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BRP E250DHLSCS, Service Manual

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BRP E250DHLSCS Service Manual Download Page 4

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SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
  1 SPECIAL TOOLS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
  2 INSTALLATION AND PREDELIVERY   . . . . . . . . . . . . . . 25
  3 MAINTENANCE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
  4 ENGINE COVER SERVICE   . . . . . . . . . . . . . . . . . . . . . . 87
  5 ENGINE MANAGEMENT MODULE (EMM)  . . . . . . . . . . 91
  6 SYSTEM ANALYSIS  . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
  7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 123
  8 FUEL SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
  9 OILING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
10 COOLING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
12 MIDSECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
13 GEARCASE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

GEARCASE – STANDARD ROTATION  . . . . . . . . . . . . 278
GEARCASE – COUNTER ROTATION  . . . . . . . . . . . . . 300

14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SAFETY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1
INDEX  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART   . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS

EMM

 SERVICE CODE CHART

Summary of Contents for E250DHLSCS

Page 1: ......

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: ...NE MANAGEMENT MODULE EMM 91 6 SYSTEM ANALYSIS 109 7 ELECTRICAL AND IGNITION 123 8 FUEL SYSTEM 161 9 OILING SYSTEM 185 10 COOLING SYSTEM 201 11 POWERHEAD 211 12 MIDSECTION 247 13 GEARCASE 265 GEARCASE...

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 SC 2008 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: ...C models Identifying Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead Model Number Shaft Color Gearcase E250DHLSCS 20 BL L2 E250DHXSCS...

Page 12: ...versize 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 Crankshaft J...

Page 13: ...mation 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 283 Lubricant HPF XR Gearcase L...

Page 14: ...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 15: ...TOOLS 13 1 SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS 14 UNIVERSAL TOOLS 14 ELECTRICAL IGNITION TOOLS 16 FUEL OIL SYSTEM TOOLS 17 POWERHEAD TOOLS 17 GEARCASE TOOLS 18 TRIM AND TILT TOOLS 21 SHOP...

Page 16: ...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 17: ...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 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...Purpose Lubricant P N 777192 Oil XD100 P N 777118 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 777225 Anti Corrosion Spray P N 777193 Silicone spray P N 775630 Oil XD30 P N 777219 HPF...

Page 25: ...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 26: ...Sealing Compound P N 317201 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 27: ...0 CONTROL CABLE INSTALLATION 51 ELECTRICAL HARNESS CONNECTIONS 53 WATER PRESSURE GAUGE 53 CANBUS CONNECTIONS 54 FUEL AND OIL PRIMING 56 FUEL REQUIREMENTS 56 FUEL SYSTEM PRIMING 57 OIL REQUIREMENTS 57...

Page 28: ...controls 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 gau...

Page 29: ...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 30: ...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 31: ...Battery Charging on p 30 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 32: ...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 33: ...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 34: ...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 35: ...fuel hoses Multi outboard applications require separate fuel tank pickups and hoses A fuel selector switch may be used for kicker motors as long as it has enough flow capacity for the larger out board...

Page 36: ...er separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC6797 1 2 3 Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5 16 in 7 9 mm min I D 3 8 in 9 5 mm min I...

Page 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...If drill fixture is unavailable refer to Drilling and Hardware Diagrams on p 46 for measure ments Position drill fixture on top of transom or bracket and align indicator points with centerline The ind...

Page 48: ...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 49: ...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 50: ...ufacturer s recommendations and to Dual Outboard Centerlines on p 44 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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...eaks 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 60: ...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 61: ...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 62: ...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 63: ...OIL warning has been tested Refer to Oil Requirements on p 57 When starting the outboard for the first time refer to Oil Supply Priming on p 59 Trim and Tilt Fluid Make sure trim and tilt reservoir is...

Page 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...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 72: ...70 INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 73: ...77 TRIM AND TILT 79 BATTERY AND BATTERY CONNECTIONS 80 FUEL AND OIL SYSTEMS 80 FUEL FILTER 80 OIL FILTERS AND OIL RESERVOIR 81 AIR SILENCER 81 HOSES AND CONNECTIONS 81 SPARK PLUGS 82 INDEXING 82 EXHAU...

