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BRP EVINRUDE E-TEC BE50DPLABA, Service Manual

The BRP Evinrude E-TEC BE50DPLABA is a powerful and reliable outboard motor that delivers top-notch performance on the water. Ensure proper maintenance and repairs with the free Service Manual available for download on manualshive.com. This manual provides step-by-step instructions to keep your Evinrude running smoothly.

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42

ROUTINE SERVICE

LUBRICATION

Swivel Bracket and Trailering 
Bracket

Lubricate the swivel bracket 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 Tube

Lubricate the tilt tube grease fittings with 

Triple-

Guard 

grease.

Throttle and Shift Linkage

Disconnect the battery cables at the battery.

Remove clips and washers from throttle and shift
lever pins. Carefully, remove casing guides from
pins.

IMPORTANT:

DO NOT disturb cable trunnion

adjustments.

Shift remote control into FULL THROTTLE/
REVERSE position to fully extend the plastic cas-
ing guides.

Apply 

Triple-Guard 

grease to:

•

Cable attachment pins of both the throttle and
shift levers

•

Inner casings of both the throttle and shift
cables.

2-Cylinder models

1.

Grease fitting

2.

Tilt support

DR31329

3-Cylinder models

1.

Grease fitting

2.

Pivot points

3.

Lower swivel bracket area

DR5073

1

2

1

1

3

2

1.

Tilt tube fittings

DR38798

1.

Attachment pins, throttle and shift cables

2.

Inner casings, throttle and shift cables

002214

 

1

 

1

2

1

Summary of Contents for EVINRUDE E-TEC BE50DPLABA

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

Page 2: ...D 189 11 MIDSECTION 237 12 GEARCASE 285 GEARCASE SERVICE 40 60 HP MODELS 292 GEARCASE SERVICE 75 90 HP MODELS 314 13 TRIM AND TILT 339 14 MANUAL STARTER 363 SAFETY S1 INDEX I1 TROUBLE CHECK CHART T1 D...

Page 3: ...ALLATION INSTRUCTIONS 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 SERVICE SPECIF...

Page 4: ...patch screws be required always replace with a new one When replacement parts are required use Evin rude Johnson Genuine Parts or parts with equiva lent characteristics including type strength and mat...

Page 5: ...rd may drop unexpectedly 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 disc...

Page 6: ...merican 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 CFR Code of Federal Regulations CPS cr...

Page 7: ...changes such as altitude adjustments for exam ple Owner s Responsibility The owner operator is required to have outboard maintenance performed to maintain emission lev els within prescribed certifica...

Page 8: ...nue through the alphabet as AG AH etc will not use letters from the word INTRODUCES to identify models Refer to Administrative Bulletin 2012 03 A for additional information DESIGN FEATURES B Blue Pain...

Page 9: ...ric Power Tilt E40DHSLAB_ 20 in White F 11 32 0 34 2 90 1 Remote Electric Power Tilt E50DTLAA_ 20 in Blue F 12 32 0 375 2 67 1 Tiller Electric Power Tilt E50DPLAA_ 20 in Blue F 12 32 0 375 2 67 1 Remo...

Page 10: ...oke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm C...

Page 11: ...Type Capacitor Discharge Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control...

Page 12: ...oke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm C...

Page 13: ...Capacitor Discharge Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Info...

Page 14: ...o 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journals 2 1870 to 2 1875 i...

Page 15: ...ing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC10WEP 0 028 003 in 0 71 m...

Page 16: ...auti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No 12 3...

Page 17: ...3 mm diameter This example has a cross sectional area of 2 08 mm Cross Section 3 Cross Section 3 in mm mm in mm mm 6 0 3335 0 58 14 73 170 3 12 65 0 0808 2 05 3 31 5 0 2646 0 517 13 12 135 1 13 52 0 0...

Page 18: ...18 REFERENCE INFORMATION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 19: ...ENDING UNIT ADJUSTMENT 75 90 HP 34 TRIM TAB ADJUSTMENT 35 DUAL OUTBOARD ALIGNMENT 36 OPERATIONAL CHECKS 37 COOLING SYSTEM 38 ENGINE FLUSHING 39 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 4...

Page 20: ...components Water intake screens check condition Cooling system check water pump indicator water pressure Anticorrosion anodes check condition Gearcase check condition Propeller check condition Fuel a...

Page 21: ...h the service manual set Common Practices All Models Control Cable Identification IMPORTANT Identify control cable function before rigging outboard Identify each control cable Put the control handle i...

Page 22: ...d section behind the straight section Cable Hose and Wire Routing Refer to Control Cable Identification on p 21 Apply soapy water to the inside surfaces of grom met and install cables and fuel line as...

Page 23: ...remove slack With outboard in NEUTRAL place the cable trun nion into the lower anchor pocket Adjust the trun nion nut so the casing fits onto the shift lever pin If there are not enough threads on th...

Page 24: ...5 N m SystemCheck Harness Connections Place the wiring harness through notch in lower motor cover and route to the recess in the fly wheel cover Secure the cable with a tie strap as shown Before insta...

Page 25: ...l tie straps as shown To prevent wire chafing harness must be routed below the flywheel cover Connect the I Command Engine Interface Cable to the EMM CANbus connector 2 CYLINDER MODELS To prevent inte...

Page 26: ...temCheck connector with 6 Pin Connector Seal P N 586076 If connecting to an existing I Command Classic network connect the purple wires between the I Command Ignition and Trim Harness and the I Comman...

Page 27: ...ns Water Pressure Gauge To display engine water pressure install a water pressure hose fitting in the cylinder block as shown Use Pipe Sealant with Teflon on the threads of the hose fitting Refer to i...

Page 28: ...the battery negative post LAST Install a starwasher on the threaded battery post Stack cables from the outboard then cables from accessories Finish this connection with a hex nut Do not use wing nuts...

Page 29: ...he outside diameter of the hose when installed on the fitting Chose a clamp so that the outside diameter of the hose is approximately in the middle of the clamp ing range of the clamp A WARNING DO NOT...

Page 30: ...stepless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accessories Catalog Position correct size clamp over hose Install hose on fitting Close clamp ear fully with Oe...

Page 31: ...s are equipped with a throttle friction adjustment knob located on the steering handle Tighten the knob to reduce the effort required to hold a throttle setting Turn the knob clockwise to increase fri...

Page 32: ...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 prevent damage to equipme...

Page 33: ...Loosen cam screw and rotate eccentric cam to adjust full down gauge position If the needle was above the lowest mark move the thick part of the cam TOWARD the contact point Tighten the screw and reche...

Page 34: ...the engine is trimmed to the full down position the bow of the boat goes deeper into the water If the trim limiter rod is left out the bow could plow into the water causing the boat to bow steer resul...

Page 35: ...d to the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw as follows 40 90 HP 35 to 40 ft...

Page 36: ...gnments 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 amou...

Page 37: ...Prevention Start outboard and shift to FORWARD Turn outboard OFF while control is in FORWARD Try to restart the outboard Outboard should not start Shift back to NEUTRAL and restart outboard Shift to...

Page 38: ...eed Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use COOLING SY...

Page 39: ...in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Turn water supply on Run outboard at IDLE only until full operating tem perature is reached Leave the outboar...

Page 40: ...GPM Gallons per minute 2 LPM Liters per minute Install flushing adapter onto gearcase water inlet screens A steady stream of water should flow from the overboard indicator while the engine is running...

Page 41: ...g it with grease Make sure wiper nut is installed and not damaged Tiller Handle Lubricate the tiller handle grease fittings with Tri ple Guard grease A WARNING Failure to regrease as recommended could...

Page 42: ...s from throttle and shift lever pins Carefully remove casing guides from pins IMPORTANT DO NOT disturb cable trunnion adjustments Shift remote control into FULL THROTTLE REVERSE position to fully exte...

Page 43: ...stall propeller hardware and propeller Gearcase Lubricant Draining IMPORTANT Always check the fill level of the gearcase lubricant at the upper plug before removing the lower drain fill plug A tie str...

Page 44: ...n is recommended when lubricant is contaminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 20 for service frequency and recommended lubricants Secure the g...

Page 45: ...ads Install the filler cap 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 the u...

Page 46: ...e spark plug opposite the fuel injector nozzle Put an ink mark on the 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...

