...

Page 289: ...ch must be released to its normal open position before the interrupt function can be activated again This circuit is not func tional above 2500 RPM GEARCASE REMOVAL AND INSTALLATION Gearcase Removal R...

Page 290: ...n p 294 Coat the driveshaft splines with Moly Lube DO NOT coat top surface of the driveshaft because lubricant may prevent seating of the driveshaft in the crankshaft Apply Adhesive 847 to the lower e...

Page 291: ...ousing Position alignment bolts 2 as indicated IMPORTANT Remove and replace alignment screws with appropriate 3 8 in mounting screws after all other gearcase mounting screws are installed and tightene...

Page 292: ...Disassembly Rotate the driveshaft counterclockwise to unlock the impeller key Remove the four impeller hous ing screws Slide the water pump off the driveshaft Remove the impeller key O ring impeller p...

Page 293: ...ller cup is open On outboard models with 1 2 in diameter water tube install the water tube grommet with the inside taper facing up On outboard models with 5 8 in diameter water tube apply a light coat...

Page 294: ...7 in the seal groove and install the special shaped O ring seal Apply Gasket Sealing Compound to both sides of a new impeller plate gasket Install the gasket and impeller plate Apply Triple Guard grea...

Page 295: ...g cover On 25 in and 30 in outboard models place the appropriate water tube spacer and grommet on the impeller housing cover After water pump is assembled completely rotate driveshaft counter clockwis...

Page 296: ...ry for correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTANT The NEUTRAL detent is a two step design Make sure the NEUTRAL detent ball...

Page 297: ...for twisted splines and damaged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase da...

Page 298: ...e propeller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using Propeller Shaft Bearing Housing Puller Kit P N 354060 DO NOT use tools designed to push on the pro...

Page 299: ...o move the clutch dog as far forward as possible This will help ease removal of the pinion nut Use Driveshaft Holding Socket P N 311875 Pin ion Nut Holder P N 334455 and Wrench Retainer P N 341438 to...

Page 300: ...325867 to break the lock Install the tools as shown by clamping them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gea...

Page 301: ...e holes in the driveshaft retainer and the lower driveshaft Install the roll pin to the specified dimension Shift Housing Gear and Propeller Shaft Removal Push down on the shift rod This will move the...

Page 302: ...gearcase housing Use Gearcase Alignment Gauge Kit P N 5006349 to check the condition of gearcase housing prior to reassembly Refer to instructions provided with kit Use additional Gauging Head as foll...

Page 303: ...g Push the pin out of the clutch dog Remove all parts Remove the gear thrust bearing and thrust washer from the shift housing Remove the shift lever pin from the housing Remove shift shaft cradle and...

Page 304: ...pring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at 90 angle into the housing as shown while depressing the ball and spring with a suitable tool On...

Page 305: ...housing IMPORTANT Bearing and washer must be installed in the correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing re...

Page 306: ...nstallation Assemble the following components of Pinion Bearing Remover and Installer P N 391257 as shown IMPORTANT Spacers are different sizes and cannot be interchanged 1 Retaining spring 006907 1 P...

Page 307: ...on new O ring on the pinion bearing retain ing screw Apply Gasket Sealing Compound to O ring Apply Nut Lock to screw threads Install the screw and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m D...

Page 308: ...er Shaft Bearing Housing Service Rear Seal Removal Remove seals using Puller Bridge P N 432127 and Small Puller Jaws P N 432131 Position the plate on top of the housing to support the bridge and tight...

Page 309: ...t O ring grooves Sand off any sharp edges that might cut O ring Remove any nicks or burrs on front of bearing housing Bearing Installation Oil then install new bearings in bearing housing Place the le...

Page 310: ...s before installing Use Seal Installation Tool to install new seals back to back in bearing housing Seal Installation Tool P N 354056 L2 M2 Install inner seal with lip facing toward the bearing housin...

Page 311: ...hrust bearing and pinion onto the drive shaft Use Driveshaft Seal Protector P N 318674 when installing or removing the bearing housing Lightly coat the threads of the pinion nut with out board lubrica...

Page 312: ...ckness required Select the fewest number of shims to achieve the correct thickness Remove the driveshaft from the tool and add the required shims between the bearing housing and the thrust washer IMPO...

Page 313: ...the shift rod while pushing it through the cover to avoid damaging the O ring L2 TYPE GEARCASES Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket Place the gasket on the gear...