Page 74: ...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 75: ...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 76: ...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 65 Place outboard...

Page 77: ...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 78: ...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 79: ...nt inspection can minimize potential gearcase damage Remove propeller Refer to Propeller Hardware Installation on p 65 Inspect bushing and blade surfaces Replace damaged or worn propellers Clean prope...

Page 80: ...the gearcase Refer to GEARCASE LEAK TEST on p 270 Overheated lubricant will have a black color and burned odor Internal gearcase inspection is recommended when lubricant is contaminated or shows signs...

Page 81: ...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 82: ...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 83: ...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 84: ...eramic 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 T...

Page 85: ...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 86: ...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 87: ...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 88: ...sconnect 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...

Page 89: ...SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 88 LATCH HOOK INSTALLATION 88 UPPER COVER CAP REPLACEMENT 88 LOWER COVER SERVICE 89 LOWER COVER REMOVAL 89 LOWER COVER INSTALLATION 89 LATCH HANDLE INSTA...

Page 90: ...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 91: ...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 92: ...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 93: ...IONS 98 START ASSIST CIRCUIT SAC 98 ROM VERIFICATION 98 IDLE CONTROLLER 98 RPM LIMITER 98 SHIFT INTERRUPT 98 ENGINE MONITOR AND WARNING SYSTEMS 98 FAULT CODE CREATION AND STORAGE 98 ENGINE MONITORING...

Page 94: ...signal RPM 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...

Page 95: ...mperature Sensor s 11 Water in Fuel Sensor Fuel Filter 12 Trim Tilt Sending Unit 13 Water Pressure Sensor w adaptor harness 14 LED indicators 15 Fuel Pump high pressure 16 Starter Solenoid 17 Oil Inje...

Page 96: ...ircuit 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 1000...

Page 97: ...engine fault codes The EMM provides 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 acce...

Page 98: ...d will restart for one minute intervals until problem 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 c...

Page 99: ...he EMM Crankshaft Position Sensor The CPS is a magnetic device It is mounted on the reed plate next to the flywheel Ribs spaced on the flywheel mark crankshaft posi tion As the ribs pass the magnetic...

Page 100: ...PM At 6250 RPM fuel and ignition to the cylinders is shut off Normal engine operation resumes when engine RPM returns to the specified range Shift Interrupt The shift interrupt function of EMM program...

Page 101: ...MM 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 s...

Page 102: ...l Injector Pressure Test on p 171 Check for external fuel leakage that could allow fuel and or vapor to enter the engine through the air intake Check for internal fuel leakage from a leaking injector...

Page 103: ...must turn ON before it will communicate with any outside device Power is normally sup plied to the EMM when the key switch is ON Switched B 12 V is supplied to the engine wire harness Current enters...

Page 104: ...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 105: ...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 106: ...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 107: ...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 108: ...the Replace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Fuel Injector Installation on p 180 Reports Engine reports provide service records and...

Page 109: ...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 110: ...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 111: ...CATORS 113 KEY ON 113 STARTING 113 RUNNING 114 IGNITION OUTPUT TESTS 115 REQUIRED IGNITION SYSTEMS 115 WIRING INSPECTION 115 CRANKSHAFT POSITION SENSOR CPS TEST 116 SYSTEM VOLTAGE TEST 116 IGNITION VO...

Page 112: ...f the spark plugs Check the fuse and the emergency stop switch lanyard Operational Inspections Run the outboard to confirm actual symptoms before performing any unnecessary procedures Inspection shoul...

Page 113: ...UEL DELIVERY TESTS on p 120 Outboard runs low on power misfires Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 113 Use the Evinrude Diagnostics software...

Page 114: ...ORTANT 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 th...

Page 115: ...er For NO LIGHT check for SAC circuit problem LED 2 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 c...

Page 116: ...bove expected range Code 16 CPS intermittent loss of sync Code 23 EMM temp sensor circuit fault Code 24 EMM temp below expected range Code 28 Shift switch malfunction Code 37 Water in fuel Code 41 POR...

Page 117: ...ed 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 circuit Negative terminal of...

