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BRP Evinrude E-TEC Series Service Manual Download Page 93

ELECTRICAL AND IGNITION

CHARGING SYSTEM TESTS

91

6

CHARGING SYSTEM TESTS

Charging System Circuit Diagram

1. Marine battery

  6. Key switch connector

2. RED wire (POS)

  7. Fuse (10 amp)

3. BLACK wire (NEG)

  8. Stator

4. Starter solenoid

  9. 

EMM

5. Main harness ground

10. Battery charge module

007351

17 16 15 14 13 12 1

1 10

25 24 23 22 21 20 19 18

2  1

34 33 32 31 30 29 28 27 26

9  8  7  6  5  4  3  2  1

5

+

1

2

3

3

4

5

9

8

6

NEG

1

2

3

4

1

2

3

4

NEG

10

FUSE 

7

2  1

4

A B

Summary of Contents for Evinrude E-TEC Series

Page 1: ...Main Menu...

Page 2: ......

Page 3: ...ered trademark of The General Motors Corporation Locquic and Loctite are registered trademarks of The Henkel Group Lubriplate is a registered trademark of Fiske Brothers Refining Company NMEA is a reg...

Page 4: ...41 9 COOLING SYSTEM 157 10 POWERHEAD 167 11 MIDSECTION 197 12 GEARCASE 243 13 TRIM AND TILT 267 14 MANUAL STARTER 279 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1 DIAGRAMS IMPORTANT For complete outbo...

Page 5: ...ENT 6 LIST OF ABBREVIATIONS 6 EMISSION RELATED INSTALLATION INSTRUCTIONS 7 MANUFACTURER S RESPONSIBILITY 7 DEALER S RESPONSIBILITY 7 OWNER S RESPONSIBILITY 7 EPA EMISSION REGULATIONS 7 MODEL DESIGNATI...

Page 6: ...required always replace with a new one When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Use of subs...

Page 7: ...edly 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 c...

Page 8: ...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 9: ...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 10: ...T 3 R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex II 2011 MODEL RUN or SUFFIX DESIGN FEATURES B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injection G Graphite Paint H...

Page 11: ..._ 57 L 35 1 ci 13 28 0 46 H 20 White Manual Tilt Tiller Steering Electric Start Touch Troll E25DELII_ 57 L 35 1 ci 13 28 0 46 H 20 Blue Manual Tilt Remote Steering Electric Start E25DPLII_ 57 L 35 1 c...

Page 12: ...wo Cycle Displacement 35 1 cu in 575 cc Bore 2 992 in 76 mm Stroke 2 500 in 63 50 mm Standard Bore 2 9916 to 2 9931 in 75 989 to 76 026 mm To bore oversize add piston oversize dimension to standard bo...

Page 13: ...gnition Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1100 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label...

Page 14: ...nauti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No 12...

Page 15: ...T ADJUSTMENT 26 TRIM TAB ADJUSTMENT 27 OPERATIONAL CHECKS 28 COOLING SYSTEM 29 WATER INTAKE SCREENS 29 ENGINE FLUSHING 30 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 31 LUBRICATION 32 STEER...

Page 16: ...n any loosened components Water intake screens check condition Cooling system check water pump indicator Anticorrosion anodes check condition Gearcase check condition Propeller check condition Fuel an...

Page 17: ...f the hoist is at least twice the weight of the outboard DO NOT allow the lift hook or chain from the hoist to come in contact with any part of the engine during lifting Model Lifting Fixture 15 30 HP...

Page 18: ...ock Carefully lift engine with hoist To avoid damage to the outboard lift the outboard in one smooth motion DO NOT allow the outboard to bounce CAUTION To avoid damage to the outboard DO NOT allow the...

Page 19: ...ple Guard grease Cable Retainer Clip Installation When installing retainer clips on control arm link age pins clips should be locked and must not be bent or deformed For proper installation review the...

Page 20: ...les to avoid binding or chafing through all engine steering and tilting angles Control Cable Installation Refer to Control Cable Identification on p 17 Make sure the remote control is in NEUTRAL and t...

Page 21: ...and adjust the trunnion nut so the casing fits onto the throttle lever pin IMPORTANT Move control handle to FOR WARD and pull back slowly to NEUTRAL Make sure the engine throttle lever is against the...

Page 22: ...tie straps as shown Route trim and tilt connector under air silencer Use tie strap to secure connector as shown Install battery cables and secure with tie strap Route battery cable through grommet of...

Page 23: ...to 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 n...

Page 24: ...The clamp identification numbers appear on the side of the clamp near the top of the ear Refer to Clamp Selection chart for dimensions Clamp Selection To select the correct size Oetiker clamp measure...

Page 25: ...r 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 O...

Page 26: ...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 friction...

Page 27: ...tilting the tiller handle Neutral Switch Adjustment Adjust neutral switch as follows Make sure neutral switch is centered on shift lever detent Loosen two neutral switch bracket screws Center the neu...

Page 28: ...st be adjusted so that the gauge needle is aligned with the lowest gauge mark with the outboard trimmed all the way DOWN Check if the gauge needle is above or below the lowest gauge mark Tilt engine U...

Page 29: ...or right when its load is evenly distributed adjust the trim tab as follows With the remote control in NEUTRAL and the engine OFF loosen the trim tab screw If the boat pulled to the right move rear o...

Page 30: ...and restart outboard Shift to REVERSE Turn outboard OFF while con trol is in REVERSE Try to restart the outboard Outboard should not start Tachometer Pulse Setting SystemCheck Confirm accuracy of tach...

Page 31: ...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 SYSTEM Check the condition of cooling system...

Page 32: ...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 outboard...

Page 33: ...oles on each side of the gearcase with water proof tape to make sure enough water travels to the powerhead Water can drain from auxil iary inlets resulting in engine overheat A steady stream of water...

Page 34: ...t 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 T...

Page 35: ...heck proper throttle and shift function Propeller Shaft Debris from the water can become lodged around propeller shaft Frequent inspection can minimize potential gearcase damage Remove propeller Refer...

Page 36: ...of one hour to determine if there is an abnormal amount of water in the oil If water is present refer to GEARCASE LEAK TEST on p 247 Overheated lubricant will have a black color and burned odor Intern...

Page 37: ...Add Evinrude Johnson Biodegradable TNT Fluid as needed to bring level to the bottom of the fill plug threads Install the filler cap and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt...

Page 38: ...ramic 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 Tr...

Page 39: ...identify oiling 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...

Page 40: ...e coatings to anodes or anode fasteners Avoid using metal based antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface Th...

Page 41: ...n at idle speed After approximately 15 seconds move throttle to IDLE position Wait another 15 seconds At this point advance throttle to FULL in neutral EMM LEDs will flash indicating that outboard is...

Page 42: ...orage 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...

Page 43: ...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 44: ...42 ROUTINE SERVICE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 45: ...VER SERVICE 43 3 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 44 LATCH HOOK INSTALLATION 44 LOWER COVER SERVICE 45 LOWER COVER REMOVAL 45 LOWER COVER INSTALLATION 45 LATCH HANDLE INSTALL...