Page 314: ...Protector P N 318674 slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase Adjust shift rod to move clutch dog as far forward as possible Be sure excess grease is...

Page 315: ...h Retainer P N 341438 to tighten the pinion nut to a torque of 100 to 110 ft lbs 136 to 149 N m Pad handle of holder to prevent damage to gear case Propeller Shaft Bearing Housing and Gear Installatio...

Page 316: ...haft Bearing Housing Installer P N 354058 Gearcase Fixture P N 354059 and an appropriate floor press 10 ton or greater to install housing into gearcase Align and level gearcase assembly in fixture as...

Page 317: ...htly apply Triple Guard Grease to new bearing housing O rings Install O rings in grooves in the housing Grease the machined side surfaces of bearing housing Place bearing housing in gearcase Align ret...

Page 318: ...n ing screws Tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 286 WATER PUMP SERVICE on p 290 SHI...

Page 319: ...ng on M2 type gearcases is PRESSED into gearcase housing Remove the two retaining screws holding the pro peller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using...

Page 320: ...s pulled out Unscrew the shift rod from the detent lever Remove screws cover and shift rod from the gearcase Discard the cover gasket Remove the shift rod O ring from inside of cover and discard Use a...

Page 321: ...out of the clutch dog Remove all components from the shaft Remove the gear thrust bearing and thrust washer from the shift housing IMPORTANT The shift housing supports the reverse gear on counter rota...

Page 322: ...coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent into the housing as shown while depressing the ball and spring with a s...

Page 323: ...ase 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 IMPORTANT Bearing and washer must be installed in...

Page 324: ...p 304 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 deteriorated Clamp the propeller...

Page 325: ...sure distance from flange of housing to flat surface as shown Add the appropriate shims to create a dimension of 0 140 in 3 556 mm To determine thickness of shims use the following example 1 389 in re...

Page 326: ...threads of the for ward gear bearing housing Install forward gear assembly with correct shims in bearing housing IMPORTANT To prevent damage to threads install forward gear bearing housing assembly by...

Page 327: ...d pinion onto the drive shaft Use Driveshaft Seal Protector P N 318674 when installing or removing the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten t...

Page 328: ...embly Mea sure clearance between the gauge bar and the pinion at several locations If variance is greater than 0 002 in 0 050 mm replace the pinion or driveshaft as necessary and repeat check Subtract...

Page 329: ...assem bly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing Shift Rod Cover Refer to Shift Rod Cover on p 311 Pinion Gear and Driveshaft Installati...

Page 330: ...e to install retainer screws Bearing housing is approximately level with gearcase Apply Ultra Lock to threads and install two retain ing screws Tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N...

Page 331: ...338 STERN BRACKETS 338 TROUBLESHOOTING 338 SYMPTOMS CHART 339 SERVICE PROCEDURES 339 PRESSURE LEAKDOWN TEST 339 ELECTRICAL CIRCUIT TESTS 342 RELAY TESTING 342 TRIM AND TILT MOTOR CURRENT DRAW TESTS 3...

Page 332: ...e E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease 60 70 Ft lbs 81 95 N m DO NOT OVER TIGHTEN 84 108 In lbs 9 5 12 N m 58 87 Ft lbs 79 118 N m 35 52 In lbs 4 0 5 9 N m 60 84 In lbs 7 9 5 N m 4...

Page 333: ...t down to the top of the trim range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be manually raised or lowered through the ent...

Page 334: ...o the pump through the open DOWN check valve In the trim range fluid is pushed from the top of the trim cylinders by the pistons and returns to the reservoir Only fluid from the top of the tilt cylind...

Page 335: ...linders Fluid from the bottom of the cylinders returns through the open UP check valve to the pump In the tilt range all of the fluid from the bottom of the tilt cylinder returns through the UP check...

Page 336: ...er extends The fluid above the piston is com pressed producing high pressure This high pressure fluid passes through the impact relief valves in the tilt piston dissipating much of the energy of the i...

Page 337: ...filter valve opens and allows fluid to flow from the reservoir to the top of the tilt cylinder The outboard will tilt down to the top of the trim range Thermal Expansion Relief Ambient air temperature...

Page 338: ...ers Trimming Outboard OUT Pull gearcase out farther than the desired final position up into the tilt range if necessary Close the manual release valve Manually push the gearcase in or down until it is...