Page 47: ...g system leaks Make certain the oil tank is filled and oil supply is not contaminated Air Silencer The air silencer maximizes air flow while minimiz ing noise Routine cleaning of the air silencer is r...

Page 48: ...ased antifouling paint on the 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 i...

Page 49: ...tem 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 FULL in neutral...

Page 50: ...age make sure it is reinstalled with factory specified hardware Refer to the Predelivery and Installation Guide Outboard Mounting Bolts Check and re tighten outboard mounting bolts to a torque of 40 f...

Page 51: ...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 system and fu...

Page 52: ...52 ROUTINE SERVICE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 53: ...3 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 54 LATCH HOOK INSTALLATION 54 LOWER COVER SERVICE 54 LOWER COVER REMOVAL 54 LOWER COVER INSTALLATION 55 LATCH HANDLE INSTALLATION 56 TRIM...

Page 54: ...sition with opening toward the front Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m LOWER COVER SERVICE Lower Cover Removal Remove lower engine cover screws Loosen port side cover slightly...

Page 55: ...side cover Connect trim tilt switch connector Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enough to hold the grommet in place S...

Page 56: ...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 Tighten nut to a t...

Page 57: ...WITCH 62 THROTTLE POSITION SENSOR 63 CRANKSHAFT POSITION SENSOR 63 NEUTRAL SWITCH 63 INTERNAL EMM FUNCTIONS 64 ENGINE MONITOR SYSTEM 65 S A F E WARNING SYSTEM 66 SHUTDOWN MODE 66 DIAGNOSTIC SOFTWARE F...

Page 58: ...ter valve activation 60 65 HP EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections can damage the EMM DO NOT run the outboard with loose or dis...

Page 59: ...e Sensor AT 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fuel Injector 14 Tachometer SystemCheck Gauge 15 I Command CANbus Display 16 D...

Page 60: ...s less than 71 F 57 4 C or greater than 313 F 156 C a sensor 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...

Page 61: ...l 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 codes Air Temperature...

Page 62: ...rter the EMM begins counting oil pump pulse cycles When it reaches 40 65 HP 4800 pulses 75 90 HP 6000 pulses the EMM To recover from S A F E mode the oil pump must cycle for a minimum of three pulses...

Page 63: ...e a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 occurrences the EMM Approximate air gap between CPS and flywheel encoder ribs is 0...

Page 64: ...es when engine RPM returns to the specified range Neutral RPM Limiter This feature prevents engine damage due to excessive RPM if accelerated in NEUTRAL Neu tral engine speed is limited to 1800 RPM Ex...

Page 65: ...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 self tests by...

Page 66: ...est on p 141 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 or vapor separator ve...

Page 67: ...purple of the EMM J1 B connec tor The EMM is also turned ON when it begins to receive AC voltage from the stator while the out board is being cranked ROPE START MODELS Diagnostic communications on non...

Page 68: ...mation The outboard model and serial numbers displayed on the Identity screen must match the identifica tion label on the outboard swivel bracket The serial number and cylinder location displayed on...

Page 69: ...hours of the last occurrence Historical faults cannot be erased Static Tests Static Tests allow diagnostic testing of system components while the outboard is NOT running Ignition Test Use the diagnos...

Page 70: ...y changes can be observed Refer to DYNAMIC TESTS on p 80 Prime Oil This test is used to cycle the oil injection pump for priming the oiling system Perform this test with outboard running to activate o...

Page 71: ...h an installed tiller conversion kit MUST be set to TILLER Ignition Timing Use the Ignition Timing screen to check and adjust EMM timing EMM timing must be synchro nized to crankshaft position Refer t...

Page 72: ...ot set an absolute fixed speed After the offset is changed the EMM continues to control engine operation normally Engine idle speed is not fixed Fuel Injector Servicing All E TEC fuel injectors use so...

Page 73: ...be available to enhance the operation of an outboard Select Engine Software Update from the Utilities menu and refer to the instructions pro vided with the program IMPORTANT If using Diagnostic Power...

Page 74: ...ory and follow the instructions provided with the program IMPORTANT Whenever the EMM is replaced EMM timing must be synchronized to crankshaft position Refer to TIMING ADJUSTMENTS on p 117 EMM SERVICI...

Page 75: ...en performing the following tasks Make sure isolator mounts are placed in slots in of EMM case Slide EMM into position Apply Nut Lock to threads of EMM retaining screws Tighten to a torque of 30 to 42...

Page 76: ...76 ENGINE MANAGEMENT MODULE EMM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 77: ...G 81 RUNNING 82 IGNITION OUTPUT TESTS 83 REQUIRED IGNITION SYSTEMS 83 WIRING INSPECTION 83 CRANKSHAFT POSITION SENSOR CPS TEST 84 SYSTEM VOLTAGE TEST 84 STATIC IGNITION TEST 85 RUNNING IGNITION TESTS...

Page 78: ...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 should incl...

Page 79: ...Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 81 Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS volt ages System voltage should be ste...

Page 80: ...IMPORTANT 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...

Page 81: ...ins to turn until the outboard is running for 2 seconds During starting all four LEDs should light and then go off in sequence LED 1 CHARGING OKAY Stator signal 30 V or higher LED 2 CRANK POSITION OKA...

Page 82: ...circuit shorted Code 102 No 2 ignition timing circuit shorted Code 103 No 3 ignition timing circuit shorted LED 3 Sensor circuits 5 V SENSOR FAULT For LIGHT ON check for possible fault codes Code 12...

Page 83: ...rom EMM white red provides 55 VDC to the high pressure fuel pump the oil injection pump the fuel injectors and the igni tion coils Capacitor Connected to 55 V circuit white red to stabilize current on...

Page 84: ...Results EMM ON not running approximately 1 V less than battery voltage system voltage is GOOD EMM ON not running no voltage check 12 V power to EMM Repair connection or wiring RUNNING 55 V 2 system vo...

Page 85: ...gency stop switch lanyard must be 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 consist...

Page 86: ...tage and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 88 Check for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace sp...

Page 87: ...ignition coil connector Refer to engine wiring diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil tests available Before replacing an ignition coil be sur...

Page 88: ...uity between pin 2 of fuel pump connector and ground Use the fuel pump static test to activate the control function of the EMM Resistance should drop as EMM connects the control circuit to ground Refe...

Page 89: ...switched 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...

Page 90: ...the voltage at pin 2 blue red wire of the the water valve connector Voltage should drop while the static test is active Exhaust Water Valve Dynamic Test Use the diagnostics program to perform a dynami...

Page 91: ...EST 101 CHARGING SYSTEM TESTS 102 ELECTRIC START CIRCUIT 104 ELECTRIC START TESTS 106 REMOTE CONTROL SWITCH TESTS 108 TILT TRIM RELAY TEST 110 EXHAUST WATER VALVE TEST 110 SystemCheck CIRCUIT TESTS 11...

Page 92: ...o 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m N A T IMPORTANT DO NOT lubri...

Page 93: ...s 2 7 to 4 N m 60 to 84 in lbs 7 to 9 5 N m F 30 to 42 in lbs 3 4 to 4 8 N m 24 to 36 in lbs 2 7 to 4 N m B 15 to 30 ft lbs 20 to 41 N m X J 002249 A Triple Guard Grease B Gasket Sealing Compound C Ad...

Page 94: ...sition sensor Capacitor 7 8 Ignition coil Main harness ground 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34...

Page 95: ...1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34 33 32 31 30 29 28 27 26 24 25 23 22 21 20 19 18 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B J1 A J2 4 1 2 3 1 2 3 1 2 3 4 5 6 2 3 4 5 6 1 2...

Page 96: ...Pin No Description of Circuit Wire Color 1 vacant 2 Diagnostic connector Red 3 Diagnostic connector White 4 vacant 5 vacant 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Bootstr...

Page 97: ...or ground Black 15 vacant 16 vacant 17 vacant 18 vacant 19 Ignition cylinder 2 75 90 HP Orange Purple 19 Ignition cylinder 2 40 60 HP Orange Green 20 Injector ground Black 21 Injector ground Black 22...

Page 98: ...f the EMM J1 B connector and the main harness ground Sensor circuit grounds Check continuity between terminal pins 26 and 27 of the EMM J1 A connector and the appropriate sensor ground connections Ref...

Page 99: ...ure 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 the throttle body housing...

Page 100: ...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 sensor resis tance Air Temperature S...