Page 118: ...Diagnostics software 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...

Page 119: ...gnition circuit Check system voltage 55 V input to ignition circuit on pin 4 of EMM J1 B connector Static Ignition Test Perform the static ignition test using Evinrude Diagnostics software and an indu...

Page 120: ...observe timing light strobe Look for a consistent flash and only one flash per revolution The strobe of the timing light should be the same for each cylinder IMPORTANT Test on primary circuit if strob...

Page 121: ...ils or wiring Primary circuit resistance reading less than 2 or within specification and EMM ignition output volt age is 130 V or higher Refer to Ignition Coil Tests on p 119 Repair high tension spark...

Page 122: ...ntinuity If the resistance reading starts as a negative num ber or the reading goes down in value the capac itor already retains some stored energy Ground the capacitor and test again FUEL DELIVERY TE...

Page 123: ...jector activation should be carefully confirmed Results No injectors actuate Use the Monitor screen of the diagnostics soft ware to make sure voltage is present on the system voltage circuit Refer to...

Page 124: ...some injector wires Test the resistance of individual injector circuits between the injector connector and injector con trol wire at the EMM Check battery cable connections Make sure all grounds are...

Page 125: ...G SYSTEM TESTS 133 12 V CHARGING CIRCUIT 133 AUXILIARY BATTERY CHARGE WIRE 134 55 V ALTERNATOR CIRCUIT 134 ELECTRIC START CIRCUIT 135 ELECTRIC START TESTS 137 REMOTE CONTROL SWITCH TESTS 139 TILT TRIM...

Page 126: ...3 5 4 7 N m F 60 84 In lbs 7 9 5 N m 30 42 In lbs 3 5 4 7 N m F B 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...

Page 127: ...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 128: ...ctor 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 129: ...ed 3 Diagnostic 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 B...

Page 130: ...2 Orange Blue 20 Injector cylinder 4 Purple 21 Switched B 12V Purple 22 Injector ground Black 23 Oil solenoid Blue 24 Ignition ground Black 25 Ignition cylinder 6 none V4 Orange Green V6 26 Ignition c...

Page 131: ...en terminal pins 17 18 and 24 of the EMM J1 B connector and port and starboard cylinder head ground screws Sensor circuit grounds Check continuity between terminal pins 4 and 11 of the EMM J1 A connec...

Page 132: ...ital multimeter to mea sure sensor resistance 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 th...

Page 133: ...istance reading must change evenly as the sensor lever is moved Engine Temperature Sensor Test Remove the electrical connector from the engine temperature sensor Use a digital multimeter to measure se...

Page 134: ...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 c...

Page 135: ...and the positive B battery cable terminal of starter solenoid IMPORTANT This outboard has dual output charging Each output is isolated and regulated Each output is 25 A Combined output is approxi mat...

Page 136: ...ire must be at least 10 gauge and it must be protected by a 50 A fuse or circuit breaker at the battery With outboard running at 1000 RPM voltage must read higher than with key OFF and increase steadi...

Page 137: ...PURPLE wire 15 Neutral Safety Switch remote control 7 6 pin connectors 16 RED starter motor cable 8 Ignition switch 17 Electric starter motor 9 PURPLE wire switched B 20 21 22 23 24 25 26 14 15 16 17...

Page 138: ...ontains 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 139: ...rter 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 140: ...or 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 Sna...

Page 141: ...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 continu...

Page 142: ...ts 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 swit...

Page 143: ...30 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 an...

Page 144: ...urn 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 an...

Page 145: ...wire 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 t...

Page 146: ...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 U...

Page 147: ...637 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 washe...

Page 148: ...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 Coat...

Page 149: ...tion 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 directly...

Page 150: ...ORTANT Make sure the timing pointer is set and the outboard reaches operating tempera ture before timing verification is performed TPS CALIBRATION Use Evinrude Diagnostics software to tell the EMM wha...

Page 151: ...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 152: ...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 153: ...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 154: ...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 155: ...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 156: ...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 157: ...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 138 Starte...