Page 46: ...pply Ultra Lock to screw threads Place latch into position with roller toward the front Tighten screws securely Front Insert bracket into pocket Apply Ultra Lock to screw threads Place hook into posit...

Page 47: ...tall fuel hose on fuel connector fitting Secure with new Oetiker clamp Place port cover on outboard If equipped route battery and trim cables through grommet opening Place starboard side cover into po...

Page 48: ...ining cover screws and tighten all screws to 24 to 36 in lbs 3 to 4 N m Install cable entry cover grommets cable entry cover and cable entry cover screws Tighten screws to 24 to 36 in lbs 3 to 4 N m I...

Page 49: ...coat of Triple Guard grease to latch handle shaft Insert handle into lower cover Apply Ultra Lock to screw threads Place spring washer and hook into position and tighten screw to a torque of 180 in l...

Page 50: ...48 ENGINE COVER SERVICE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 51: ...54 LOW OIL SWITCH 54 THROTTLE POSITION SENSOR 55 CRANKSHAFT POSITION SENSOR 55 NEUTRAL SWITCH 55 INTERNAL EMM FUNCTIONS 56 ENGINE MONITOR SYSTEM 56 S A F E WARNING SYSTEM 57 SHUTDOWN MODE 58 DIAGNOST...

Page 52: ...RPM profile and engine hours Oiling ratios 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 wit...

Page 53: ...S 5 Throttle Position Sensor TPS 6 Neutral Switch 7 Air Temperature Sensor AT 8 Oil Level Switch 9 Engine Temperature Sensor 10 Ignition Coil 11 Fuel Injector 12 Diagnostic Connector 13 Oil Injection...

Page 54: ...to SHUTDOWN MODE on p 58 If EMM temperature is less than 22 F 30 C or the circuit fails the EMM If sensor reads less than 71 F 57 4 C or greater than 313 F 156 C a sensor circuit fault is detected an...

Page 55: ...Use Evinrude Diagnostics software to troubleshoot the sensors Refer to the EMM Service Code Chart at the back of this manual for a complete list of all engine fault codes The EMM provides a 5 V DC sig...

Page 56: ...er LOW OIL is displayed the EMM counts oil pump pulse cycles again When it reaches 6700 pulses the EMM To recover from S A F E mode Oil level must be above one quarter The warning resets after three o...

Page 57: ...his signal to identify crankshaft posi tion and speed generate a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 occurrences the EMM A...

Page 58: ...engine speed is limited to 1100 RPM Engine Monitor and Warning Systems Refer to ENGINE MONITOR SYSTEM on p 56 Refer to S A F E WARNING SYSTEM on p 57 Refer to SHUTDOWN MODE on p 58 Fault Code Creation...

Page 59: ...ht remains ON until the key is turned OFF or the failure is cor rected The warning will reoccur at the next start up if the problem is not corrected S A F E WARNING SYSTEM The S A F E Speed Adjusting...

Page 60: ...tores valuable information about the outboard and its running history This information can be used for troubleshooting for checking parts information and for making adjustments to the system Use Evinr...

Page 61: ...teries will produce false results Use Accessory Power Cable Kit P N 5008092 to connect an external 12 volt battery to the Power Supply Tool when performing these static tests Fuel pump Fuel injector I...

Page 62: ...red 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 Faul...

Page 63: ...p 78 Tachometer This test is used to check operation of the tachom eter circuit Dynamic Tests Dynamic tests are performed with the outboard running Ignition Test This test momentarily disables the ign...

Page 64: ...se the XD100 setting for Conventional use runabouts cruisers Moderate applications Powerhead Break In Use the diagnostics software to start break in oil ing after a powerhead rebuild The break in oili...

Page 65: ...d replacement Crankshaft replacement Flywheel removal or replacement CPS replacement EMM replacement EMM software replacement IMPORTANT Make sure the outboard reaches operating temperature before maki...

Page 66: ...ace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Vapor Separator and Fuel Injector Service on p 132 Reports Engine reports provide service recor...

Page 67: ...refer to the instructions provided with the program IMPORTANT Software replacement requires a Bootstrap Tool P N 586551 EMM Transfer EMM Transfer is used to save engine history data when the EMM must...

Page 68: ...hen performing the following tasks Make sure isolator mount is in place on recoil starter housing Slide pin at rear EMM into posi tion on isolator mount IMPORTANT Turn self tapping screws counter cloc...

Page 69: ...AMP METER TEST 70 EMM LED INDICATORS 71 KEY ON 71 STARTING 71 RUNNING 72 IGNITION OUTPUT TESTS 73 REQUIRED IGNITION SYSTEMS 73 WIRING INSPECTION 73 CRANKSHAFT POSITION SENSOR CPS TEST 74 SYSTEM VOLTA...

Page 70: ...ppearance of 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 Inspe...

Page 71: ...dicators for system sta tus information Refer to EMM LED INDICA TORS on p 71 Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS volt ages System voltage should be steady...

Page 72: ...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 disabl...

Page 73: ...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 OKAY in...

Page 74: ...LIGHT ON check for possible fault codes Code 12 TPS circuit fault Code 13 TPS below expected range Code 14 TPS above expected range Code 16 CPS intermittent loss of sync Code 23 EMM temp sensor circu...

Page 75: ...ovides EMM with input Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated Alternator Output System Voltage System voltage from EMM white red provides 55 VDC to the high pressu...

Page 76: ...e 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...

Page 77: ...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 consis...

Page 78: ...age and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 78 Inspect for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace s...

Page 79: ...black meter lead to pin 1 and repeat test to confirm harness ground Harness resistance test If control signal is NOT present calibrate multime ter to low ohms scale Use appropriate adapters on meter...

Page 80: ...nuity 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 Ref...

Page 81: ...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 82: ...80 SYSTEM ANALYSIS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 83: ...H TESTS 98 KEY SWITCH TEST 98 NEUTRAL START CIRCUIT TEST 98 NEUTRAL START SWITCH TEST 99 EMERGENCY STOP SWITCH TEST 99 TILT TRIM RELAY TEST 100 SYSTEMCHECK CIRCUIT TESTS 101 TACHOMETER CIRCUIT TESTS 1...

Page 84: ...6 in lbs 9 5 to 12 N m F 60 to 84 in lbs 7 to 9 5 N m IMPORTANT DO NOT lubricate TPS to throttle shaft surface 31 to 48 in lbs 3 5 to 5 5 N m F 60 to 84 in lbs 7 to 9 5 N m A Triple Guard Grease B Gas...

Page 85: ...head is seated F 31 to 49 in lbs 3 5 to 5 5 N m F 31 to 48 in lbs 3 5 to 5 5 N m F 10 to 12 ft lbs 14 5 to 16 5 N m 60 to 84 in lbs 7 to 9 5 N m N A Triple Guard Grease B Gasket Sealing Compound C Ad...