Page 101: ...unded 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 continuity replace stator Stator Voltage...

Page 102: ...t be able to run the outboard continuously at approximately 5000 RPM such as in a test tank or on a marine dynamometer The test consists of monitoring the system s response to a partially discharged b...

Page 103: ...N check battery voltage at battery 12 V Then use Electrical Test Probe Kit P N 342677 and a digital multimeter set to read 55 VDC to check voltage on white red wires at J2 connector of EMM Voltage at...

Page 104: ...9 18 FUSE J1 B J1 A J2 4 B A NEG A B 2 1 6 5 4 15 10 2 3 M A S C M B 1 2 3 4 5 6 2 1 7 8 9 9 11 12 13 14 1 1 Marine battery 9 PURPLE wire switched B 2 RED wire POS 10 Engine Management Module EMM 3 BL...

Page 105: ...Engine Wire Harness Contains the following circuits Red purple output wire from fuse provides 12 V to instrument harness Purple wire provides switched 12 V to EMM Yellow red wire provides switched 12...

Page 106: ...rminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to terminal A of solenoid and ground NEG to terminal B of solenoid Measure resis t...

Page 107: ...ter cable of solenoid terminal Connect negative lead to starter motor terminal Activate starter motor and observe voltage reading No Load Current Draw Test Securely fasten starter in a vise or suitabl...

Page 108: ...nd 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 conti...

Page 109: ...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 110: ...ivated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure red and black wires are connected to 12 V battery power supply Set voltmeter to 12...

Page 111: ...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 112: ...re of the Sys temCheck 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 113: ...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 114: ...lternator output can help determine the flywheel s condition Refer to CHARGING SYSTEM TESTS on p 102 Flywheel Removal Remove the recoil starter assembly rope start models Refer to RECOIL STARTER REMOV...

Page 115: ...s and washers Hold puller body with han dle and tighten pressing screw until flywheel releases Turn the center screw and lift the fly wheel off of the crankshaft Stator Service Disconnect stator harne...

Page 116: ...TIMING ADJUSTMENTS on p 117 IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis connect ignition coil electrical connector Remove two ignition coil retainin...

Page 117: ...ark 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 across from the pointer Label this mark...

Page 118: ...programming IMPORTANT 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...

Page 119: ...starter positive cable from post on starter Remove the battery negative cable from the double ended stud Remove two starter mounting screws and double ended stud Remove the starter Starter Installatio...

Page 120: ...gently 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 la...

Page 121: ...ock Tool P N 777077 to release locking tab of connector housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push c...

Page 122: ...seated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 connector of the EMM is an AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull connector from...

Page 123: ...releas ing the tab and then pushing the terminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gasket...

Page 124: ...124 ELECTRICAL AND IGNITION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 125: ...PRIMING 140 VENT LINE CLAMP 140 PRIMING THE FUEL SYSTEM 140 FUEL SYSTEM TESTS 141 FUEL SYSTEM PRESSURE TEST 141 PRESSURE REGULATOR TEST 142 VAPOR SEPARATOR VENT CHECK 142 FUEL INJECTOR PRESSURE TEST 1...

Page 126: ...lbs 2 7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F 002154a Tighten in 3 stages A Triple Guar...

Page 127: ...n lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Ad...

Page 128: ...7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F A Triple Guard Grease B Gasket Sealing Compound...

Page 129: ...20 in lbs 7 14 n m 10 14 in lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m F F IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease...

Page 130: ...system Fuel lift pump 2 to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel in...

Page 131: ...to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel injector s Fuel return mani...

Page 132: ...EMM Fuel injector Fuel circulation pump 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 GREEN BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15...

Page 133: ...mp 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 11 PURPLE GREEN 2 BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B...

Page 134: ...age NOTE A small amount of fuel may be released when the fuel connector is dison nected Store portable fuel tanks in well ventilated areas away from heat sources and open flames Close the vent screw o...

Page 135: ...amage the out board 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 fuel additives ca...

Page 136: ...aches the pump internal pump pressure forces the fuel from the pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure...

Page 137: ...with the fuel level in the fuel chamber Hot fuel causes an increase in vapor pressure This results in a lower fuel level in the vapor separator The float valve drops and the vent opens This allows fu...

Page 138: ...manifolds route fuel through the high pressure side of the fuel system Fuel Supply Manifold The fuel supply manifold supplies pressurized fuel to the inlet port of each fuel injector Fuel Return Mani...

Page 139: ...tor s unique fuel flow characteristics Fuel injectors MUST NOT be moved from one cylinder to another EMM program ming is associated with the cylinder location of each injector Installing an injector o...

Page 140: ...hose Once fuel flow is observed connect fuel supply hose from fuel tank to hose fitting on outboard Secure hose with Oetiker clamp TILLER MODELS Connect the fuel hose connector to the quick con nect f...

Page 141: ...on p 144 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying enough fuel to vapor separa...

Page 142: ...uous Fuel Injector Pressure Test This test requires Injector Test Fitting kit P N 5005844 Disconnect the battery cables at the battery Loosen oil tank assembly to provide access to fuel manifolds Refe...

Page 143: ...purple or green Resistance should be the same as or slightly higher than the injector alone Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter with...

Page 144: ...lift pump Temporarily install a vacuum gauge T fitting and 8 in 20 3 cm of clear vinyl hose between the fuel supply hose and fuel lift pump inlet Secure con nections with tie straps to prevent fuel or...

Page 145: ...e anti siphon valve from fuel tank Install adapter fittings and a 36 in 91 4 cm length of clear hose to the inlet side tank end of valve Fill clear hose with water to a height of 20 in 500 mm Water mu...

Page 146: ...uitable con tainer Slowly open gauge s venting valve Clean up any spilled fuel with shop towels A WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use caution when...

Page 147: ...d pressure on bulb and check for fuel leaks Connect battery cables Run outboard and check for fuel leaks Fuel Lift Pump Service The fuel lift pump is serviceable as a complete assembly or can be repai...

Page 148: ...f circulation pump Remove clamp and vapor vent hose from separator cover Remove clamps and vapor separator cooling water hoses Remove clamps and fuel return manifold and fuel supply hose from bottom o...

Page 149: ...n remove the manifold assemblies Installation Check condition of sealing O rings on fuel mani fold fittings Lubricate O rings with outboard lubri cant and insert fuel manifold fittings into injector B...

Page 150: ...emoval Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 146 Remove fuel manifolds Refer to Fuel Manifold Service on p 149 Remove t...

Page 151: ...to continue turn ing the puller nut clockwise Turn the puller nut until the fuel injector is removed from the fuel injector housing Remove fuel injector puller from injector Remove crush ring and O ri...

Page 152: ...Supply Tool P N 587005 to supply power to the EMM use Accessory Power Cable Kit P N 5008092 to connect an external 12 volt battery to the Power Supply Tool If the internal batteries of the Power Suppl...

Page 153: ...rease 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 stages starting with the lowe...

Page 154: ...tle body Remove screws and reed plate assembly from the crankcase Disassembly All reed plate assembly and reed valve assem blies must be cleaned prior to reassembly DO NOT use strong carburetor cleane...

Page 155: ...eed valve retaining screws Install gasket on reed plate assembly DO NOT use sealer on the gasket Prime screw threads with Locquic Primer and let dry Apply Nut Lock to threads Position reed valve on re...

Page 156: ...7 to 13 5 N m Install vapor separator vent hose and main bear ing vent hose Secure with tie straps Install air temperature sensor crankshaft position sensor and throttle position sensor electrical con...

Page 157: ...V 165 LOW OIL WARNING 166 NO OIL WARNING 166 CYLINDER AND CRANKCASE 166 OIL RECIRCULATION SYSTEM 167 OIL CONTROL SETTINGS 168 OIL INJECTION RATE 168 BREAK IN OILING 169 OIL SUPPLY PRIMING 169 OILING S...

Page 158: ...P F F 30 to 42 in lbs 3 5 to 5 N m X 30 tp 42 in lbs 3 5 5 N m 30 to 42 in lbs 3 5 5 N m 008058 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboa...

Page 159: ...n lbs 3 5 to 5 N m X 30 to 42 in lbs 3 5 to 5 N m 30 to 42 in lbs 3 5 to 5 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubrica...

Page 160: ...M OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 40 65 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1...