Page 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...SURE REGULATOR TEST 171 VAPOR SEPARATOR VENT CHECK 171 FUEL INJECTOR PRESSURE TEST 171 FUEL INJECTOR RESISTANCE TEST 172 CIRCULATION PUMP RESISTANCE TEST 172 LIFT PUMP PRESSURE TEST 172 LIFT PUMP VACU...

Page 164: ...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 165: ...11 N m F 96 120 in lbs 11 13 5 N m 10 18 in lbs 1 2 N m 96 120 in lbs 11 13 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...

Page 166: ...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 167: ...ylinder crankcase Water Separator Fuel filter Fuel supply to vapor separator Vapor separator Vent hose to throttle body Electric fuel circulation pump 20 to 35 psi Fuel supply manifold Fuel injector s...

Page 168: ...pacitor 10 11 12 13 Grounds neg Fuel Injector grounds High pressure fuel pump Fuel filter water separator 20 21 22 23 24 25 26 14 15 16 17 18 19 8 9 10 11 12 13 1 2 3 4 5 6 7 18 19 20 21 22 23 24 25 2...

Page 169: ...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 170: ...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 171: ...mation is recorded and assigned to the 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 EM...

Page 172: ...p 173 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 173: ...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 174: ...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 175: ...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 176: ...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 177: ...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 178: ...bly 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 24 to 36...

Page 179: ...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 180: ...linder locations Use Evinrude Diag nostics Software to make sure that EMM program ming matches injector positioning The Injector Coefficients screen displays injector serial num bers Use caution when...

Page 181: ...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 182: ...ne per screw on injec tor retaining screws Install screws and washers through mounting flange of injector and thread into cylinder head Tighten screws in stages starting with the lower screw First tor...

Page 183: ...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 184: ...o 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 war...

Page 185: ...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 148 1 Throttle linkage 2 TPS electrical con...

Page 186: ...184 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 187: ...OIL WARNING 192 CYLINDER AND CRANKCASE 192 OIL RECIRCULATION SYSTEM 193 OIL CONTROL SETTINGS 194 OIL PRIMING 194 OILING RATES 194 BREAK IN OILING 194 OILING SYSTEM TESTS 195 OIL INJECTION PUMP STATIC...

Page 188: ...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 189: ...0 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 4 4 5 6 7 004110 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8 9...

Page 190: ...anifold 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 Re...

Page 191: ...OILING SYSTEM OIL SUPPLY DIAGRAMS V6 189 9 006870 Rear View 6 4 5 3 Top View 1 2...

Page 192: ...190 OILING SYSTEM OIL RECIRCULATION DIAGRAMS V6 OIL RECIRCULATION DIAGRAMS V6 004111a 2 4 6 1 3 5...

Page 193: ...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 tan...

Page 194: ...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 N...

Page 195: ...lation Internal powerhead oil drain passages connect the lowest point of the intake port area of the cylin der block to external thread in check valves External hoses connect these check valves to a h...

Page 196: ...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 59 Oi...

Page 197: ...onfirmed 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...

Page 198: ...retest For a higher than expected reading test resis tance of the injection pump If injection pump resistance reading is approximately 2 3 injection pump winding is good Isolate faulty component Repa...

Page 199: ...se compare to oil flow at other distribution hoses No oil discharge compare to oil flow at other distribution hoses If one or more hoses fail to discharge oil check for a kinked or restricted hose bef...

Page 200: ...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 201: ...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 202: ...ose 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 203: ...MOSTATS 204 BLOCK VENTING 204 OPERATION 204 CYLINDER BLOCK CYLINDER HEAD COOLING 204 EMM AND VAPOR SEPARATOR COOLING 205 ENGINE TEMPERATURE CHECK 206 SOFTWARE METHOD 206 PYROMETER METHOD 206 IDLE OPER...

Page 204: ...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 250 300HP 90 V6 Evinrude E TEC 5 Outgoing water warm hot Incoming Water cool 6 004109b 6 RE...

Page 205: ...e water pump outlet connects with the water supply tube located in the outboard s midsection Grommets seal the water tube to the water pump housing and the inner exhaust housing Water supplied to the...

Page 206: ...t and pressure valve operation IMPORTANT Restricted or inadequate water flow through the outboard reduces cooling system performance and may lead to severe powerhead damage Cylinder Block Cylinder Hea...

