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BRP Evinrude E-TEC, Manual

The BRP Evinrude E-TEC is a high-performance outboard motor known for its reliability and efficiency. To ensure proper maintenance and operation, users can download the manual for free from manualshive.com. With detailed instructions and troubleshooting tips, this manual is essential for maximizing the performance of your Evinrude E-TEC.

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Electrical and Ignition

93

6

Electrical and Ignition

Table of Contents

Service Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  94
Ignition System Circuit Diagram, 2-Cylinder Models   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  96
Ignition System Circuit Diagram, 3-Cylinder Models   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  97
Electrical Harness Connections   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  98
Ground Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  100
Fuse  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  100
Sensor Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  101

Crankshaft Position Sensor (CPS) Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  101
Throttle Position Sensor (TPS) Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  101
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  102
Air Temperature Sensor (AT) Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  102

Stator Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  103
Charging System Tests   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  104
Electric Start Circuit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  106
Electric Start Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  108
Remote Control Switch Tests   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Tilt/trim Relay Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  112
Exhaust Water Valve Test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  113

SystemCheck

 Circuit Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  113

Tachometer Circuit Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  116
Flywheel and Stator Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  116

Flywheel Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  116
Stator Service  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  118
Flywheel Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  118

Ignition Coil Servicing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  119
Timing Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  119

Timing Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  119
Timing Verification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  120
TPS Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  121

Electric Starter Servicing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  121
Connector Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  122

Deutsch

 Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  122

AMP

 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  124

Packard 

Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  126

Summary of Contents for Evinrude E-TEC

Page 1: ...any 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 Com...

Page 2: ...stem 179 10 Powerhead 191 11 Midsection 241 12 Trim and Tilt 291 13 Manual Starter 315 Safety S 325 Index I 349 Trouble Check Chart T 357 Diagrams IMPORTANT For complete outboard rigging and control i...

Page 3: ...7 Product Reference and Illustrations 7 Emission Related Installation Instructions 8 Manufacturer s Responsibility 8 Dealer s Responsibility 8 Owner s Responsibility 8 EPA Emission Regulations 9 Mode...

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

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

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

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

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

Page 10: ...after April 2012 follow the model identification shown above subsequent versions continue through the alphabet as AG AH etc will not use letters from the word INTRODUCES to identify models Refer to A...

Page 11: ...mote Electric Power Tilt E60DSLAG_ 20 I2 F 11 32 0 34 2 90 1 Remote Electric Power Tilt E60DTLAG_ 20 I2 F 11 32 0 34 2 90 1 Tiller Electric Power Tilt E60DGTLAG_ 20 I2 F 11 32 0 34 2 90 1 Tiller Elect...

Page 12: ...shaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Crankshaft Journal 1 5747 to 1 5752 in 40 0 to 40 01 mm Rod Crankpin 1 3757 t...

Page 13: ...tting 6 pulse 12 pole Engine Fuse P N 967545 10 A Ignition System Type Capacitor Discharge Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft P...

Page 14: ...shaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Crankshaft Journal 1 5747 to 1 5752 in 40 0 to 40 01 mm Rod Crankpin 1 3757 t...

Page 15: ...Ignition System Type Capacitor Discharge Firing Order 1 2 3 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer t...

Page 16: ...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 07...

Page 17: ...Tab Adjustment 33 Dual Outboard Alignment 34 Operational Checks 35 Cooling System 36 Water Intake Screens 36 Engine Flushing 36 Running the Outboard Using a Hose and Flushing Adapter 37 Lubrication 38...

Page 18: ...rical and ignition wires inspect for wear or chafing Emergency cut off switch es and tether cord check operation EMM access EMM information resolve any service codes Engine Monitor self test and warni...

Page 19: ...Catalog B Biodegradable TNT Fluid P N 763439 Use only in Power Trim Tilt System of 3 cylinder models B Power Trim Tilt Fluid P N 775612 Use only in Power Tilt System of 2 cylinder models C Triple Guar...

Page 20: ...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 21: ...ins until all cables wires and hos es have been routed and grommet has been in stalled in the lower engine cover Make sure the remote control is in NEUTRAL and throttle is in the IDLE position Pull fi...

Page 22: ...ion 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 stop If not remove s...