Page 161: ...OILING SYSTEM 161 8 75 90 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1 5 4 6 6 5 6 5 008061...

Page 162: ...162 OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 40 65 HP 75 90 HP 002483a Starboard view Port view 002223 Starboard view Port view...

Page 163: ...RED Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK No oil signal to SystemCheck gauge TAN YELLOW 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 1...

Page 164: ...or warn ing display should show LOW OIL Add enough oil to raise level to at least one quar ter capacity The LOW OIL warning should not display Failure to follow these recommen dations could void the o...

Page 165: ...ols activation of the pump The oil manifold distributes the oil supplied by the pump Electrical Circuit 55 V The oil injector is powered by the 55 V electrical circuit The EMM controls pump operation...

Page 166: ...e warning resets after three oil pump pulse cycles when the outboard has been stopped and restarted If outboard has been run for more than 3 hours with NO OIL faults codes 34 117 the EMM Cylinder and...

Page 167: ...the upper cylin der port Crankcase Main Bearing Recirculation The movement of oil through the main bearings is controlled by internal passages external fittings and hoses and check valves Lower to upp...

Page 168: ...XD100 out board lubricant and is not recommended for all applications IMPORTANT The XD100 setting is not avail able on all models Use the XD100 setting for Conventional use runabouts cruisers Moderat...

Page 169: ...et up Use Evinrude Diagnostics software to make sure the break in program has been started on a new outboard Use the diagnostics software to start break in oiling after a powerhead rebuild The operato...

Page 170: ...nly This will produce false results Refer to Communication on p 67 The EMM controls the pump by providing ground through pin 23 blue wire of the J1 B connector and pin B blue wire of the oil pump conn...

Page 171: ...eter lead to pin A white red wire of oil injection pump electrical connector Observe voltage at pin A Voltage at pin A should be approximately 12 V Set digital multimeter to a scale that reads 55 V DC...

Page 172: ...ly inserted into manifold Refer to Oil Distribution Hoses on p 173 Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remo...

Page 173: ...lacement Oil Hose P N 778708 to the correct length Insert hose support in manifold end of hose IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully...

Page 174: ...o a torque of 30 to 42 in lbs 3 5 to 5 N m Install protective sleeves and route oil distribution hoses from the oil distribution manifold to the crankcase oil delivery fittings Refer to OIL SUP PLY DI...

Page 175: ...w s from oil pump assembly Twist and pull up on oil pump to remove from tank DO NOT pull up on oil manifold Installation Apply a drop of outboard lubricant to a new oil pump o ring Install o ring on o...

Page 176: ...d in front of oil tank baffle to prevent interference with the LOW OIL switch ALL MODELS Install oil pump retainer screw s Tighten securely IMPORTANT Turn self tapping screws counter clock wise to sta...

Page 177: ...G 182 WATER PRESSURE CONNECTION 182 OPERATION 183 CYLINDER BLOCK CYLINDER HEAD COOLING 183 EMM AND VAPOR SEPARATOR COOLING 183 ENGINE TEMPERATURE CHECK 184 SOFTWARE METHOD 184 PYROMETER METHOD 184 IDL...

Page 178: ...5 6 8 7 10 60 65 HP 004971 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Exhaust housing Cylinder block Pressure relief valve Thermostat Water suppl...

Page 179: ...01818 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply EMM to vapor separator Overboard...

Page 180: ...cing IMPORTANT The water pump housing on 2 cylinder models includes a small hole to the rear of the water outlet This hole provides cooling water for the tip of the exhaust passage Be sure to use the...

Page 181: ...ncreases Spring tension sets the opening pressure Overheating A restricted or faulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing completely...

Page 182: ...Circulated water flows through the EMM and vapor separator before exiting through the overboard indicator Water Pressure Connection A fitting and hose for an accessory water pressure gauge can be con...

Page 183: ...ows down through the cylinder head to a passage in the cyl inder block Water flows through the block to the exhaust housing and then out of the outboard At higher speeds water pressure opens the press...

Page 184: ...e monitor display indicates a WATER TEMP warning refer to WATER TEMP HOT Cir cuit Test on p 112 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature sens...

Page 185: ...Relief Valve Inspection The pressure relief valve should be closed at IDLE speed Water should not flow past the plunger and seal Start the outboard and check IDLE operating tem perature If IDLE tempe...

Page 186: ...und SLOWLY tighten temperature sensor to a torque of 50 to 70 in lbs 5 6 to 8 0 N m Wait 10 minutes for trapped air to bleed from cav ity Thermal compound may seep past threads Retighten sensor THERMO...

Page 187: ...n performing the following additional tasks Coat threads of thermostat cover with Triple Guard grease and install new O ring Install and tighten cover to a torque of 120 to 144 in lbs 13 5 to 16 N m P...

Page 188: ...sassembly Pay close attention when performing the following additional tasks Install a new plunger seal squarely over ridge in housing Apply a light coat of Triple Guard grease to a new cover o ring a...

Page 189: ...ANING 204 POWERHEAD INSPECTION 205 POWERHEAD ASSEMBLY 207 CRANKSHAFT ASSEMBLY 207 PISTONS AND CONNECTING RODS 209 CYLINDER HEAD INSTALLATION 211 CRANKSHAFT AND CONNECTING ROD INSTALLATION 212 CRANKCAS...

Page 190: ...X F 60 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m F 60 84 In lbs 7 9 5 N m B J 18 20 ft lbs 24 5 27 N m B X 002283 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blu...

Page 191: ...Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant P Permatex No 2 Q Gel Seal II X See Service Manual Procedure Y Extreme...

Page 192: ...0 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m B 60 84 In lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B J X 002281 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lo...

Page 193: ...A D D D 15 20 Ft lbs 20 27 N m 110 130 Ft lbs 149 176 N m A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant P P...

Page 194: ...d pistons broken or stuck piston rings scored cylinder walls Return throttle to idle position and reconnect CPS connector Replace spark plugs Refer to Spark Plug Indexing on p 46 POWERHEAD REMOVAL 2 C...

Page 195: ...tronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist Loosen the screws holding the exhaust water valve to the exhaust housing M...

Page 196: ...use only the 1 1 8 in short screws P N 398067 included with the tool to avoid damage to electronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool and support weight of po...

Page 197: ...embly Label connectors for reassembly locations Refer to EMM SERVICING on p 74 Remove flywheel and stator Refer to FLYWHEEL AND STATOR SERVICING on p 114 Remove ignition coils and fuel injectors Refer...

Page 198: ...holding the shift shaft 2 cylinder models Slide entire shift linkage assembly from crank case Remove the ball guide and spring of the shift detent assembly from the crankcase 2 Cylinder Models 1 Throt...

Page 199: ...MPORTANT Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin Remove crankcase flange screws Loosen in stages and remove the main bearing nuts...

Page 200: ...t P N 331638 to loosen in stages the rod cap retaining screws DO NOT remove the screws Use one hand to support the piston and remove the rod cap screws with your other hand Remove each piston and rod...

Page 201: ...essing Tool P N 326356 to remove the wrist pin bearing Be careful not to lose any of the 28 needle bear ings or the two wrist pin washers Do not mix bear ings with those from another cylinder If any o...

Page 202: ...housing O ring Discard O ring Use a punch to remove the housing seal Discard seal Inspect housing and replace if necessary Remove the O ring from crankshaft sleeve and inspect it Replace the O ring if...

Page 203: ...s to be replaced Use external retaining ring pliers to remove the lower bearing retaining ring IMPORTANT If the lower main bearing is removed from the crankshaft it must be dis carded DO NOT reuse it...

Page 204: ...Seal and Gasket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block crankcase cylin der head and water cover Carefully remove any carbon accumulation from...

Page 205: ...warpage must not exceed 0 006 in 0 15 mm per inch of measurement Replace head if warpage exceeds this dimension Check fuel deflector pins for damage Crankshaft Measure the diameter of each crankpin a...

Page 206: ...eler gauge to measure the ring end gap Ring end gap should be 0 011 to 0 023 in 0 28 to 0 58 mm IMPORTANT Ring end gap increases approxi mately 0 003 in 0 076 mm for each 0 001 in 0 025 mm increase in...

Page 207: ...he lower main bearing If the installer sticks on the sleeve after installa tion thread Slide Hammer P N 391008 into installer and pull it off IMPORTANT Inspect sleeve after installation Sleeve must no...