Page 207: ...Cooling Two external water supply hoses direct water flow into the exhaust plenum area of the cylinder block The water reduces exhaust runner temper atures and circulates through the cylinder block T...

Page 208: ...ble shoot cooling system If engine temperature tests within range but the SystemCheck gauge indicates a WATER TEMP warning refer to WATER TEMP HOT Circuit Test on p 143 Software Method Use Evinrude Di...

Page 209: ...6 C check thermo stat and pressure relief valve operation Pressure Relief Valve The pressure relief valve should be closed at IDLE speed Water should not flow past the plunger and seal If IDLE temper...

Page 210: ...at seals against cylinder head Seal must be properly fitted to flange of thermostat Check thermostat for cracks heat damage or signs of corrosion Check for proper operation Thermostat opens at 143 F 6...

Page 211: ...cap 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 A...

Page 212: ...210 COOLING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 213: ...NG 223 POWERHEAD INSPECTION 224 CYLINDER HEAD 224 CRANKSHAFT 224 CYLINDER BORE 225 PISTONS 225 PISTON RINGS 225 BEARINGS 226 POWERHEAD ASSEMBLY 226 CRANKSHAFT 226 PISTONS AND CONNECTING RODS 229 CYLIN...

Page 214: ...to 92 05 60 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 B X 120 144 In lbs 13 5 16 5 N m 120 144 In lbs 13 5 16 5 N m Apply Pipe Thread...

Page 215: ...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 216: ...214 POWERHEAD SERVICE CHART Taper Pin Tool Hole for Storage Scale FULL SIZE...

Page 217: ...ING Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 174 To prevent accidental starting...

Page 218: ...hreads Fasten appropriate 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...

Page 219: ...Injector Service on p 178 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 powerh...

Page 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...r ings could be misaligned Refer to CYLINDER BLOCK CLEANING on p 223 Coat pistons rings cylinder walls and ring com pressor with outboard lubricant Center connecting rod in piston and locate piston ri...

Page 233: ...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 234: ...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 235: ...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 236: ...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 237: ...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 238: ...to PRES SURE RELIEF VALVE SERVICING on p 209 Install shift linkage Refer to Shift Linkage Instal lation on p 235 Install throttle linkage Refer to Throttle Linkage Installation on p 236 Install fuel...

Page 239: ...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 240: ...ral 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 AND STA TOR SERVICING on p 145 1 Rear po...

Page 241: ...ng outboard to service Index all spark plugs Refer to Spark Plug Indexing on p 82 Adjust timing pointer and check engine timing Refer to TIMING ADJUSTMENTS on p 147 Use Evinrude Diagnostics software t...

Page 242: ...240 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings 006972...

Page 243: ...POWERHEAD POWERHEAD VIEWS 241 11 Starboard Hose Routings 006952...

Page 244: ...242 POWERHEAD POWERHEAD VIEWS Port 006993...

Page 245: ...POWERHEAD POWERHEAD VIEWS 243 11 Starboard 006973...

Page 246: ...244 POWERHEAD POWERHEAD VIEWS Front 006974...

Page 247: ...POWERHEAD POWERHEAD VIEWS 245 11 Rear 006975...

Page 248: ...246 POWERHEAD POWERHEAD VIEWS Top 006957...

Page 249: ...ION 252 EXHAUST HOUSING 253 EXHAUST HOUSING REMOVAL 253 EXHAUST HOUSING DISASSEMBLY 254 CLEANING AND INSPECTION 255 EXHAUST HOUSING ASSEMBLY 255 EXHAUST HOUSING INSTALLATION 258 STERN BRACKET 259 REMO...

Page 250: ...68 73 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...

Page 251: ...t lbs 25 27 N m 60 84 In lbs 7 9 5 N m B F F F 144 168 In lbs 16 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 Grease B Gasket Sea...

Page 252: ...250 MIDSECTION SERVICE CHART 004117...

Page 253: ...lar 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...

Page 254: ...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 255: ...t be removed Refer to POWERHEAD REMOVAL on p 215 Remove and discard four lower mount screws Remove the steering arm ground lead and screw Remove two upper mount screws Remove the exhaust housing Remov...