Page 339: ...ve Fluid flows from the bottom of the tilt cylinder in the tilt range to the top of the tilt cylinder The excess fluid equal to the volume of the piston rod is vented to the reservoir In the trim rang...

Page 340: ...determined the Symp toms Chart on p 339 should help locate the problem Keep a manual release valve and a valve body in stock for troubleshooting Use these parts when the Service Procedures on p 339 ca...

Page 341: ...ani fold assembly was faulty Remove temporary assembly and replace it with correct one STEP 6 Install replacement pump manifold assembly and retest If all symptoms are not corrected recon sider the pr...

Page 342: ...servoir cap one full turn Loosen the manual release valve three turns Some fluid will bypass the reservoir cap These steps will relieve the pressure in the unit Remove the manual release valve retaini...

Page 343: ...n and up several times to purge air With all rods fully extended run the unit down momentarily to reduce pressure Check fluid level again and add fluid if necessary Remember that all rods must be comp...

Page 344: ...operating speed aids evalu ation of the electric motor and certain mechanical components Use a battery rated at 360 CCA 50 Ah or higher that is in good condition and fully charged to per form this tes...

Page 345: ...good condition and fully charged to per form this test Connect a 0 to 50 A ammeter in series with the battery positive terminal ammeter red lead toward battery Attach or hold a vibration or mechanica...

Page 346: ...UP position If results are different replace the trim gauge If results agree refer to Trim Sender Test Trim Sender Test IMPORTANT To avoid immediate meter dam age never apply a multimeter to an electr...

Page 347: ...from the connector by using a suitable tool to depress the tab While the tab is depressed pull on the wire from the rear of the connector to release it from the connector Separate the trim tilt unit...

Page 348: ...rim tilt unit from the stern brackets Installation Place trim tilt unit into position Apply Triple Guard grease to the lower pin and install the pin If loosened tighten the tilt tube nut to a torque o...

Page 349: ...e and install through hole in the stern bracket Attach the ground wire to the trim tilt unit Release the tilt support and lower the outboard Tighten the manual release valve to a torque of 45 to 55 in...

Page 350: ...tic split rings on the manual release valve for nicks and cuts Inspect tip of valve for damage The two plastic split rings are not available separately If rings are damaged replace the manual release...

Page 351: ...Replace if necessary Remove the four screws securing motor to pump manifold assembly Remove the wire shield from the pump manifold Remove the motor and inspect the motor O ring and the O ring on the...

Page 352: ...not available separately Do not remove pump or any control valves from the body Remove the manifold Remove five O rings from cylinder body Check machined surfaces for nicks and scratches Tilt Piston R...

Page 353: ...he rod Remove the washer Slide the tilt piston off the rod Be careful not to lose the springs plungers or small check valves in the piston assembly Remove and discard the small inner O ring and large...

Page 354: ...o in the large relief holes and the two nine coil springs go in the small relief holes Set the piston aside Use a screwdriver to carefully pry the scraper out of the end cap Discard the scraper Remove...

Page 355: ...ring over the threads Clean any thread locking material from the threads on the inside of the nut Spray threads of with Locquic Primer and let dry Apply a small amount of Nut Lock to the threads Slide...

Page 356: ...pull each piston out with a rag wrapped around the rod and the top of the cylinder Drain the remaining fluid from the cylinders Inspect both bores of the trim cylinders for exces sive scoring If one...

Page 357: ...l facing out Lubricate and install a new O ring on the outside of the end cap Lubricate and install a new O ring and two new back up rings on the trim rod piston Place one back up ring on each side of...

Page 358: ...9 5 N m Oil and install the manual release valve Thread the valve just past the snap ring groove Do not install the snap ring at this time The valve will be removed later for the Pressure Leakdown Tes...

Page 359: ...body Use Trim Cylinder End Cap Remover Installer P N 436710 or Universal Spanner Wrench P N 912084 Tighten caps to a torque of 60 to 70 ft lbs 81 to 95 N m Tilt Rod Installation Lubricate the tilt rod...

Page 360: ...s Rotate the coupler clockwise and then counterclockwise until no more air bubbles come out of the pump Install the filter screen Lubricate and place a new O ring on the motor Make sure the cable is o...

Page 361: ...ssure Check the fluid level again and add fluid if necessary Remember that all rods must be completely up to check the fluid level Test the unit by performing the Pressure Leakdown Test on p 339 Check...