Page 86: ...2 1 3 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 34 33 32 31 30 29 28 27 26 9 8 7 6 5 4 3 2 1 1 2 3 1 2 3 8 1 2 5 1 2 3 4 4 3 4 1 7 2 7 1 6 NEG 2 3 1 2 3 Key switch stop circuit Tiller handle sto...

Page 87: ...il solenoid Blue 3 Switched B to EMM Purple 4 Crankshaft position sensor CPS Yellow 5 Injector cylinder 2 Green 6 Injector cylinder 1 Blue 7 System Ground Black 8 System Ground Black 9 Stator winding...

Page 88: ...terminal pins 7 and 8 of the EMM con nector and the main harness ground Sensor circuit grounds Check continuity between terminal pin 29 of the EMM connector and the appropriate sensor ground connecti...

Page 89: ...on sensor Use a digital multimeter to measure sensor resis tance between the yellow and white wires The complete circuit can be tested by measuring between pins 4 and 12 of the EMM connector The CPS i...

Page 90: ...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 91: ...calibrated 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 m...

Page 92: ...n connector from the engine harness 6 pin connector Connect Stator Test Adaptor tool P N 354719 to stator connector Connect meter leads to terminals of adaptor tool Rotate the flywheel with the starte...

Page 93: ...y 6 Key switch connector 2 RED wire POS 7 Fuse 10 amp 3 BLACK wire NEG 8 Stator 4 Starter solenoid 9 EMM 5 Main harness ground 10 Battery charge module 007351 17 16 15 14 13 12 11 10 25 24 23 22 21 20...

Page 94: ...odule and the positive B battery cable terminal of starter solenoid Fluke model 334 or 336 Snap On model MT110 or EETA501 and various other amp meters should be available through local tool suppliers...

Page 95: ...heck stator and alternator circuit BEFORE replacing the battery charge module Refer to STATOR TESTS on p 89 and 55 V Alternator Circuit on p 93 55 V Alternator Circuit Check battery ground cable for c...

Page 96: ...A S C M B 1 2 3 4 5 6 8 9 13 1 2 3 1 Marine battery 10 Battery charge module connector 2 RED wire POS 11 Engine Management Module EMM 3 BLACK wire NEG 12 YELLOW RED wire start 4 Starter solenoid 13 Y...

Page 97: ...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 98: ...terminal 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 resi...

Page 99: ...rter 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 suitab...

Page 100: ...d 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 contin...

Page 101: ...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 102: ...B connec tion to TNT motor Terminals 87 and 30 are 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 Diagr...

Page 103: ...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 and terminal 2 black wire If...

Page 104: ...key switch ON Using a jumper wire con nect tan black wire pin 4 of the engine harness connector to a clean engine ground The LOW OIL light should turn on after 40 seconds If the LOW OIL light does no...

Page 105: ...Hz replace tachome ter If meter reads low or no signal confirm output on gray wire at pin 24 of EMM J1 A connector Reading OK Check condition of tachometer circuit gray wire Repair as needed Reading n...

Page 106: ...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 harness connector...

Page 107: ...y wheel removal or replacement Refer to TIMING ADJUSTMENTS on p 106 IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis connect ignition coil electrical con...

Page 108: ...ming 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 the EM...

Page 109: ...r bearings and commutator Disconnect the battery cables at the battery Remove lower motor covers Refer to Lower Cover Removal on p 45 Remove the starter positive cable from post on starter Remove thre...

Page 110: ...e any trace of oil or metal dust from commutator Check the armature on a growler for shorted turns using a test light or meter Inspect armature insu lation for indications of overheating or damaged wi...

Page 111: ...ew Lock to the brush card screws before installing Place armature in frame Apply Moly Lube to the armature bushing Route the brush leads and install the springs and brushes IMPORTANT Incorrect orienta...

Page 112: ...f starter pinion shaft with Starter Bendix Lube DO NOT use liquid or aerosol spray lubricants Install pinion spacer and spring Install spacer and retaining nut Tighten nut to a torque of 20 to 24 ft l...

Page 113: ...Electrical Grease is recom mended Incorrect grease application can cause electrical or warning system problems To disconnect the connector press the latch and pull the connectors apart To connect the...

Page 114: ...in 14 16 gauge notch of crimping pliers AMP Connectors IMPORTANT Always use the appropriate meter test probes and adapters when testing compo nents fitted with these terminals Electrical grease is NOT...

Page 115: ...N 777281 SUPER SEAL The J1 A connector of the EMM is an AMP Super Seal connectors Disconnect Depress BOTH latches and pull connector from plug Connect Push connector into plug until latches engage Te...

Page 116: ...erminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gasket on wires and feed wires through the correc...

Page 117: ...UEL INJECTORS 124 FUEL SYSTEM PRIMING 125 VENT LINE CLAMP 125 PRIMING THE FUEL SYSTEM 125 FUEL SYSTEM TESTS 126 FUEL SYSTEM PRESSURE TEST 126 VAPOR SEPARATOR VENT CHECK 127 FUEL INJECTOR PRESSURE TEST...

Page 118: ...lbs 12 2 N m 14 ft lbs 19 N m 22 to 23 5 ft lbs 30 to 32 N m A F 31 to 48 in lbs 3 5 to 5 5 N m F 84 to 106 in lbs 9 5 to 12 N m S 007406 Tighten in 4 stages A Triple Guard Grease B Gasket Sealing Co...

Page 119: ...s 1 8 to 2 N m F 84 to 106 in lbs 9 5 to 12 N m Tighten until screw head is seated C E 35 to 60 in lbs 4 0 to 6 8 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red U...

Page 120: ...vapor separator Fuel filter Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply to injectors internal passage Fuel injector s Fuel return to vapor separator internal passage Pressu...

Page 121: ...2 3 Stator EMM Fuel injector 4 5 6 Fuel circulation pump WHITE RED 55 V BLACK ground wires 7 8 9 BLUE GREEN BROWN 008046 2 1 1 2 1 2 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 34 33 32 31 30 29...

Page 122: ...ge 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 of...

Page 123: ...damage 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 c...

Page 124: ...pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure components of the fuel system from contaminants Refer to INSPEC...

Page 125: ...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 consis tent fuel pressure in the fuel system...

Page 126: ...ch injector and its location on the outboard is identified by the EMM DO NOT install an injector without updating the compensa tion software Each service injector includes its fuel flow infor mation o...

Page 127: ...hose connector to the quick con nect fitting on the outboard Use the primer to fill the vapor separator The high pressure fuel circuits and injectors will prime as the outboard is cranked with the sta...

Page 128: ...upply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying enough fuel to vapor separator Refer to Lift Pump Pressure Test on p 128 If the above tests ar...

Page 129: ...ting Secure with tie strap Pressurize the injector to 30 psi 207 kPa Pres sure must hold for at least five minutes Refer to FUEL DELIVERY TESTS on p 78 for additional test procedures Fuel Injector Res...