Page 256: ...g 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 from the...

Page 257: ...ge of housing The maximum allowable run out is 0 009 in 0 228 mm If you do not have access to a dial indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a dist...

Page 258: ...washers Lubricate the upper mount with soapy water and push into place in the adapter housing The mount radius must face aft with the TOP mark facing up Apply Locquic Primer and Nut Lock to the upper...

Page 259: ...to exhaust housing screws and nuts to a torque of 60 to 84 in lbs 7 to 9 5 N m If removed coat the lower mounts with soapy water and press into the exhaust housing with the OUTSIDE mark facing outward...

Page 260: ...Ultra Lock to upper mount screws and tighten to a torque of 50 to 60 ft lbs 68 to 81 N m Attach the ground lead and star washer to the steering arm s starboard side If necessary replace the exhaust ad...

Page 261: ...must be removed Refer to TRIM AND TILT on p 313 Stern Bracket Disassembly Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaft and thrust wash...

Page 262: ...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 263: ...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 264: ...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 265: ...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 266: ...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 267: ...SE ASSEMBLY 293 SHIFT HOUSING GEAR AND PROPELLER SHAFT INSTALLATION 293 SHIFT ROD COVER 294 PINION GEAR AND DRIVESHAFT INSTALLATION 295 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION 296 FINAL...

Page 268: ...n lbs 6 8 9 5 N m B B 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 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 1...

Page 269: ...27 N m A 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 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 B 60 84 In lbs 7 9 5 N m A 108 132 In lbs 12 15...

Page 270: ...A B B 18 20 Ft lbs 24 27 N m A 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 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...

Page 271: ...225HO 250 300 HP 14 26 538 and 14 24 583 90 V6 20 in 60 V6 90 V6 25 in 90 V6 30 in M2 front water inlets and straight leading edge pressed in propeller shaft bearing housing with retaining flange heav...

Page 272: ...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 273: ...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 274: ...n p 277 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 275: ...replace alignment screws with appropriate 3 8 in mounting screws after all other gearcase mounting screws are installed and tightened Apply Gasket Sealing Compound to threads of the gearcase retaining...

Page 276: ...WATER PUMP SERVICE Disassembly Rotate the driveshaft counterclockwise to unlock the impeller cam Remove the four impeller hous ing screws Slide the water pump off the driveshaft Remove the impeller dr...

Page 277: ...ound Install the cup in the impeller housing Install the water tube grommet with the inside taper facing up Install the impeller housing cover and tighten screws to a torque of 24 to 36 in lbs 3 to 4...

Page 278: ...ler and slide water pump down over cam Be sure impeller cam does not fall out of position IMPORTANT Make sure the impeller engages the impeller cam Serious powerhead damage will result if impeller cam...

Page 279: ...sary 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 ba...

Page 280: ...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 dam...

Page 281: ...he 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 282: ...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 lo...

Page 283: ...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 ge...

Page 284: ...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 d...

Page 285: ...f 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 fo...

Page 286: ...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 s...

Page 287: ...spring 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...

Page 288: ...ousing 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 rear...

Page 289: ...Installation 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...

Page 290: ...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 Dri...

Page 291: ...ler 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 tigh...

Page 292: ...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 let...

Page 293: ...ls 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 housi...

Page 294: ...ust 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 lubricant...

Page 295: ...ickness 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 IMP...

Page 296: ...he 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 gearc...

Page 297: ...al 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...

Page 298: ...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 Installation...

Page 299: ...Shaft 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 300: ...tly 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 reta...

Page 301: ...ain 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 270 WATER PUMP SERVICE on p 274 S...

Page 302: ...g 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 303: ...is 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...

Page 304: ...t 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 rotati...

Page 305: ...ly 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...

Page 306: ...lace 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 the...

Page 307: ...on p 287 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 propelle...

Page 308: ...e 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 follow ing example 1 389 in read...

Page 309: ...e 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...

Page 310: ...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 to...

Page 311: ...sembly 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 Subtrac...

Page 312: ...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 294 Pinion Gear and Driveshaft Installatio...

Page 313: ...se 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...