Page 23: ...el cover Install electrical cover and secure with screws I Command Network Connections If the outboard will be used with I Command or other NMEA 2000 compliant CANbus instruments use the following con...

Page 24: ...rence with engine cover latch bundle excess wiring behind EMM cooling water hose Secure I Command connectors to back side of engine harness with tie strap 2 Cylinder Models 1 Flywheel cover 2 Harness...

Page 25: ...ect the purple wires between the I Command Ignition and Trim Harness and the I Command Engine Interface Cable This connec tion supplies power to the network when the key switch is on I Command Digital...

Page 26: ...tteries are used with an Evinrude outboard installation of additional equipment may be required as defined by the battery manufacturer When installing lithium ion batteries installers MUST correctly i...

Page 27: ...ls battery posts and connectors with a solution of baking soda and water Use a wire brush or battery terminal tool to remove cor rosion buildup Rinse and clean all surfaces Connecting the Battery IMPO...

Page 28: ...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 Refer to Oetiker Clamp Chart on p 54 Clamp Installation A constan...

Page 29: ...pped with a steering friction adjustment Steering friction is not required when remote steering is used Adjust steering friction with outboard mounted to boat by loosening or tightening the adjustment...

Page 30: ...s motor well when fully tilted adjust the tilt limit cam to reduce full tilt position WARNING Tighten knob only enough to hold throttle at a constant engine speed Over tightening will prevent quick t...

Page 31: ...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 UP and engage tr...

Page 32: ...e sending unit to pivot Disengage the tilt support Lower the outboard against the thrust rod Observe the trim gauge If the needle does not show center position tilt the outboard up and adjust the send...

Page 33: ...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 of the trim tab...

Page 34: ...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 35: ...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 REVERSE Turn outboard OFF whil...

Page 36: ...leaks or restrictions water intake screens water pump all internal water passages thermostats all external water hoses and fittings vapor separator cooling passages and fittings EMM cooling passages a...

Page 37: ...pter may be used to provide cooling water when running the outboard to Flush the engine Run for an extended period of time such as when performing diagnostic work Run the engine on a dynamometer Prepa...

Page 38: ...ase Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable before coating it with grease Make sure wiper nut is installed and not damaged Tiller Handle Lubricate the...

Page 39: ...attery 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 contr...

Page 40: ...earcase Lubricant Draining IMPORTANT Always check the fill level of the gearcase lubricant at the upper plug before remov ing the lower drain fill plug A tie strap can be used to check lubricant level...

Page 41: ...and rec ommended lubricants Secure the gearcase in a vertical position Remove the lubricant level plug and the lubricant drain fill plug Use Gearcase Filler P N 501882 to slowly fill the gearcase wit...

Page 42: ...bs 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 unit hold the trim switch ON an additional 5 to 10 seconds after the...

Page 43: ...he 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 wit...

Page 44: ...stem 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 recom...

Page 45: ...metal based 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 resis...

Page 46: ...ve 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 WARNING Turn the key switch OFF and disconnect the Crankshaft Position Sensor CPS to prevent...

Page 47: ...e of the driveshaft because lubricant may prevent seating of the driveshaft in the crankshaft 2 Cylinder Models Apply Adhesive 847 to the exhaust housing seal s outer surface Place the seal in the gea...

Page 48: ...to threads of the gear case retaining screws Tighten the screws to a torque of 3 8 in screws 18 to 20 ft lbs 24 to 27 N m 7 16 in screw 28 to 30 ft lbs 38 to 40 N m 5 16 in screw 10 to 12 ft lbs 13 5...

Page 49: ...ghtening If a previ ously installed screw is re used use a wire brush to remove any old thread locking material or corro sion and lubricate threads with Triple Guard grease Install screws and washers...

Page 50: ...e MUST be in NEUTRAL throughout these procedures Throttle Control Method Fully advance throttle control and then start the outboard All four SystemCheck lights will turn on and the outboard will run a...

Page 51: ...opeller Clean and grease propeller shaft Blow water from gearcase speedometer pickup system gearcase speedometer models only Lubricate all grease fittings and linkages Inspect outboard steering system...