Page 130: ...mal pressure Perform the Lift Pump Vacuum Test on p 129 Make sure no air leaks or restrictions exist in the fuel supply hose or boat fuel system Low pressure Check pulse hoses and fittings for restric...

Page 131: ...ceeding There should be no air or vapor bubbles visible in the clear hose The maximum inlet fuel vacuum should not exceed 4 in Hg 13 5 kPa at the inlet to the fuel lift pump under any operating condi...

Page 132: ...ical connector If outboard runs start and run at IDLE for 5 sec onds and STOP outboard If outboard does NOT run crank for 10 seconds Disconnect the battery cables at the battery 1 Anti siphon valve 2...

Page 133: ...the battery Remove filter carefully to prevent spilling contents Inspect contents for any presence of water If water is present identify the source and correct the problem Take additional fuel samples...

Page 134: ...t the fuel hoses to the fuel pump Secure with Oetiker clamps Place fuel pump in position on the oil tank Secure the fuel pump with new pushnuts P N 354365 Be sure fuel hoses are routed in channels on...

Page 135: ...in the correct cylinder locations Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning The Injector Coefficients screen displays injector serial numbers fo...

Page 136: ...read adaptor and stud into face of injector Hold mounting cup securely Use slide hammer to sep arate injector from mount housing Remove adaptor from injector Remove crush ring and O rings from injecto...

Page 137: ...icient Files to EMM Use the Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM Select the Injectors tab Select the cylinder tab for injector being replaced Select...

Page 138: ...during assembly Place injector and insulator in the proper cylinder location Temporarily install injector screws finger tight Position fuel injector wiring vapor separator wiring and electrical connec...

Page 139: ...e is 14 ft lbs 19 N m Final torque is 22 to 23 5 ft lbs 30 to 32 N m Tighten vapor separator to powerhead mounting screw to 29 to 48 in lbs 3 3 to 5 5 N m I Install fuel supply hose Secure with Oetike...

Page 140: ...nostics software to run fuel pump Observe for fuel leaks Run outboard and check for fuel leaks IMPORTANT Pay close attention to fuel vapor separator fuel injector connection for leaks Repair any leaks...

Page 141: ...mbly Inspection Inspect the leaf plate assemblies for damage or contamination Leaf plates must not be distorted Leaf valve must not be cracked or chipped Leaf plate stops must not be distorted or loos...

Page 142: ...Install throttle body on reed plate and install new screws IMPORTANT If old screws must be re used make sure all previous thread locking material is removed and apply Nut Lock to threads Tighten the...

Page 143: ...V 147 LOW OIL WARNING 147 NO OIL WARNING 147 CYLINDER AND CRANKCASE 148 OIL RECIRCULATION SYSTEM 148 OIL CONTROL SETTINGS 149 OIL INJECTION RATE 149 BREAK IN OILING 150 OIL SUPPLY PRIMING 150 OILING S...

Page 144: ...g F 31 to 48 in lbs 3 5 to 5 5 N m X Tighten until screw head is seated A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant X Se...

Page 145: ...oard 7 9 4 5 Oil supply to crankcase Oil supply to cylinder block Cylinder 1 oil lines Cylinder 2 oil lines Oil supply to crankcase Oil supply to cylinder block Rope Start Models ONLY J Clamp crankcas...

Page 146: ...144 OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM 007316...

Page 147: ...LACK WHITE RED wires 55 V EMM injector control BLUE Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK MWS Connector EMM 008047 A B 17 16 1...

Page 148: ...r capacity The LOW OIL warning should not display Failure to follow these recommen dations could void the outboard warranty if a lubrication related failure occurs COMPONENTS The oiling system include...

Page 149: ...proximate oil reserve at Low Oil activation 0 375 qt 0 35 l NO OIL Warning After LOW OIL is displayed the EMM counts oil pump pulse cycles again When it reaches 6700 pulses the EMM To recover from S A...

Page 150: ...trolled by check valves 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 uppe...

Page 151: ...an option to run the outboard at a reduced oil injection rate This set ting REQUIRES the use of Evinrude XD100 out board lubricant and is not recommended for all applications IMPORTANT The XD100 sett...

Page 152: ...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 153: ...ly This will produce false results Refer to Communication on p 58 The EMM controls the pump by providing ground through pin 2 blue wire of the J1 A connector and pin A blue wire of the oil pump connec...

Page 154: ...ve meter lead to pin B white red wire of oil injection pump electrical connector Observe voltage at pin B Voltage at pin B should be approximately 12 V Set digital multimeter to a scale that reads 55...

Page 155: ...ly inserted into manifold Refer to Oil Distribution Hoses on p 154 Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remo...

Page 156: ...8 in 16 mm Visually inspect for hose supports Oil distribution hoses have specific locations and routing DO NOT alter the location of any hoses The oil distribution manifold includes a built in hose...

Page 157: ...ct the electrical connector to the low oil switch IMPORTANT Note oil distribution hose rout ings before proceeding with disassembly Remove oil distribution hoses from the manifold Remove oil tank reta...

Page 158: ...oil distribution hoses Check oil system operation and routing of oil sys tem hoses Repair any oil leaks and kinked or misrouted hoses Install engine covers Oil Injection Pump Removal Remove oil distr...

Page 159: ...OPERATION 161 CYLINDER BLOCK CYLINDER HEAD COOLING 161 VAPOR SEPARATOR EMM AND BATTERY CHARGE MODULE COOLING 161 ENGINE TEMPERATURE CHECK 162 SOFTWARE METHOD 162 PYROMETER METHOD 162 IDLE OPERATING TE...

Page 160: ...6 7 8 10 9 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Exhaust housing Cylinder block Pressure relief valve Thermostat Water supply to...

Page 161: ...housing with liner must seal against a separate water pump plate The bottom plate MUST seal to gearcase Refer to WATER PUMP SERVICE on p 250 for servicing IMPORTANT The water pump housing includes a...

Page 162: ...stricted or faulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing completely Thermostat The thermostat controls water flow and operating temper...

Page 163: ...ng and then out of the outboard At higher speeds water pressure opens the pressure relief valve at approximately 2800 RPM Water flows through the valve to the cylinder head and bypasses the thermostat...

Page 164: ...shoot cooling system Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature sensor readings at IDLE speed should be 167 F 5 F 73 C 3 C Typical temperature...

Page 165: ...ssure 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...

Page 166: ...LOWLY 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 THERMOSTAT...

Page 167: ...orming the following additional tasks Install a new plunger seal on plunger Apply a light coat of Gasket Sealing Compound to a new o ring and place in groove in plate Install thermostat gasket thermos...

Page 168: ...166 COOLING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 169: ...LINDER BORE 178 PISTONS 179 PISTON RINGS 179 POWERHEAD ASSEMBLY 179 CRANKSHAFT ASSEMBLY 179 PISTONS AND CONNECTING RODS 181 CRANKSHAFT ASSEMBLY INSTALLATION 182 CRANKCASE ASSEMBLY 183 CYLINDER HEAD IN...