Page 208: ...et Sealing Compound to outer edge of O ring Place lower seal housing on crankshaft Lubricate upper main bearing with outboard lubri cant and install on crankshaft Pack lip of upper oil seal with Moly...

Page 209: ...the flywheel Apply Needle Bearing Grease to the wrist pin bearings Install the bearings in the small end of the connecting rod Align bearings with Wrist Pin Bearing Tool P N 336660 Place the two wrist...

Page 210: ...Gel Seal II has been removed from the cyl inder block and crankcase mating flanges If traces of hardened Gel Seal II are left main bearings could be misaligned Refer to CYLIN DER BLOCK CLEANING on p...

Page 211: ...ase and install in cylinder head Apply soapy water to water dam and insert into block Apply a 1 16 in 2 mm bead of RTV Adhesive around each water passage on the block and cyl inder head as shown Insta...

Page 212: ...f cylinders Remove numbered connecting rod caps Gently lower crankshaft into place Align tab on lower bearing seal housing with hole in crankcase Align upper oil seal in groove Locate each main bearin...

Page 213: ...s dot on rod and that both dots face fly wheel Tightening rod cap screws without Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent damage to the connecting rod and cra...

Page 214: ...rcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 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 Torqui...

Page 215: ...nk case mating flange The sealer must not come within 1 4 in 6 4 mm of bearings IMPORTANT Gel Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or repl...

Page 216: ...ng Compound to both sides of a new water cover gasket Place gasket and cover on cylinder block Apply Nut Lock to cover screws Position J clamps as shown Tighten all screws to a torque of 60 to 84 in l...

Page 217: ...to threads Install arm screw and washer and tighten screw to a torque of 120 to 144 in lbs 13 5 to 16 N m Throttle Linkage Installation Apply Nut Lock to threads of throttle lever screw Insert spring...

Page 218: ...gnition coils Refer to Fuel Injector Installation on p 152 and IGNITION COIL SERVICING on p 116 IMPORTANT All injectors must be installed in their original location Improper injector installation can...

Page 219: ...emblies and remove Inspect mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position wi...

Page 220: ...aust housing If necessary rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines Apply Triple Guard grease to the threads and Gasket Sealing Compound to the shank of the p...

Page 221: ...rews and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Connect cooling water hoses to exhaust housing Connect the power trim connectors and exhaust water valve connector 60 65 Secure cables in c...

Page 222: ...ousing Guide into position over alignment pin at rear of exhaust housing If necessary rotate flywheel in a clockwise direction to align crankshaft and drive shaft splines Apply Triple Guard grease to...

Page 223: ...ews to a torque of 60 to 84 in lbs 7 to 9 5 N m Place the shift rod in the shift rod lever Install the retaining pin and washer Tighten pin to a torque of 60 to 84 in lbs 7 to 9 5 N m Check shift link...

Page 224: ...on p 319 Tighten adjustment screws to 60 to 84 in lbs 7 to 9 5 N m Final Adjustments After installing a new or rebuilt powerhead perform the following procedures before returning outboard to service...

Page 225: ...225 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS 2 Cylinder Port Hose Routings 2 Cylinder Starboard Hose Routings 006490 006491...

Page 226: ...226 POWERHEAD POWERHEAD VIEWS 2 Cylinder Port Dressed Powerhead 2 Cylinder Starboard Dressed Powerhead 008428 008159...

Page 227: ...227 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Port Rope Start Models 2 Cylinder Starboard Rope Start Models 008370 008185...

Page 228: ...228 POWERHEAD POWERHEAD VIEWS 2 Cylinder Front 008160...

Page 229: ...229 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Rear 008161...

Page 230: ...230 POWERHEAD POWERHEAD VIEWS 2 Cylinder Top 008162...

Page 231: ...POWERHEAD POWERHEAD VIEWS 231 10 2 Cylinder Top Rope Start Models 008186...

Page 232: ...232 POWERHEAD POWERHEAD VIEWS 3 Cylinder Port Hose Routings 3 Cylinder Starboard Hose Routings 006760 006761...

Page 233: ...233 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Port Dressed Powerhead 3 Cylinder Starboard Dressed Powerhead 008163 008164...

Page 234: ...234 POWERHEAD POWERHEAD VIEWS 3 Cylinder Front 008166...

Page 235: ...235 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Rear 008167...

Page 236: ...236 POWERHEAD POWERHEAD VIEWS 3 Cylinder Top 008165...

Page 237: ...XHAUST HOUSING ASSEMBLY 252 STERN BRACKET 40 60 HP POWER TILT 254 STERN BRACKET DISASSEMBLY 254 STERN BRACKET ASSEMBLY 255 STERN BRACKET 75 90 HP POWER TILT 256 STERN BRACKET DISASSEMBLY 256 STERN BRA...

Page 238: ...t Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex No 2 Q Gel Seal II 004304 60 84 in lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B F 16 18 ft...

Page 239: ...9 5 N m E 60 84 In lbs 7 9 5 N m C C A B B 60 84 In lbs 7 9 5 N m F 150 180 In lbs 17 20 N m A A C B 18 20 Ft lbs 24 5 27 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lub...

Page 240: ...BRACKET 40 60 HP POWER TILT 144 168 In lbs 16 19 N m F 10 16 In lbs 1 2 N m 45 50 Ft lbs 61 68 N m A A A 45 50 Ft lbs 61 68 N m A Triple Guard Grease B Gasket Sealing Compound 002220 IMPORTANT Use Tri...

Page 241: ...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 A A A A A B 1...

Page 242: ...19 N m 144 168 In lbs 16 19 N m F 40 45 Ft lbs 54 61 N m See Text A 144 168 In lbs 16 19 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock...

Page 243: ...s 2 3 3 4 N m 36 48 In lbs 4 5 4 N m 36 40 Ft lbs 49 54 N m 18 20 Ft lbs 24 5 27 N m 24 36 In lbs 2 7 4 N m A F F F A A D D 18 20 Ft lbs 24 5 27 N m Switched 12V For CANbus To Engine Key Switch Connec...

Page 244: ...he collar 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 ste...

Page 245: ...e Use 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...

Page 246: ...Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p 292 Remove the powerhead Refer to Powerhead POWERHEAD REMOVAL on p 194 Remove the three lower mount cover screws Separate lower mount covers f...

Page 247: ...valve and bracket in position Apply Nut Lock to screws install and tighten 60 to 84 in lbs 7 to 9 5 N m Exhaust Relief Muffler Remove exhaust relief muffler cover to inspect fil ter element Clean or r...

Page 248: ...Place lower thrust washer on the steering shaft and place the lower front mount into position Install lower side mount covers Install and tighten the screws in stages to a torque of 16 to 18 ft lbs 2...

Page 249: ...ND INSTALLATION on p 292 Remove the powerhead Refer to POWER HEAD REMOVAL on p 194 Remove and discard four lower mount screws Remove the exhaust housing Lower Mount Service Remove lower mount covers a...

Page 250: ...s and tighten to a torque of 150 to 180 in lbs 17 to 20 N m Exhaust Housing Installation Bring the exhaust housing into position with the stern bracket Install four new lower mount screws with lock pa...

Page 251: ...inner exhaust housing to the adapter housing Remove the water tube from the inner exhaust housing Discard water tube grommet Remove the seal from the bottom flange of the inner exhaust housing Remove...

Page 252: ...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 distorted housing replace it I...

Page 253: ...Apply Adhesive 847 to the bottom flange of the inner exhaust housing Install a new seal Apply Triple Guard grease to outer seal surface Clean and degrease the adapter housing and outer exhaust housing...

Page 254: ...60 to 84 in lbs 7 to 9 5 N m STERN BRACKET 40 60 HP Power Tilt Stern Bracket Disassembly Remove the bumpers from the upper mount retaining screws Remove the screws upper mount and ground lead from the...

Page 255: ...ed to two thirds its origi nal size Stern Bracket Assembly Assemble the tie bar to the stern brackets Place the ground lead and starwasher between the port stern bracket and tie bar Lubricate the swiv...

Page 256: ...hesive 847 to heads of the upper mount screws Place the bumpers on the upper mount screws STERN BRACKET 75 90 HP Power Tilt Stern Bracket Disassembly Before servicing the stern bracket Remove gearcase...