Page 52: ...apparent pressure and vacuum test gearcase Repair gearcase as needed Battery s Replace batteries that cannot be charged Power Trim and Tilt Remove filler cap and check fluid level Inspect the power tr...

Page 53: ...s Disconnect oil supply hose and oil return hose from outboard Drain and clean all oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime...

Page 54: ...360 410 349729 331 352335 346 351685 316 349759 301 346153 256 346152 241 352703 226 353516 I D P N 1 2 3 8 1 4 1 8 3 4 1 1 1 4 1 1 2 1 3 4 2 2 1 4 695 352868 66 3 to 69 5 mm 2 61 to 2 73 in 845 35865...

Page 55: ...3 Engine Cover Service Table of Contents Upper Cover Service 56 Latch Hook Installation 56 Lower Cover Service 56 Lower Cover Removal 56 Lower Cover Installation 56 Latch Handle Installation 57 Trim...

Page 56: ...en port side cover slightly and disconnect trim tilt switch connector Then remove port and starboard covers Lower Cover Installation Installation of lower motor covers will be easier if the following...

Page 57: ...ighten all screws to 24 to 36 in lbs 3 to 4 N m Latch Handle Installation Apply a light coat of Triple Guard grease to latch handle shaft Insert handle into lower cover Apply Ultra Lock to screw threa...

Page 58: ...m Trim Switch Installation Place switch into position through cover Install nut on switch Tighten nut to a torque of 10 to 16 in lbs 1 to 2 N m Install electrical connector Refer to Connector Servicin...

Page 59: ...ensor 63 Low Oil Switch 64 Throttle Position Sensor 64 Crankshaft Position Sensor 65 Neutral Switch 65 Internal EMM Functions 66 Engine Monitor System 67 S A F E Warning System 68 Shutdown Mode 68 Dia...

Page 60: ...tivation 40 H O and 60 HP 2 cylinder models only EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections can damage the EMM DO NOT run the outboar...

Page 61: ...0 10 0 0 10 10 10 1 10 1 10 1 10 0 0 10 0 0 0 1 1 1 1 10 0 0 10 1 10 10 0 0 1 10 0 1 10 0 1 10 1 10 1 10 0 0 0 0 0 1 1 1 10 0 0 1 10 0 0 0 0 40 4 4 40 40 4 4 40 40 40 0 0 0 0 0 40 4 40 40 40 0 0 40 4...

Page 62: ...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 63: ...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 S...

Page 64: ...E mode the oil pump must cycle for a minimum of three pulses with the oil level above one quarter If outboard has been run for more than 3 hours with NO OIL faults codes 34 117 the EMM Throttle Positi...

Page 65: ...e air gap between CPS and flywheel encoder ribs is 0 073 inch 1 85 mm Use the Evinrude Diagnostics software Monitor screen to check CPS operation The software should show an RPM reading while the outb...

Page 66: ...mes 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 E...

Page 67: ...lete 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 sound ing a half second beep SystemCheck gauges self test by tu...

Page 68: ...Test on p 144 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 v...

Page 69: ...ters the EMM at pin 28 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 Diagnosti...

Page 70: ...ion Static information is viewed when the outboard is NOT running This includes manufacturing infor mation The outboard model and serial numbers displayed on the Identity screen must match the identif...

Page 71: ...operating hours of first and last occurrences Active Faults An active fault is a service code that currently exists Active faults become occurred faults only if the outboard is running Historical Faul...

Page 72: ...ngine Monitoring system Check Engine This test is used to check the CHECK ENGINE circuit of the Engine Monitoring system Tachometer This test is used to check operation of the tachom eter circuit Dyna...

Page 73: ...Use 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 oi...

Page 74: ...position sensor voltage Refer to TPS Calibration on p 121 Perform TPS Calibration after replacing or adjust ing any throttle body or throttle linkage parts Idle Speed Control Use the Idle Adjust func...

Page 75: ...e used to document the running history of an out board Reviewing this information can help iden tify or resolve some service issues Click the print button in a window of the diagnos tics software to p...

Page 76: ...date IMPORTANT Software replacement requires the use of Bootstrap Tool P N 586551 Install tool between engine and boat harness key stop switch connectors as instructed by update program EMM Transfer E...