Page 170: ...al Grease M RTV Sealant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease F 84 to 106 in lbs 9 5 to 12 N m E H 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft l...

Page 171: ...10 H H B D B H D D H H A 007739 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 Permatex No 2 Q Gel Seal II...

Page 172: ...linder head damaged 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 36 POW...

Page 173: ...th hoist Remove the two exhaust housing to powerhead nuts and six exhaust housing to powerhead screws Use a suitable tool to carefully separate the pow erhead from exhaust housing IMPORTANT Do not dam...

Page 174: ...must be installed in their original location Improper injector installa tion can result in powerhead failure Remove ignition coils Remove the electric starter Refer to Starter Removal on p 107 Remove...

Page 175: ...y from the crankcase Cylinder Head Removal Loosen in stages and remove cylinder head retaining screws Remove the cylinder head Dis card cylinder head gasket Crankcase Disassembly Remove screws and exh...

Page 176: ...val Carefully lift crankshaft straight up and remove from crankcase Connecting Rods and Pistons Use an appropriate ring expander to remove all piston rings from pistons Discard the rings Remove wrist...

Page 177: ...Remove upper seal from crankshaft Discard the seal A new upper seal must be installed on assembly Remove the upper main bearing Remove the lower bearing seal housing Remove the housing O ring Discard...

Page 178: ...essary To remove the sleeve use Slide Hammer P N 432128 and Puller Jaws P N 432130 Remove the lower main bearing only if it needs to be replaced Use external retaining ring pliers to remove the lower...

Page 179: ...Gel 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...

Page 180: ...age Bearings Inspect upper and lower main bearings for excess wear nicks or scratches Replace if necessary Cylinder Bore Use a Cylinder Bore Gauge to inspect each cylin der bore for an out of round ov...

Page 181: ...edge against the side of the piston Rings must be even or just below the surface of piston Rings must move freely in piston ring groove POWERHEAD ASSEMBLY IMPORTANT Proceed slowly Make no forced assem...

Page 182: ...lower hous ing seal with Gasket Sealing Compound Press against outer case of the seal to install seal in the lower housing with extended lip facing down Lubricate seal lip with Moly Lube Install a new...

Page 183: ...Apply outboard lubricant to the wrist pin bearings wrist pin and wrist pin bore Install the bearings in the small end of the connecting rod Place the piston over the connecting rod and bearings Insta...

Page 184: ...that all Gel Seal II has been removed from the cylinder block and crankcase mating flanges If traces of hardened Gel Seal II are left main bearings could be misaligned Refer to CYLINDER BLOCK CLEANING...

Page 185: ...PORTANT Gel 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 cau...

Page 186: ...block Apply Nut Lock to cover screws Tighten all screws in sequence to a torque of 84 to 106 in lbs 9 5 to 12 N m Cylinder Head Installation Apply soapy water to water dam and insert into block Place...

Page 187: ...k as shown Place a new gasket on the powerhead Apply Nut Lock to screws Install exhaust megaphone and secure with three screws Tighten screws to a torque of 84 to 106 in lbs 9 5 to 12 N m Apply Nut Lo...

Page 188: ...ever and shaft assembly Guide shaft through bushings in crankcase IMPORTANT Shift lever and shaft must be positioned with pin toward the rear of the cylinder block Install shift lever and detent on sh...

Page 189: ...and pressure valve assembly Refer to THERMOSTAT AND PRESSURE RELIEF VALVE SERVICING on p 164 Install electrical harness Install fuel injectors and ignition coils Refer to Fuel Injector Vapor Separato...

Page 190: ...wise direction to align crankshaft and driveshaft splines Apply Triple Guard grease to the threads of the powerhead screws Loosely install all powerhead screws before tight ening Tighten the eight pow...

Page 191: ...ower Cover Installation on p 45 Shift Linkage Adjustment Adjust shift linkage as follows STEP 1 Move shift lever into neutral position Make sure shift lever detent is in neutral posi tion Make sure ge...

Page 192: ...before returning outboard to service Index all spark plugs Refer to Spark Plug Indexing on p 36 Use Evinrude Diagnostics software to start pow erhead break in oiling Refer to Powerhead Break In on p 6...

Page 193: ...191 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS Port Electric Start Models Starboard Electric Start Models 008359 008278...

Page 194: ...192 POWERHEAD POWERHEAD VIEWS Port Rope Start Models Starboard Rope Start Models 008430 008431...

Page 195: ...193 POWERHEAD POWERHEAD VIEWS 10 Front 007809...

Page 196: ...194 POWERHEAD POWERHEAD VIEWS Rear 007810...

Page 197: ...195 POWERHEAD POWERHEAD VIEWS 10 Top 008280...

Page 198: ...196 POWERHEAD NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 199: ...207 STERN BRACKET POWER TILT MODELS 208 STERN BRACKET DISASSEMBLY POWER TILT 208 STERN BRACKET ASSEMBLY POWER TILT 210 TRIM SENDING UNIT REMOVAL 214 TRIM SENDING UNIT INSTALLATION 215 STERN BRACKET MA...

Page 200: ...0 to 84 in lbs 7 to 9 5 N m A A A A A A 35 to 61 in lbs 4 to 7 N m E 144 to 168 in lbs 16 to 19 N m 10 to 16 in lbs 1 to 2 N m A A X 40 to 45 ft lbs 54 to 61 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36...

Page 201: ...19 N m 60 to 84 in lbs 7 to 9 5 N m A X 40 to 45 ft lbs 54 to 61 N m A 10 to 16 in lbs 1 to 2 N m 60 to 84 in lbs 7 to 9 5 N m 35 to 61 in lbs 4 to 7 N m A A A A A A A A Use Triple Guard grease on al...

Page 202: ...N m E 60 to 84 in lbs 7 5 to 9 N m A A 18 to 20 ft lbs 24 5 to 27 N m 18 to 20 ft lbs 24 5 to 27 N m 24 to 36 in lbs 2 7 to 4 1 N m 35 to 61 in lbs 4 to 7 N m 35 to 61 in lbs 4 to 7 N m A A A 84 to 1...

Page 203: ...lbs 14 5 to 16 5 N m A 22 to 23 ft lbs 30 to 32 N m A 10 to 12 ft lbs 14 5 to 16 5 N m E 10 to 12 ft lbs 14 5 to 16 5 N m 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft lbs 14 5 to 16 5 N m 10 to 12 f...

Page 204: ...in lbs 2 2 to 3 4 N m V X 11 to 18 in lbs 1 2 to 1 9 N m X 9 to 15 in lbs 1 to 1 7 N m X X 26 to 28 ft lbs 35 to 38 N m A 36 to 60 in lbs 4 1 to 6 8 N m A X 18 to 24 in lbs 2 to 2 7 N m 10 to 20 ft lb...

Page 205: ...pper mounts Remove washers from lower mounts Remove the exhaust housing Remove lower mount bracket rubber mount Check condition of the lower front mount Replace if deteriorated or damaged Exhaust Hous...