Page 257: ...discard Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to TILT TUBE 75 90 HP on p 244 Remove the two tilt tube washers Remove the anode Remove the swivel bracket Inspec...

Page 258: ...tainer Remove the trail lock arm and bushings from the swivel bracket Remove the two trim rod rollers from the swivel bracket Remove the tilt support and bushing from the swivel bracket and inspect th...

Page 259: ...in the swivel bracket Tighten bushing to a torque of 28 to 30 ft lbs 38 to 41 N m Install the two trim rod rollers on the swivel bracket Tighten to a torque of 216 to 240 in lbs 25 to 27 N m Install...

Page 260: ...seals in the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compound Coat the bushings and seal lips with Triple Guard grease Coat tilt tube bushings wi...

Page 261: ...and stern brackets through the two forward grease fit tings Install the exhaust housing Refer to Exhaust Housing Installation on p 250 STERN BRACKET 40 HP Manual Tilt Clamp Screw Service Inspect clam...

Page 262: ...ering friction pin When the pin is flush with the inside surface of the casting remove the steering friction thrust ring Tighten the steering friction screw until the steer ing friction pin can be rem...

Page 263: ...link screws and nuts from the stern brackets Remove the two stern bracket flange screws and separate the stern brackets from the swivel bracket Place the tilt run lever in the RUN position Loosen the...

Page 264: ...acket Insert the reverse lock pins in the swivel bracket and part way through the reverse lock springs Place the reverse lock assembly between the springs Push the pins through the springs and the rev...

Page 265: ...e tilt tube nuts loosely Starboard stern bracket Thrust washer Bushing Swivel bracket Bushing Thrust washer Port stern bracket Apply Nut Lock to threads of the two flange screws Install the two screws...

Page 266: ...ing friction bushing in the swivel bracket with groove in line with the setscrews Apply Triple Guard grease to the steering friction pin Install the pin in the swivel bracket flush with inside surface...

Page 267: ...e steering arm Install and tighten the mount retaining screws to a torque of 24 to 26 ft lbs 32 5 to 35 N m Place the mount screw bumpers on the upper mount screws Tilt Assist Cylinder The optional ac...

Page 268: ...cket lower pivot pin access hole and tighten securely TILLER HANDLE SERVICE Standard Removal Use Ball Socket Remover tool P N 342226 to unsnap the throttle cable clip from the throttle lever Remove th...

Page 269: ...friction control so there is no restriction on grip IMPORTANT Do not back screw out com pletely Nut is under spring tension Use Twist Grip Remover P N 390767 to depress the grip detents Tighten screw...

Page 270: ...ut of the steering handle and remove cable IMPORTANT DO NOT remove the inner handle except to replace it Use a punch and mallet to drive out the steel pin holding the inner handle into the steering ha...

Page 271: ...ly Install the throttle cable seal in inner handle If removed apply Loctite Depend 300 adhesive to inner handle at areas shown Install the metal outer handle over the plastic inner handle and drive th...

Page 272: ...roller pin and into the slots of the inner handle Place the rollers on the ends of the roller pin Assemble the helix halves on the handle and slide the grip over the helix Be sure the twist grip s spe...

Page 273: ...o throttle lever Place throttle cable in upper anchor pocket Install cable retainer on anchor block Hold twist grip in full SLOW position Pull firmly on cable to remove backlash Adjust cable anchor so...

Page 274: ...e the throttle cable anchor screw and washer Loosen throttle cable retainer screw And remove the tie strap holding the tiller handle elec trical harness Remove retainer clip from shift cable 1 Cable a...

Page 275: ...ering arm Remove the screws attaching tiller bracket to steering arm Remove tiller bracket and handle Disassembly Loosen throttle friction control so there is no restriction on grip IMPORTANT Do not b...

Page 276: ...wires Refer to CONNEC TOR SERVICING on p 120 Use Twist Grip Remover P N 390767 to depress the grip detents Tighten screw and remove the grip by pulling grip Remove the helix halves rollers and guides...

Page 277: ...asher retaining the inner handle tab Use an appropriate tool to carefully pry up on the inner handle retaining tab Use a wooden dowel and a soft mallet to remove the inner handle Remove shift cable re...

Page 278: ...nspect the steering handle components for wear cracks or damage Replace parts if necessary Assembly Apply Nut Lock to threads of shift pin and install shift pin into shift handle Tighten to a torque o...

Page 279: ...tter pin Install shift cable retainer on shift cable trunnion Use a soft faced mallet to install the inner handle Secure tab of the inner handle into the outer han dle Tab must be flush with the back...

Page 280: ...on outer handle Install trim switch wiring through inner steering handle IMPORTANT Trim switch wiring must NOT be twisted through the throttle twist grip or inner tiller handle wire guide Insert wire...

Page 281: ...cable Lubricate end of the pin guides rollers helix halves and inner handle guide slot with Moly Lube Place the guides over the roller pin and into the slots of the inner handle Place the rollers on t...

Page 282: ...top switch assembly and connect to har ness Install bottom cover of tiller handle with seven screws Installation The steering arm can be positioned straight or angled 15 port or starboard by moving th...

Page 283: ...ced into the lower engine cover Shift Cable Adjustment Pull firmly on shift cable casing to remove back lash With outboard and tiller handle shift lever in NEUTRAL place the cable trunnion into the lo...

Page 284: ...ip in full SLOW position Pull firmly on cable to remove backlash Adjust cable anchor so throttle cam is against idle stop when anchor screw aligns with throttle body boss Then rotate anchor four turns...

Page 285: ...SHAFT INSTALLATION 310 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION 312 FINAL ASSEMBLY AND ADJUSTMENT 313 GEARCASE SERVICE 75 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION 314 WATER PUMP SER...

Page 286: ...In lbs 13 5 16 5 N m A B C 60 84 In lbs 7 9 5 N m D B C B A B 96 120 In lbs 11 13 5 N m 60 84 In lbs 7 9 5 N m B A 18 20 Ft lbs 24 5 27 N m A 40 45 Ft lbs 54 60 N m 35 40 Ft lbs 47 54 N m B 48 80 In...

Page 287: ...0 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 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61...

Page 288: ...bs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m A A C A A J 14 18 In lbs...

Page 289: ...ttle Refer to SERVICE SPECIFICATIONS AB MOD ELS on p 12 If the propeller blades have too much pitch the engine will operate below its normal range at full throttle Power will be lost and powerhead dam...

Page 290: ...peller Hardware Installation IMPORTANT Depending on propeller style dif ferent thrust bushings spacers and cotter pin keepers are used See the Evinrude Johnson Genuine Parts and Accessories Catalog fo...

Page 291: ...mine source of leak If the gauge does not indicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leaks Make necessary repairs and repeat test Install Gearcase Vacuum Tester P N 50...

Page 292: ...in screw and washer and remove 7 16 14 x 3 5 in screw and washer Remove the four 3 8 16 x 1 5 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being care...

Page 293: ...not turn and is positioned prop erly in the shift rod lever below the crankcase Apply Triple Guard grease to threads of the gearcase retaining screws Tighten the screws to a torque of 3 8 in screws 18...

Page 294: ...ter pump off the driveshaft Remove the impeller key impeller plate and gasket Dis card the gasket Remove all the parts from the housing Inspection Check impeller for overheating hub separation and oth...

Page 295: ...on install the impeller into the liner with the slot for the impeller key facing out Apply a thin bead of Adhesive 847 in the seal groove and install the special shaped O ring seal Apply Gasket Sealin...

Page 296: ...oove of the impeller housing grommet Install the grommet on the impeller housing Before installing gearcase shift rod adjustment MUST be checked Refer to SHIFT ROD ADJUSTMENT on p 296 SHIFT ROD ADJUST...

Page 297: ...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 damage Hydrostatic Sea...

Page 298: ...from Universal Puller Set P N 378103 Remove the two retaining rings using Retaining Ring Pliers P N 331045 Remove the retainer plate from the gearcase COA3571 9437 A CAUTION Retaining rings are under...

Page 299: ...the pinion nut from the bottom of the driveshaft Pad handle of the wrench to prevent damage to gearcase Remove the four driveshaft bearing housing screws Remove the driveshaft from the gearcase The be...