Page 314: ...312 GEARCASE COUNTER ROTATION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 315: ...322 STERN BRACKETS 322 TROUBLESHOOTING 322 SYMPTOMS CHART 323 SERVICE PROCEDURES 323 PRESSURE LEAKDOWN TEST 323 ELECTRICAL CIRCUIT TESTS 326 RELAY TESTING 326 TRIM AND TILT MOTOR CURRENT DRAW TESTS 3...

Page 316: ...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 317: ...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 318: ...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 319: ...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 320: ...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 321: ...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 322: ...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 323: ...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 324: ...em has malfunctioned and the cause has not been determined the Symp toms Chart on p 323 should help locate the problem Keep a manual release valve and a valve body in stock for troubleshooting Use the...

Page 325: ...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 326: ...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 327: ...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 328: ...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 329: ...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 330: ...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 331: ...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 332: ...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 333: ...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 334: ...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 335: ...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 336: ...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 337: ...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 338: ...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 339: ...rod O 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...

Page 340: ...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 341: ...the bevel 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...

Page 342: ...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 Test on p...

Page 343: ...body Use Trim Cylinder End Cap Remover Installer P N 436710 or Universal Spanner Wrench P N 912084 Torque caps to 60 to 70 ft lbs 81 to 95 N m Tilt Rod Installation Lubricate the tilt rod piston Slide...

Page 344: ...te 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 on the...

Page 345: ...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 323 Check...

Page 346: ...344 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 347: ...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 348: ...S 2...

Page 349: ...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 350: ...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 351: ...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 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ...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 359: ...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 360: ...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 361: ...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 362: ...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 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ...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 370: ...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 371: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 372: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 373: ...Warning 197 No Oil Warning 192 Engine Temperature Check 203 Engine Temperature Sensor 131 Exhaust Housing Assembly 255 Cleaning and Inspection 255 Disassembly 253 254 Installation 258 Removal 253 Exh...

Page 374: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Key Switch Circuit Tests 139 Operation Check 62 Start Circuit 137 L n 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 375: ...d Gap 230 Inspection 225 Installation 230 Removal 220 Pistons Assembly 229 Inspection 225 Installation 230 Removal 219 Powerhead Assembly 226 Cleaning 223 Disassembly 217 Inspection 224 Installation 2...

Page 376: ...or 95 131 Exhaust Pressure Sensor 83 95 Oil Pressure 96 191 Tests 130 Throttle Position Sensor 97 130 148 Serial Number Location 9 Service Charts Electrical and Ignition 124 Fuel System 162 Gearcase 2...

Page 377: ...Removal 334 Tilt Rod Assembly 336 Installation 341 Tilt Support 315 Tilt Tube Installation 252 Lubrication 76 Removal 251 Timing Adjustmenst Timing Pointer 147 Timing Adjustments Timing Verification 1...

Page 378: ...Tilt Cylinder End Cap Remover Installer P N 326485 334 341 Tilt Cylinder Seal Protector P N 326005 337 Tilt Tube Service Kit P N 434523 251 Torquing Socket P N 346187 219 233 Transom Drill Fixture P...

Page 379: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 380: ......

Page 381: ...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 382: ...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 383: ...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 384: ...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 385: ...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 386: ...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 387: ...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 388: ...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 389: ......

Page 390: ...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 391: ...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 392: ...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 393: ...sor 2 25 Fuel Injector 6 26 Ignition Coil 4 27 Low Oil Switch 28 Trim Sending Unit 29 Tilt Limit Switch 30 Trim Tilt Motor 006579 FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 3 5 4 6 26 10 1 2...

Page 394: ...3 LED 1 ON Running LOW BATTERY 5 minutes Battery voltage 15 5 V Check battery connections and wiring 28 Shift switch malfunction LED 3 ON Running 10 seconds Check shift switch linkage and switch acti...

Page 395: ...range LED 3 ON Running 10 seconds 0 4 V 73 Oil pressure ABOVE expected range LED 3 ON Running 10 seconds 4 6 V 74 Water pressure sensor circuit fault detected LED 3 ON Running 10 seconds 0 15 V 4 85 V...

Page 396: ......

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