Page 206: ...exhaust housing screws Remove mount Check condition of the mounts Replace if deterio rated or damaged Installation Apply Triple Guard grease to threads of the two mount to exhaust housing screws Inst...

Page 207: ...ays aligned with pin as screw is tight ened Lower mount Apply Triple Guard grease to threads of the lower mount screws Install rubber bumper and washer Install screw through lower mount Tighten screw...

Page 208: ...move overboard indicator grommet from muf fler Remove Oetiker clamp Install muffler drain hose on new muffler with tie strap Install muffler drain hose through hole Secure muffler with new Oetiker cla...

Page 209: ...aust housing only if studs are loose Installation If studs are removed clean threads with cleaning solvent Apply Ultra Lock to upper threads of studs Install studs and tighten to a torque of 10 to 12...

Page 210: ...ing screws Use a soft mallet to remove lower mount bracket and thrust washer If equipped with a steering friction device remove the steering friction nut Slide the steering arm out of the swivel brack...

Page 211: ...se the outboard and engage the tilt support Remove the electrical connector from the trim sending unit Refer to CONNECTOR SERVICING on p 111 Remove the trim tilt cable connector Refer to TRIM AND TILT...

Page 212: ...ion of the anode Replace the anode if it has been reduced to two thirds its origi nal size Stern Bracket Assembly Power Tilt Assemble stern and swivel brackets with tilt tube nuts tilt tube bushings t...

Page 213: ...l bushings in hydraulic unit Position hydrau lic unit between stern brackets and install the angle adjustment rod Place the ground lead between the port stern bracket and tie bar as shown Assemble the...

Page 214: ...iple Guard grease to the outside of the upper and lower bushings Install the upper and lower bushings in the swivel bracket Use Seal Installation tool P N 350958 to install new upper and lower seals i...

Page 215: ...wn Install locking nut Temporarily tighten locking nut three to four full turns Final adjustment will be performed later Apply Triple Guard grease to both sides of thrust washer Install thrust washer...

Page 216: ...CE on p 203 Install tiller handle Refer to TILLER HANDLE SERVICE on p 227 Adjust tiller steering friction Refer to Steering Friction Adjustment on p 24 Trim Sending Unit Removal Remove two screws Remo...

Page 217: ...ender electrical connector on harness Refer to CONNECTOR SERVICING on p 111 Install tie straps on cable clamp and harness IMPORTANT Operate trim unit and make sure the wiring harness will not be damag...

Page 218: ...crew and allow it to dry four to five minutes Then apply Ultra Lock to threads Install shoulder screw and swivel plate onto clamp screw and handle assembly Tighten screw to a torque of 60 to 84 in lbs...

Page 219: ...ut of the swivel bracket and remove the thrust washer Remove the steering friction lever washers and plate Use an appropriate tool to pry the upper and lower seals from the swivel bracket 1 Mallet 2 L...

Page 220: ...move the tilt pin two tie bar screws and tie bar Remove nuts washers and pins from stern brack ets Remove tilt tube nuts tilt tube bushings thrust washers handle and stern brackets 1 Friction plate 2...

Page 221: ...n lever in the RUN position Loosen the bellcrank setscrew Push down on link Unhook reverse lock release rod from pin and remove rod from bellcrank Remove the bellcrank tilt lock lever and port stop li...

Page 222: ...move the shallow water drive link and reverse lock assembly from the swivel bracket Remove cotter pins and disassemble shallow water drive and reverse lock assembly as needed If tilt lock assembly req...

Page 223: ...el bracket when pressing in bushings Assemble reverse lock link and reverse lock lever as shown Install pin and secure with new cotter pin Place pin through the shallow water drive link as shown Secur...

Page 224: ...RTANT Make sure the rounded end of the spring is installed as shown Use an appropriate tool to hook the straight end over the pin as shown Install the tilt lock lever and port stop link in the swivel...

Page 225: ...e two reverse lock springs to the reverse lock lever Use an appropriate tool to connect the reverse lock springs to the top of the swivel bracket Install tilt tube bushings thrust washers handle and s...

Page 226: ...tilt pin Tighten the tilt tube nuts to a torque of 40 to 45 ft lbs 54 to 61 N m then back off 1 8 to 1 4 turn Install friction screw and spring in swivel bracket Apply a light coat of Triple Guard gr...

Page 227: ...he steering friction plate washers and lever Apply Triple Guard grease to both sides of thrust washer Install thrust washer on steering arm Slide the steering arm through the swivel bracket Align slot...

Page 228: ...sides of thrust washer Install thrust washer on steering arm Install lower mount bracket on steering arm Install lower mount retaining screws Tighten screws to a torque of 10 to 12 ft lbs 14 5 to 16 5...

Page 229: ...sher from shift lever pin and remove shift cable connector from shift lever pin Remove cable anchor screw and washer from shift cable retainer Remove locknuts from screws on bottom of steering arm Rem...

Page 230: ...ORTANT Do not back screw out com pletely Nut is under spring tension Remove eight screws and bottom cover of tiller handle Remove shift handle screw and shift handle Remove stop switch screws Loosen s...

Page 231: ...Remove shift cable retainer Remove screw and washer from shift link Remove shift cable and shift link Remove cotter pin from shift link and remove shift cable Remove four shift lever bracket retaining...

Page 232: ...l switch and bracket 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 Pull the throttle pin ou...

Page 233: ...ully pry the trim switch out of the twist grip Remove the throttle friction control Remove nut washer and bushing from port side of tiller handle Remove steering handle screw Remove base from tiller h...

Page 234: ...omponents for wear cracks or damage Replace parts if necessary Refer to Emergency Stop Switch Test on p 99 to test stop switch Assembly Install bracket on handle Install four screws Tighten screws sec...

Page 235: ...wo bushings in base Hook spring to roll pin and recess in base as shown Turn tilt release lever one turn to apply tension to the spring Hold lever in position and install base in bracket Make sure spr...

Page 236: ...ion control Press the trim switch into the twist grip Be sure trim switch UP position aligns with the twist grip indicator line as shown Install trim switch wiring through inner steering handle IMPORT...

Page 237: ...ng for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Make sure trim switch wiring is NOT twisted before proceeding Install the throttle cable Install the throttle pin...

Page 238: ...switch wires through inner tiller handle as twist grip assembly is installed Be sure the twist grip s speed indicator line is positioned with the speed range symbol on the handle Snap the grip into pl...

Page 239: ...rely Install shift lever assembly Install four shift lever bracket retaining screws Tighten screws securely Install shift link and cable on shift lever Apply Ultra Lock to threads of screw and install...

Page 240: ...nut securely Install stop switch housing spring but ton and stop switch Secure with two screws Tighten screws securely Route shift and throttle cables and wiring harness as shown Install bottom cover...

Page 241: ...set to center or angled to port or starboard 20 Install rear washer and screw in appropriate loca tion Tighten both screws to a torque of 18 to 20 ft lbs 25 to 27 N m Install locknuts on screws Hold...