Page 77: ...ehind oil tank bosses Installation Installation is the reverse of removal Pay close attention when performing the following tasks Make sure isolator mounts are placed in slots in of EMM case Slide EMM...

Page 78: ...Engine Management Module EMM Notes 78 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 79: ...y ON 84 Starting 84 Running 84 Ignition Output Tests 85 Required Ignition Systems 85 Wiring Inspection 86 Crankshaft Position Sensor CPS Test 86 System Voltage Test 86 Static Ignition Test 87 Running...

Page 80: ...Check the fuse and the emergency stop switch lanyard Diagnostic Inspections Before running the outboard use Evinrude Diag nostics software to review historical information saved in the EMM Check the...

Page 81: ...the following Make sure the outboard can be cranked easily with no mechanical binding Check the EMM LED Indicators for system status information Refer to EMM LED Indicators on p 84 Troubleshooting Ou...

Page 82: ...rcuits only when necessary All EMM output currents are DC current Use the diagnostics software Dynamic Tests to isolate a faulty cylinder See Dynamic Tests on p 83 Use an inductive timing light to che...

Page 83: ...s 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 disab...

Page 84: ...ENSORS OKAY 5 V For NO LIGHT check for Code 12 TPS circuit fault Code 13 TPS below expected range Code 14 TPS above expected range Code 19 In Gear tiller models Code 23 EMM temp sensor circuit fault C...

Page 85: ...essive NO OIL faults Code 34 oil injection pump circuit open Code 40 engine overheat low rpm Code 43 engine overheat Code 117 Critical NO OIL detected Ignition Output Tests Use the Evinrude Diagnostic...

Page 86: ...and grounds Use a digital ohmmeter to test resistance on all ground circuits and connections Ohmmeter read ings should be approximately 0 0 W Check that all engine wire harness grounds have continuity...

Page 87: ...using Evinrude Diagnostics software and an inductive timing light IMPORTANT DO NOT perform static tests us ing Diagnostic Power Supply Tool P N 587005 with internal 9 volt batteries only This will pr...

Page 88: ...Test capacitor and all ground connections Refer to System Voltage Test on p 86 Refer to Ignition Control Circuit Tests on p 88 Refer to Ignition Coil Tests on p 89 IMPORTANT If a running problem occur...

Page 89: ...onnector pro vides continuity to ground The secondary spark plug lead provides conti nuity If all of the above tests are good and a cylinder does not have spark replace the ignition coil with a known...

Page 90: ...y 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 Refer t...

Page 91: ...ched by the EMM The Dynamic Tests screen allows the control signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always check the...

Page 92: ...ater valve Monitor 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...

Page 93: ...ature Sensor AT Test 102 Stator Tests 103 Charging System Tests 104 Electric Start Circuit 106 Electric Start Tests 108 Remote Control Switch Tests 110 Tilt trim Relay Test 112 Exhaust Water Valve Tes...

Page 94: ...7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m A 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m F 24 to 36 in lbs 2 7 to 4 N m F 24 to 36 in lbs 2 7 to 4 N m N F 008029 IMPORTANT DO NOT lubric...

Page 95: ...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 X 15 to 30 ft lbs 20 to 41 N m Z 002249 A Triple Guard Grease B Gasket Sealing Compound C Adhesi...

Page 96: ...1 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 4 5 6 7 8 9 10 11 12 13 20 21 22 23 24 25 26 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 6 5 4 3 2 1 1 2 7 2 1 5 7 3 6 4 8 J1 A J1 B J2...

Page 97: ...2 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 4 5 6 7 8 9 10 11 12 13 20 21 22 23 24 25 26 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 6 5 4 3 2 1 1 2 3 7 2 1 5 7 3 6 4 8 J1 A J1 B J2 0...

Page 98: ...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 Bootst...

Page 99: ...ant 14 Injector ground Black 15 vacant 16 vacant 17 vacant 18 vacant 19 Ignition cylinder 2 3 cylinder models Orange Purple 19 Ignition cylinder 2 2 cylinder models Orange Green 20 Injector ground Bla...

Page 100: ...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 101: ...te 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 and requires no adjustment Air gap or clearance...