Page 362: ...360 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 363: ...6 OUTBOARD FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY S 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFET...

Page 364: ...S 2...

Page 365: ...elf but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommen...

Page 366: ...ORWARD 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 by operator How can loss of...

Page 367: ...o 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 can loss of speed control be mi...

Page 368: ...eel 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 be hit If steering jams opera...

Page 369: ...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 earlier If moved up or down even...

Page 370: ...kage 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 stored base ment or cottage could be i...

Page 371: ...tion 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 Plug Boots Not torn or cracked...

Page 372: ...er 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 trapped in tank a...

Page 373: ...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 something solid and does not stay on...

Page 374: ...d 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 Check for a high speed...

Page 375: ...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 warnings marked closely Test...

Page 376: ...and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key s...

Page 377: ...un 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 warnings marked closely Assemb...

Page 378: ...Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Repla...

Page 379: ...t 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 P N 396748 use only the spec...

Page 380: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils ca...

Page 381: ...ust 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 CO accu mulation In high con...

Page 382: ...Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in...

Page 383: ...er 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 pressure inside may build Ba...

Page 384: ...tches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters...

Page 385: ...re to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little childre...

Page 386: ...ual 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 received training related to c...

Page 387: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 388: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 389: ...Warning 202 No Oil Warning 197 Engine Temperature Check 209 Engine Temperature Sensor 134 Exhaust Housing Assembly 269 272 Cleaning and Inspection 269 Disassembly 266 267 268 Installation 274 Removal...

Page 390: ...ts 121 Static IgnitionTest 120 Timing 107 Instrument Harness 129 Intake Manifold Assembly 186 Disassembly 185 Inspection 185 Installation 186 Removal 185 Kn n n n n n n n n n n n n n n n n n n n n n n...

Page 391: ...Description 196 Oil Tank 37 196 Oiling Rate 60 106 199 Oiling System Components 196 Electrical Circuits 191 Engine Lubricant 59 New Engine Set Up 37 59 Oil Distribution Hose Replacement 203 Oil Filter...

Page 392: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 393: ...emperature Sensor Description 96 Resistance Test 134 Thermostat Assembly 215 Description 210 Disassembly 215 Inspection 215 Temperature 11 13 Throttle Linkage Installation 242 Lubrication 79 Removal 2...

Page 394: ...ide Hammer Adaptor Kit P N 390898 183 Slide Hammer P N 391008 183 233 298 Slide Hammer P N 432128 227 265 Small Puller Jaws P N 432131 306 Spanner Wrench P N 432400 322 324 Stator Test Adaptor P N 500...

Page 395: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 396: ......

Page 397: ...A 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 bendi...

Page 398: ...g 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 alte...

Page 399: ...anti 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...

Page 400: ...t 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 SYSTEM ANALYSIS and ELECTRICAL AND...

Page 401: ...on Check 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 fu...

Page 402: ...air 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 al...

Page 403: ...A B C 5 1 2 3 6 4 5 1 2 3 6 4 5 1 2 3 6 4 DRC6165R MWS Instrument Wiring Harness 1 2 5 1 2 3 6 7 4 8 A B C...

Page 404: ...Dual Outboards B M M C A S 3 4 2 5 1 6 5 2 3 4 6 1 Lanyard Switch Emergency Stop Circuits B M M C A S 5 2 3 4 6 1 Single Outboard 000705 B M M C A S...

Page 405: ......

Page 406: ...39 CANbus Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 1 4 wa...

Page 407: ...PUL REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 TO OUTBOARD WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MW...

Page 408: ...tion Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will...

Page 409: ...6 Fuel Injector 6 27 Ignition Coil 6 28 Low Oil Switch 29 Trim Sending Unit 30 Tilt Limit Switch 31 Trim Tilt Motor 007085 FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 1 3 5 2 4 6 27 10 20 21...

Page 410: ...TERY 5 minutes Battery voltage 12 V below 2000 RPM or 12 5 V above 2000 RPM Perform stator charging tests 27 12 V circuit ABOVE range 3 LED 1 ON Running LOW BATTERY 5 minutes Battery voltage 15 5 V Ch...

Page 411: ...Water pressure sensor circuit fault detected LED 3 ON Running 10 seconds 0 15 V 4 85 V EMM water pressure option I Command active 75 Water pressure BELOW expected range LED 3 ON Running 10 seconds 0 4...

Page 412: ......

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