Page 242: ...eaded cable ends to make cable adjustments Shift Cable Adjustment Secure shift cable to the shift lever pin For proper installation review the following steps Place washer on pin Position retainer cli...

Page 243: ...ign Install washer between anchor and trunnion bracket Install screw Tighten screw to a torque of 84 to 106 in lbs 9 5 to 12 N m Throttle Cable Adjustment Install throttle cable connector with Ball So...

Page 244: ...toward the end of the cable Install washer between anchor and boss Install screw Tighten screw to a torque of 84 to 106 in lbs 9 5 to 12 N m IMPORTANT Rotate twist grip Make sure throt tle cam goes t...

Page 245: ...SHAFT BEARING HOUSING REMOVAL 254 SHIFTER GEAR AND PROPELLER SHAFT REMOVAL 255 BEARING AND SEAL REMOVAL 256 DRIVESHAFT SEALS 256 DRIVESHAFT BEARING 256 PINION BEARINGS 257 FORWARD BEARING 257 SHIFT R...

Page 246: ...lbs 1 1 to 1 6 N m 60 to 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m C 60 to 84 in lbs 7 to 9 5 N m D 60 to 84 in lbs 7 to 9 5 N m A B A B C A 120 to 144 in lbs 13 5 to 16 N m 007679 A Triple...

Page 247: ...load condi tions will allow the engine to run near the mid point of the RPM operating range at full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blades have too much pitch the eng...

Page 248: ...rts and Accessories Catalog for cor rect propeller hardware Apply Triple Guard grease to the entire propeller shaft before installing the propeller Install thrust bushing onto propeller shaft with tap...

Page 249: ...7 mm Hg with pump If vacuum gauge indicates leakage apply oil around suspected seal If leak stops or oil is drawn in seal is defective Repeat test gearcase must hold minimum of 15 in vacuum 381 mm Hg...

Page 250: ...because lubricant may prevent seating of the driveshaft in the crankshaft WARNING To prevent accidental starting while ser vicing twist and remove all spark plug leads During service the outboard may...

Page 251: ...6 5 N m Align the groove in the upper shift rod with the screw hole in the connector Apply Gasket Sealing Compound to threads of the shift rod connector screw Tighten screw with washer to a torque of...

Page 252: ...eller for overheating hub separation and other wear or damage Check liner and wear plate for scoring distortion and impeller material transfer Inspect the housing for cracks or melting Make sure gaske...

Page 253: ...IMPORTANT The sharp edge of key slot in the impeller is the leading edge during rotation Apply Adhesive 847 to the outer seal groove of the impeller housing Install a new seal into the groove Lightly...

Page 254: ...ound Place gasket on the gearcase Place the impeller plate over the gasket Slide the driveshaft down into the gearcase and engage the pinion Turn the driveshaft until holes of the impeller housing are...

Page 255: ...Check seal areas for visible signs of lubricant leakage Propeller Shaft Check for bent or damaged shaft Check for twisted splines and damaged threads Shift Rod Check for bent or binding rod Hydrostat...

Page 256: ...ining Ring Pliers P N 331045 Remove the retainer plate from the gearcase 1 Screws 007668 1 Body 2 Handle 3 Pressing screw 4 Washers 5 Screws obtain locally 007669 1 1 4 5 1 2 3 CAUTION Retaining ring...

Page 257: ...the pivot pin O ring Remove the propeller shaft and reverse gear components from the gearcase IMPORTANT Shifter detent balls and spring will pop out of the clutch when the propeller shaft is removed U...

Page 258: ...MOVAL IMPORTANT Inspect bearings for damage while in place If bearing is damaged remove and discard If the bearing is removed for any reason it must be replaced Driveshaft Seals Use Puller Bridge P N...

Page 259: ...Rod Bushing Remover P N 327693 under the shift rod bushing Thread the adapter of the Slide Hammer P N 391008 in the slide hammer Place the adapter through the shift rod bushing and thread into the re...

Page 260: ...blies Lubri cate all bearings shafts and gears with gearcase lubricant Press the bearings into the housings until the tools are seated on the housing Propeller Shaft Bearing Housing Bearings Use Beari...

Page 261: ...oat the shift rod O ring with Triple Guard grease and install in shift rod bushing Place a new washer and bushing on Shift Rod Bushing Installer P N 304515 Apply Gasket Sealing Compound to the outside...

Page 262: ...g Assemble tool using long spacer P N 330068 Driveshaft Bearing Oil and install a new driveshaft bearing in the bearing sleeve using Bearing Installer P N 322923 Press against the lettered side of the...

Page 263: ...fter Installation IMPORTANT Make no dry assemblies Lubri cate all bearings shafts and gears with gearcase lubricant Oil and place the forward bearing cone and roller assembly in the forward bearing cu...

Page 264: ...o hold in place while assembling Install the shifter cradle and clutch dog in the gearcase using long nose pliers Apply Triple Guard grease to a new pivot pin O ring Install O ring on the pivot pin Ap...

Page 265: ...tool in gear case Make sure the following occurs Propeller shaft must engage forward bearing Tool ramps must engage clutch dog ramps Hold tool firmly against clutch dog Gently tap propeller shaft wit...

Page 266: ...age the shifter yoke Thread the shift rod into the shifter yoke until the rod bottoms in the yoke Propeller Shaft Bearing Housing Installation Slide the retainer plate down the propeller shaft and int...

Page 267: ...ghtly apply Gasket Sealing Compound to the aft support flange of the bearing housing Align the propeller shaft bearing housing on the guide pin with the word UP toward the top Using a brass punch and...

Page 268: ...seal assembly and install it into the slot in the gearcase To complete gearcase assembly refer to WATER PUMP SERVICE on p 250 GEARCASE LEAK TEST on p 247 GEARCASE REMOVAL AND INSTALLATION on p 248 Gea...

Page 269: ...GENERAL 270 RESERVOIR FLUID 270 MANUAL RELEASE VALVE 270 STERN BRACKETS 270 TROUBLESHOOTING 270 ELECTRICAL CIRCUIT TESTS 271 RELAY TESTING 271 TRIM AND TILT MOTOR CURRENT DRAW TESTS 271 TRIM AND TILT...

Page 270: ...268 TRIM AND TILT SERVICE CHART SERVICE CHART 007632 A Triple Guard Grease W Biodegradable TNT Fluid 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 A...

Page 271: ...torage The tilt cylinder moves the outboard 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 ra...

Page 272: ...ase 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 a torque of 45...

Page 273: ...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 test IMPORTANT Specifications are for static hydraul...

Page 274: ...to green lead The motor shaft must rotate counterclockwise as viewed from the pump end when positive is applied to the green lead and negative is applied to the blue lead If test results vary replace...

Page 275: ...s With the outboard fully UP meter must show a reading below 10 ohms If results agree refer to Trim Gauge Test on p 272 If results are different replace trim sender TRIM AND TILT REPLACEMENT Removal R...