Page 102: ...Sensor Test Remove the electrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperature Sensor AT Test Remove the electrical connector fr...

Page 103: ...reads continuity replace stator Stator Voltage Output Test Electric Start Models Use a digital multimeter to check stator output voltage Set meter to read 110 VAC output Disconnect CPS Disconnect stat...

Page 104: ...able load tester to discharge the battery IMPORTANT The regulator requires voltage to operate Before proceeding make sure there is at least 7 V on the positive terminal of the starter so lenoid Discon...

Page 105: ...ON 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 a...

Page 106: ...9 10 11 12 13 14 15 16 010349 M A S C M B 1 2 3 4 5 6 5 J1 A J1 B J2 A B A B 1 2 1 2 3 4 5 6 6 12 13 3 4 10 11 1 2 9 15 7 14 8 1 Marine battery 2 RED wire POS 3 BLACK wire NEG 4 Starter solenoid 5 Fu...

Page 107: ...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 V to sole noid terminal A Yellow green wire provides gr...

Page 108: ...continuity low reading replace the solenoid Apply B to terminal A of solenoid and ground NEG to terminal B of solenoid Measure resis tance between the starter positive cable termi nal and the positive...

Page 109: ...tarter 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 suit...

Page 110: ...inal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or continuity light to test the continuity of the circuit while positioning the remote control in NEUTRAL FORWARD and RE...

Page 111: ...an 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 switch function grounds the stop circuit wire black yellow wh...

Page 112: ...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 113: ...ard before performing the following tests Refer to the Engine Wiring diagram and the MWS Instrument Wiring diagram in the back of this manual IMPORTANT Use jumper wires made with the appropriate termi...

Page 114: ...t at the purple wire and the tan blue wire has continuity between the two connectors replace SystemCheck gauge Turn the key switch OFF and reconnect all discon nected circuits CHECK ENGINE Circuit Tes...

Page 115: ...should turn on after 40 seconds If the LOW OIL light does not turn on after con necting the terminal to ground test circuit for con tinuity Turn the key switch OFF and reconnect all discon nected circ...

Page 116: ...output on gray wire at pin 16 of EMM J1 A connector Reading OK Check condition of tachometer circuit gray wire Repair as needed Reading not OK Check connection at EMM replace faulty EMM Flywheel and S...

Page 117: ...07637 and the center hole of the crankshaft Assemble the following components from Univer sal Puller Set P N 378103 Body P N 307636 Screw P N 307637 Handle P N 307638 Three screws P N 309492 Three was...

Page 118: ...eel tapers with Cleaning Solvent and let dry Align the flywheel keyway and install flywheel Coat the threads of flywheel nut with Triple Guard grease Install the washer and nut and tighten to a torque...

Page 119: ...o indicate top dead center TDC of the number 1 piston This reference to the position of the number 1 pis ton is used to synchronize the electronic timing controlled by the EMM with the mechanical posi...

Page 120: ...en the pointer retaining screw and adjust the pointer location to align with the cast in TDC boss on the flywheel Tighten retaining screw Repeat the entire adjustment process to make sure pointer is a...

Page 121: ...Do not clean the starter drive while the starter motor and drive are installed on the powerhead The cleaning agent could drain into the starter motor washing dirt from the drive into the starter beari...

Page 122: ...ne Dip Connector Servicing Deutsch Connectors IMPORTANT Electrical Grease is recommend ed Incorrect grease application can cause electri cal or warning system problems To disconnect the connector pres...

Page 123: ...to terminals Crimping Terminals Strip insulation back 3 16 in 5 mm Place termi nal in 18 gauge notch of Crimping Pliers P N 322696 Position end of wire strands in termi nal past wire crimp area and p...

Page 124: ...elease anti backout device of connector housing Next use Primary Lock Tool P N 777077 to release locking tab of connector housing Release locking tab and pull on wire to remove from connector housing...

Page 125: ...sh connector into plug until latches engage Terminal Removal Open lock mechanism and remove terminal from connector housing Terminal Installation Push terminal through seal until it is seated in con n...

Page 126: ...appropriate meter test probes and adapters when testing compo nents fitted with these terminals Disconnect Lift latch s Remove connector Connect Confirm the seal is in place Push connector onto housin...