Page 300: ...late inserted between the puller and the gearcase until the driveshaft pops loose from the pinion Shift Housing Gear and Propeller Shaft Removal Push down on the shift rod This will move the detent le...

Page 301: ...ng Water Intake Screen Inspect the water intake screen for blockage and remove it by depressing the tabs on either side of the screen and pushing upward Pinion Bearing Installation Install the water i...

Page 302: ...nstall the screw and tighten to a torque of 48 to 80 in lbs 5 5 to 9 0 N m Shift Housing Disassembly IMPORTANT The shift housing and forward gear bearing are serviced as an assembly If either are worn...

Page 303: ...e beginning assembly procedures Replace any damaged parts Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at 90...

Page 304: ...g grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the gear bearing and washer into the bearing housing Bearing and washer must be installed in the...

Page 305: ...ler Bridge P N 432127 and Large Puller Jaws P N 432129 Discard the seal Remove and discard the O ring from the bearing housing Clean the bearing housing in solvent to remove sealer from the seal bore...

Page 306: ...e bridge and tighten jaws securely behind the bearing Remove front bearing using Puller Bridge P N 432127 and Bearing Puller P N 432130 Place the puller plate on top of the housing to sup port the bri...

Page 307: ...f the bearing should be visible Bearing Installation Tool P N 326562 Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to...

Page 308: ...ring housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 40 to 45 ft lbs 54 to 60 N m IMPORTANT The original pinion nut may be used for shimming but...

Page 309: ...required shims between the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 312403 Check cl...

Page 310: ...locator pin into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Place the cover...

Page 311: ...shaft into the gearcase and through the pin ion gear Using Driveshaft Seal Protector P N 312403 slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase Align the emb...

Page 312: ...ing and larger thrust washer on hub of reverse gear Slide the gear assembly onto the propeller shaft until it engages the pinion gear Slide the bearing housing retainer plate into posi tion over the p...

Page 313: ...top Place the housing into gearcase and tap the housing with a soft face mallet to seat the O ring Apply Gasket Sealing Compound to the threads and seals of the four propeller housing retaining screws...

Page 314: ...sher Remove the four 3 8 16 x 1 75 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being careful not to bend the shift rod A WARNING To prevent accident...

Page 315: ...installs correctly Shift rod does not turn and is positioned prop erly in the shift rod lever below the crankcase IMPORTANT New gearcase screws are treated with a thread locking material Apply Triple...

Page 316: ...WATER PUMP SERVICE 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 k...

Page 317: ...housing with a square index tab Make sure vent hole in impeller cup is open Install the water tube grommet with the inside taper facing up Apply Triple Guard grease to screw threads and install the i...

Page 318: ...ller and slide water pump down over key Be sure impeller key does not fall out of position Make sure the impeller engages the impeller key Serious powerhead damage will result if impeller key is not i...

Page 319: ...arcase in NEUTRAL rotate the shift rod up or down as necessary for correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTANT The NEUTRAL d...

Page 320: ...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 damage Hydrostatic Sea...

Page 321: ...o 5 16 18 nuts obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing and reverse gear from gearcase Pinion Gear and Driveshaft Remo...

Page 322: ...5867 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 gearc...

Page 323: ...semble the driveshaft install new driveshaft retainer into the groove of the upper driveshaft Install the upper driveshaft into the lower drive shaft aligning the holes in the driveshaft retainer and...

Page 324: ...er intake screens Replace if damaged GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection Inspect pinion bearing and forward thrust surface o...

Page 325: ...tallation Assemble the following components of Pinion Bearing Remover and Installer P N 5005927 as shown S Type Gearcases 1 Pinion bearing retaining screw 2 Water screen pocket 3 Seal DSC02370 DRC7416...

Page 326: ...e bearing into the gearcase Drive the bearing into the gearcase until the washer on the tool contacts the spacer Remove the tool Place a new O ring on the pinion bearing retaining screw Apply Gasket S...

Page 327: ...shop cloth to catch ball and spring Rotate the shifter detent 90 in either direction then pull the detent out of the housing Remove the detent ball and spring Remove needle bearings from bearing housi...

Page 328: ...pressing the ball and spring with a suitable tool Once the shifter detent is past the ball remove the tool and position detent to engage NEUTRAL position Thoroughly grease 25 needle bearings with Nee...

Page 329: ...led 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 of the shaft The clutch dog is not symmetrical If...

Page 330: ...l bore and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage Do not...

Page 331: ...P N 432127 and Large Puller Jaws P N 432129 Place the puller plate on top of the housing to sup port the bridge and tighten jaws securely behind the bearing Inspect the bearing housing anode Replace a...

Page 332: ...339750 O Type gearcases Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to install new seals back to back in bearing hou...

Page 333: ...e bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 100 to 110 ft lbs 136 to 149 N m IMPORTANT The original pinion nut may be used for shim...

Page 334: ...ve the driveshaft from the tool and add the required shims between the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Dr...

Page 335: ...it through the cover to avoid damaging the O ring Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket Place the gasket on the gearcase Thread the shift rod into the shifter det...

Page 336: ...ring IMPORTANT The inside taper of the pinion gear and the driveshaft taper MUST be com pletely free of grease Clean the tapers with Cleaning Solvent Use a shop towel free of grease and lint Place the...

Page 337: ...the gear assembly onto the propeller shaft until it engages the pinion gear Lightly apply Gasket Sealing Compound to a new bearing housing O ring Install O ring in groove in the housing Install housi...

Page 338: ...rm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 291 WATER PUMP SERVICE on p 316 SHIFT R...

Page 339: ...44 RESERVOIR FLUID 344 MANUAL RELEASE VALVE 344 STERN BRACKETS 344 TROUBLESHOOTING 344 ELECTRICAL CIRCUIT TESTS 345 RELAY TESTING 345 TRIM AND TILT MOTOR CURRENT DRAW TEST S 345 TRIM AND TILT MOTOR NO...

Page 340: ...TS 40 60 HP MODELS 008842 W W 45 to 55 in lbs 5 to 6 N m 45 to 55 in lbs 5 to 6 N m 30 to 50 in lbs 4 to 5 6 N m A 60 to 85 ft lbs 82 to 115 N m E E 60 to 85 ft lbs 82 to 115 N m A A Triple Guard Grea...

Page 341: ...ELS 008841 30 to 50 In lbs 4 to 5 6 N m A A W 45 to 55 In lbs 5 to 6 N m 45 to 55 In lbs 5 to 6 N m 60 to 85 ft lbs 82 to 115 N m E 60 to 85 ft lbs 82 to 115 N m E 84 to 106 in lbs 9 5 to 12 N m E A T...

Page 342: ...utboard through the tilt 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 its entire t...

Page 343: ...c system from damage Tilt the outboard up fully engage the bracket then tilt the outboard down until the bracket is firmly in position For mooring or storing the boat with the outboard tilted a tilt s...

Page 344: ...the manual release valve with a torque wrench IMPORTANT Tighten valve to a torque of 45 to 55 in lbs 5 to 6 N m Stern Brackets Inspect the stern brackets for binding Tighten starboard tilt tube nut to...

Page 345: ...tric motor s current draw and trim tilt unit 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 con...

Page 346: ...50 Ah or higher that is in good condition and fully charged to per form this test Connect a 0 to 25 A ammeter in series with the battery positive terminal ammeter red lead toward terminal Attach or ho...

Page 347: ...trim 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 an ohmmeter to an el...

Page 348: ...b 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 wires in the braided tube to permit removal through the hole i...

Page 349: ...ough to remove the ground lead from the pump motor mounting screw 75 90 HP MODELS Remove the external snap rings from the upper pin Use a punch to remove the upper pin Retract the tilt cylinder rod Re...

Page 350: ...the bushings Install the ground lead Place trim tilt unit into position Lubricate the angle adjustment rod with Triple Guard grease Install the rod Tighten the locknuts to a torque of 20 to 25 ft lbs...

Page 351: ...nd tilt cylinder rod to match with holes in swivel bracket Apply Triple Guard grease to upper pin and install the pin Install external snap rings onto upper pin with sharp edge facing out ALL MODELS P...

Page 352: ...nts may cause flakes of paint to enter the hydraulic passages during assembly Tape the trim tilt piston rods before painting Manual Release Valve IMPORTANT Before removing manual release valve relieve...