Page 276: ...ust ment rod Remove the rod from the stern brack ets Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw Installation Lubricate the cylinder...

Page 277: ...mbly Thoroughly clean the unit before disassembling Scrub all outside surfaces with a stiff brush and hot soapy water to prevent surface dirt from con taminating internal parts Always use a lint free...

Page 278: ...gs on the housing Remove the four large motor flange retaining screws Remove the motor and discard O ring screws and washers Remove drive coupler from either the motor or the pump assembly Assembly IM...

Page 279: ...to a torque of 45 to 55 in lbs 5 to 6 N m Install retaining ring in groove Fill the oil reservoir up to the fill plug with Evinrude Johnson Biodegradable TNT Fluid Install the fill plug Run the motor...

Page 280: ...278 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 281: ...9 14 MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 280 RECOIL STARTER REMOVAL 281 RECOIL STARTER INSTALLATION 282 RECOIL STARTER DISASSEMBLY 283 RECOIL STARTER CLEANING AND INSPECTION 285 RECOIL STAR...

Page 282: ...NUAL STARTER SERVICE CHART SERVICE CHART F 84 to 106 in lbs 9 5 to 12 N m 124 to 141 in lbs 14 to 16 N m V V X Tighten securely E Red Ultra Lock F Blue Nut Lock V Lubriplate 777 X See Service Manual 0...

Page 283: ...to the side Remove the vapor separator vent hose and wiring from the retainers on the recoil starter housing Remove three recoil starter mounting screws Remove recoil starter assembly WARNING To prev...

Page 284: ...n lbs 3 5 to 5 5 N m Install stator connector in retainer groove of starter housing To prevent damage to wiring from rotating flywheel make sure stator connector is securely fastened to the starter ho...

Page 285: ...ure can dam age the threads of the housing Connect the cooling hose to the EMM Secure with tie strap RECOIL STARTER DISASSEMBLY Use Starter Spring Winder and Installer P N 342682 to service the recoil...

Page 286: ...tension is released from spring Remove retaining ring pawl and linkage Remove starter spindle screw and lock nut IMPORTANT Hold pulley down in housing and lift out spindle Carefully lift out pulley l...

Page 287: ...Replace as necessary Inspect starter rope Replace rope if frayed Cut new rope 80 in 203 cm in length Fuse ends of rope to a length of 1 2 in 12 mm Examine the pulley and the starter housing Look for...

Page 288: ...ce spring around base as shown Place starter housing over base Route the hook end of spring through the starter housing opening as shown To keep spring in position hold up on portion of spring that is...

Page 289: ...pletely pulled into housing Allow pulley to slowly unwind until tension is relieved Turn pulley counterclockwise 3 5 turns until the pulley rope channel aligns with the rope guide Secure pulley by pl...

Page 290: ...l Allow rope to slowly wind into starter Remove left hand threaded nut and retainer from tool base Remove starter assembly Install spindle screw and lock nut Tighten nut to a torque of 124 to 141 in l...

Page 291: ...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 292: ...S 2...

Page 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ...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 305: ...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 306: ...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 307: ...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 308: ...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 309: ...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 310: ...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 311: ...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 312: ...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 313: ...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 314: ...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 315: ...veshaft 256 260 Forward Gear 257 259 Pinion Gear 257 260 Propeller Shaft 258 Break In EMM Programming 150 190 Gearcase 249 266 Oiling 150 Procedure 62 C Cable Hose and Wire Routing 18 Clamp Screw Serv...

Page 316: ...Timing Verification 63 106 TPS Calibration 63 106 Driveshaft Bearing Installation 260 Removal 256 Driveshaft Seals Installation 261 Removal 256 E Electrical Circuits EMM Pin Locations 85 Fuse 86 Groun...

Page 317: ...Fuse 86 G Gearcase Assembly 261 Bearings Installation 258 Removal 256 Disassembly 253 Inspection 253 Installation 248 Leak Test 247 Lubricant 11 34 Removal 248 Seal Installation 258 Removal 256 Water...

Page 318: ...Circuits 145 Engine Lubricant 10 146 Low Oil Switch 54 New Engine Set Up 146 Oil Distribution 143 Oil Distribution Hoses 143 154 155 Oil Filters 37 Oil Recirculation 148 Oil Tank 146 155 Oiling Rate 6...

Page 319: ...ctrical and Ignition 82 Fuel System 116 Gearcase 244 Midsection 198 Oiling System 142 Powerhead 168 Shift Cable Adjustment Tiller 240 Shift Linkage Adjustment 189 Installation 186 Lubrication 33 Remov...

Page 320: ...justments Timing Pointer 106 Timing Verification 106 TPS Calibration 106 Tools Accessory Power Cable Kit P N 5008092 59 Ball Socket Installer tool P N 342225 241 Ball Socket Remover Tool P N 342226 13...

Page 321: ...ver and In staller P N 5005927 257 260 Universal Puller Set P N 378103 104 171 254 Wrench P N 334359 257 Wrist Pin Pressing Tool P N 326356 175 Wrist Pin Retainer Installation Tool P N 354720 181 Torq...

Page 322: ...I 8 INDEX...

Page 323: ...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 324: ...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 325: ...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 326: ...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 327: ...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 328: ...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 329: ...tube 4 Exhaust housing 5 Cylinder block 6 Pressure relief valve 7 Thermostat 8 Water supply to vapor separator 9 Water supply vapor separator to EMM 10 Overboard indicator outgoing water from EMM Hos...

Page 330: ...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 331: ...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 332: ...B M M C A S OFF M B S A C M ON M B S A C M START M B S A C M 4 5 6 1 2 3 MWS Key Switch and Neutral Safety Switch 000691...

Page 333: ...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 334: ...1 2 1 2 A B 6 4 1 5 7 1 Tiller to Engine Harness Connector 2 Trim Switch Connector 3 Trim Switch 4 Power Connector Trim Switch 5 Start Switch 6 Stop Switch 7 Touch Troll Switch Tiller Harness 15 30 H...

Page 335: ...ection Ignition Fault Sensors 5V Circuits Stop Circuit No Oil Overheat KEY ON LED s illuminate to indicate circuit function STARTING LED s illuminate to indicate circuit function RUNNING LED s illumin...

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Page 337: ...eck Connector 9 Neutral Switch 10 Diagnostic Connector 11 Cylinder Head Temperature Sensor 12 Ignition Coil 13 Fuel Injector 14 EMM 15 High Pressure Fuel Pump 16 Low Oil Switch 17 Oil Injector 18 Main...

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Page 339: ...range 3 3 LED 4 ON Running 8 seconds EMM Temperature 194 F 90 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running 5 minutes Battery voltage 12 5 V Perform stator ch...

Page 340: ...ED 2 ON Running 10 instances EMM counts failed ignition events Check wiring Test with known good ignition coil 82 Ignition timing circuit 2 OPEN LED 2 ON Running 10 instances 91 Fuel pump circuit OPEN...

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