Page 127: ...Terminal is crimped onto wire and then pulled back into connector housing until lock ing tab engages and terminal is seated Crimping Terminals Strip insulation back 3 16 in 5 mm Position end of wire s...

Page 128: ...Electrical and Ignition Notes 128 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 129: ...Priming 143 Vent Line Clamp 143 Priming the Fuel System 143 Fuel System Tests 144 Fuel System Pressure Test 144 Pressure Regulator Test 144 Vapor Separator Vent Check 145 Fuel Injector Pressure Test 1...

Page 130: ...4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H F 60 84 in lbs 7 9 5 N m 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 002154A Tighten in 3 stages A Triple Guard Grease B...

Page 131: ...0 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 IMPORTANT Do NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gas...

Page 132: ...N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S F 60 84 in lbs 7 9 5 N m 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 H 002154 Tighten in 3 stages A Triple Guard Grease B Gas...

Page 133: ...120 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 IMPORTANT Do NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B G...

Page 134: ...fuel system 2 Fuel lift pump 2 to 8 psi 3 Pulse hose from cylinder crankcase 4 Fuel supply to vapor separator 5 Fuel filter 6 Vapor separator 7 Electric fuel circulation pump 20 to 30 psi 8 Fuel suppl...

Page 135: ...2 Fuel lift pump 2 to 8 psi 3 Pulse hose from cylinder crankcase 4 Fuel supply to vapor separator 5 Fuel filter 6 Vapor separator 7 Electric fuel circulation pump 20 to 30 psi 8 Fuel supply manifold...

Page 136: ...25 26 27 28 29 30 31 32 33 34 1 2 3 4 5 6 7 8 9 10 11 12 13 20 21 22 23 24 25 26 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3 3 8 9 4 10 1 5 2 6 J1 A J1 B J2 010345 2 1 2 1 6 5 4 3 2 1 7...

Page 137: ...1 2 3 4 5 6 7 8 9 10 11 12 13 20 21 22 23 24 25 26 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3 3 8 9 10 4 11 1 5 2 6 J1 A J1 B J2 010346 2 1 2 1 6 5 4 3 2 1 7 2 1 3 2 1 1 Stator 2 EMM...

Page 138: ...sources and open flames Close the vent screw of the fuel tank cap if equipped to prevent escape of fuel or fuel vapors which could accidentally ignite Do not allow disconnected fuel hoses to leak fue...

Page 139: ...n 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 Clean er Use of other fuel additive...

Page 140: ...hrough 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 Inspection a...

Page 141: ...ssure in the vapor separator decreases the fuel level begins to increase An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps m...

Page 142: ...d to the injector by serial number The EMM is programmed to compensate for vari ations in fuel flow Each injector and its location on the outboard is identified by the EMM DO NOT install an injector w...

Page 143: ...uel 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 ne...

Page 144: ...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 146 If the above tests are good...

Page 145: ...y cables at the battery Loosen oil tank assembly to provide access to fuel manifolds Refer to Oil Tank Assembly on p 175 Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 148 I...

Page 146: ...he 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 appropriate adapter leads to measure t...

Page 147: ...ith tie straps to prevent fuel or air leaks START outboard and run at FULL THROTTLE for at least two minutes Monitor clear vinyl hose for the presence of air Air bubbles indicate a faulty hose connect...

Page 148: ...art and run at IDLE for 5 seconds and STOP outboard If out board does NOT run crank for 10 seconds Disconnect the battery cables at the battery Wrap a shop towel completely around the pres sure test v...

Page 149: ...g direction of fuel flow on filter Secure filter with appropriate clamps Squeeze primer bulb to prime fuel system Hold pressure on bulb and check for fuel leaks Connect battery cables Run outboard and...

Page 150: ...for fuel leaks Vapor Separator Service Removal Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 148 Disconnect circulation pump e...

Page 151: ...s and disconnect the fuel manifolds as follows Fuel supply manifold to circulation pump Fuel return manifold to vapor separator Remove fuel manifold retainer screws and remove retainers from fuel inje...

Page 152: ...r fuel manifolds Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber Removal Disconnect the battery cables at the battery Relieve fuel system pressure Refer...