Page 353: ...ase valve Discard the O rings on the housing Oil O rings and install them on the manual release valve Oil and install the manual release valve Tighten the valve to a torque of 45 to 55 in lbs 5 to 6 N...

Page 354: ...ap from the trim and tilt assem bly Remove the rod piston and end cap assembly from the cylinder of the trim and tilt assembly Drain remaining trim and tilt fluid from the cylinder of the trim and til...

Page 355: ...llation tools Make sure all tools are free from nicks burrs and scratches Replace damaged tools Use of damaged components can result in leaks or incorrect operation of trim and tilt assembly Assembly...

Page 356: ...specified torque refer to SERVICE CHARTS on p 340 Assemble the piston as shown in the SERVICE CHARTS on p 340 Tighten fasteners to specified torque SERVICE CHARTS on p 340 Apply trim tilt fluid to the...

Page 357: ...If the edge of the loading mandrel is not flush with the top of the seal groove the wrong shim was selected Check shim selection and reinstall the mandrel Lubricate the mandrel with trim tilt fluid Us...

Page 358: ...lides past the seal groove Remove the pusher tool loading mandrel and shim from the piston Lift the resizing fixture up over the piston as shown Lift resizing fixture over the seal while observing the...

Page 359: ...op Leave enough room to pour fluid into the cylinder Fill the cylinder with Power Trim Tilt Steering Fluid Failure to fill the cylinder could cause difficulty purging air from the trim and tilt assemb...

Page 360: ...upler from either the motor or the pump assembly Installation IMPORTANT Use only Evinrude Johnson Bio degradable TNT Fluid to fill the hydraulic system Install drive coupler in pump assembly Install a...

Page 361: ...or then recheck oil level Cycle the unit several times and check the oil level when the cylinder is fully extended Oil should be level with bottom of fill port Install and tighten the fill plug to a t...

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

Page 363: ...3 14 MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 364 RECOIL STARTER REMOVAL 365 RECOIL STARTER DISASSEMBLY 365 RECOIL STARTER CLEANING AND INSPECTION 367 RECOIL STARTER ASSEMBLY 367 RECOIL STARTER...

Page 364: ...ERVICE CHART SERVICE CHART E Red Ultra Lock F Blue Nut Lock V Lubriplate 777 96 to 120 in lbs 11 to 13 5 N m V V F 60 to 84 in lbs 7 to 9 5 N m 120 to 144 in lbs 13 5 to 16 N m F 120 to 144 in lbs 13...

Page 365: ...le anchor and remove the han dle Release the slip knot and ease the rope back in until the rewind spring is fully unwound If nec essary remove the starter handle bracket from the starter housing Remov...

Page 366: ...ing and remove ring from the starter Remove the friction plates and friction plate spring washer Hold the pulley in the starter housing while turning the starter over legs down Hold fingers clear of t...

Page 367: ...to a length of 1 2 in 12 mm Examine the pulley and the starter housing Look for sharp edges and rough surfaces that could fray the starter rope File and polish to remove Examine the starter and starte...

Page 368: ...ts the starter winder base Remove the crank retainer screw and the crank and pin assembly from the starter winder base Remove the starter winder base from the vise Install the rewind spring into the s...

Page 369: ...77 to boss of the starter pawl Place spring washer on the boss of the starter pawl Place the starter pawl in the pulley Place the starter housing spring in the starter housing Install the starter pawl...

Page 370: ...ie a knot in one end of the starter rope With the starter housing upside down on a bench wind the pulley counterclockwise until the rewind spring is tight Back off the rewind spring until the rope cav...

Page 371: ...STALLATION Apply Nut Lock to the threads of starter ratchet screws Install washers and ratchet on flywheel Tighten screws to a torque of 120 to 144 in lbs 13 5 to 16 N m Place the starter assembly ont...

Page 372: ...372 MANUAL STARTER NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 373: ...SYSTEM AND SAFETY 8 OUTBOARD MOUNTING SYSTEM AND SAFETY 11 IF WEAKENED PARTS COULD FAIL LATER ON THE WATER WHEN NOT EXPECTED 12 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY 13 OUTB...

Page 374: ...S 2...

Page 375: ...self 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 recomme...

Page 376: ...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 377: ...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 378: ...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 379: ...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 380: ...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 381: ...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 382: ...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 and not in...

Page 383: ...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 384: ...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 385: ...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 386: ...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 387: ...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 388: ...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 389: ...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 390: ...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 391: ...st 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 conc...

Page 392: ...t 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 i...

Page 393: ...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 394: ...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 395: ...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 396: ...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 397: ...ecting Rod 213 Crankshaft 202 203 207 208 Driveshaft 305 330 Pinion Gear 301 325 Propeller Shaft 306 331 332 Wrist Pin 201 209 Break In EMM Programming 169 224 Gearcase 294 313 316 338 Oiling 169 Proc...

Page 398: ...ming 72 150 Fuel Injector Tests 88 Fuel Pump Test 88 I Command settings 27 Idle Speed Control 72 Oil Injector Test 171 Oil Priming 174 Oiling Rate 70 168 Reports 73 Sensor Monitoring 99 Service Codes...

Page 399: ...43 Fuel Filter 47 Fuel Lift Pump 136 143 145 147 Fuel Manifolds 149 Fuel Requirements 135 Hose Routing 130 Injector Servicing 72 Intake Manifold 154 Minimum Octane 10 12 14 135 Pressure Tests 141 Prim...

Page 400: ...48 254 256 261 Muffler Installation 223 Removal 196 Servicing 247 N New Engines Outboard Rigging Procedure 21 O Oetiker Clamp Servicing 29 Oil Injector Electrical Circuit 55 V 165 Electrical Tests 170...

Page 401: ...21 Rope Replacement 370 RPM Limit 11 13 15 63 64 S S A F E Description 66 Low Oil 62 No Oil 166 Temperature 60 61 Safety 1 Sensor Tests 99 Sensors Air Temperature Sensor 61 100 Barometric Pressure Sen...

Page 402: ...NO OIL Warning Signal 166 Outboard connections 24 Tests 111 112 113 Winterization Procedure 49 T Tachometer Pulse Setting 38 Technical Data 10 12 Temperature Operating 38 184 Operation below freezing...

Page 403: ...t P N 983213 354 Injector Puller Kit P N 356461 150 Injector Test Fitting Kit P N 5005844 142 Key Switch Assembly P N 176408 68 Large Puller Jaws P N 432129 203 305 306 330 331 Lifting Fixture P N 396...

Page 404: ...cal Circuit Tests 110 Inspection 344 Installation 350 Lubrication 45 Piston Seal and End Cap 354 Removal 348 Reservoir Fluid 11 13 344 Troubleshooting 344 345 Trim Gauge Test 347 Trim Sender Adjustmen...

Page 405: ...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 406: ...king 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 FUEL SYSTEM Low or no 55 V alter...

Page 407: ...heck primer bulb 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...

Page 408: ...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 409: ...IS and ELECTRICAL AND IGNITION Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS Restricted or leaking fuel injectors Check injectors refer to FU...

Page 410: ...up check for fuel system 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...

Page 411: ...tube 4 Cylinder block 5 Pressure valve 6 Thermostat 7 Water supply to EMM 8 Water supply EMM to vapor separator 9 Overboard indicator outgoing water from vapor separator 10 Water valve Hose Routing an...

Page 412: ...hot Incoming water cool 6 4 8 9 10 1 Intake water screens 2 Water pump 3 Water tube 4 Adaptor housing 5 Cylinder block 6 Pressure valve 7 Thermostat 8 Water supply to EMM 9 Water supply EMM to vapor...

Page 413: ...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 414: ...1 I Command 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 5 wa...

Page 415: ...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 416: ......

Page 417: ...ND 12V 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 WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASH...

Page 418: ...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 419: ...ition Sensor 3 Neutral Switch 4 Stator 5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Con...

Page 420: ...5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Connector 12 Temperature Sensor 13 Igniti...

Page 421: ...ure ABOVE range 3 3 LED 4 ON Running WATER TEMP HOT 8 seconds EMM Temperature 176 F 80 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running LOW BATTERY 5 minutes Bat...

Page 422: ...ltage 4 75 V Check sensors and related wiring Check for pinched or chafed wiring 81 Ignition timing circuit 1 OPEN LED 2 ON Running 10 instances EMM counts failed ignition events Check wiring Test wit...

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