Page 153: ...he fuel injector housing as shown Thread the puller screw into the fuel injector 1 4 20 threaded hole until it seats Turn puller nut clockwise until it contacts the puller base Use a 1 2 inch 13 mm wr...

Page 154: ...be downloaded from the Evin rude Johnson dealer website Refer to the instruc tions provided with the injector kit Upload Coefficient Files to EMM IMPORTANT If using Diagnostic Power Supply Tool P N 58...

Page 155: ...ssembly Injector Cylinder head Adapter Screws Threaded areas Place injector and insulator in the proper cylinder location IMPORTANT Be careful not to pinch any wiring or hoses during assembly IMPORTAN...

Page 156: ...folds Refer to Fuel Manifold Ser vice on p 151 Intake Manifold Service Removal Disconnect vapor separator vent hose main bear ing vent hose air temperature sensor crankshaft position sensor and thrott...

Page 157: ...he intake manifold All gasket surfaces must be cleaned smooth and free of nicks Use a machinist s straight edge and a feeler gauge to check flatness in all directions Surface must be flat 0 004 in 0 1...

Page 158: ...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 center screws first and expand out ward Tighten in stages to...

Page 159: ...V 167 LOW OIL Warning 167 NO OIL Warning 167 Cylinder and Crankcase 168 Oil Recirculation System 168 Oil Control Settings 169 Oil Injection Rate 169 Break In Oiling 170 Oil Supply Priming 171 Oiling...

Page 160: ...der Models A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant X see Service Manual X F 30 to 42 in lbs 3 5 to 5 N m 30 to 42 in...

Page 161: ...els F 30 to 42 in lbs 3 5 to 5 N m 30 to 42 in lbs 3 5 to 5 N m F 30 to 42 in lbs 3 5 to 5 N m X 008059 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock...

Page 162: ...Supply Diagrams Oil Supply Diagrams 2 Cylinder Models 1 3 4 2 1 5 4 6 6 5 008060 1 Oil Tank 2 Oil Pick up filter 3 Oil Injection Pump 4 Oil Distribution Manifold 5 Crankcase Oil Inlet Port 6 Cylinder...

Page 163: ...Oil Supply Diagrams 163 8 3 Cylinder Models 1 3 4 2 1 5 4 6 6 5 6 5 008061 1 Oil Tank 2 Oil Pick up filter 3 Oil Injection Pump 4 Oil Distribution Manifold 5 Crankcase Oil Inlet Port 6 Cylinder Oil In...

Page 164: ...164 Oiling System Oil Recirculation Diagrams Oil Recirculation Diagrams 2 Cylinder Models 3 Cylinder Models 002483a Starboard view Port view 002223 Starboard view Port view...

Page 165: ...9 10 11 12 13 14 15 16 1 2 4 7 8 3 J1 A J1 B J2 010347 B A 6 5 4 3 2 1 6 5 4 3 2 1 5 6 9 10 11 12 B A 1 Stator 2 Main harness ground BLACK 3 Alternator grounds BLACK 4 Alternator output WHITE RED wire...

Page 166: ...st one quar ter capacity The LOW OIL warning should not display Components The oiling system includes the following compo nents Oil tank Oil injection pump and manifold assembly Oil level switch Elect...

Page 167: ...ng A switch in the oil tank assembly monitors the oil level in the oil tank If the oil level falls below one quarter capacity the EMM signals Approximate oil reserve at Low Oil activation 0 45 qt 0 43...

Page 168: ...ccumulation of oil from various locations in the powerhead The movement of oil is controlled by check valves Cylinder Recirculation Internal powerhead oil drain passages connect the intake port areas...

Page 169: ...also for power head break in Use Evinrude Diagnostics software to access these features The Set Oil Type option controls the injection rate for the oil being used and typical operating condi tions The...

Page 170: ...EMM programming Break In Oiling IMPORTANT DO NOT add oil in the fuel tank on Evinrude E TEC models The EMM automatically supplies extra oil to the engine as follows 40 90 HP First two hours above 2000...

Page 171: ...les are acceptable Large bubbles must be eliminated through continued priming Repair any fuel or oil leaks The oiling system on these models can also be primed using the Self Winterizing feature if di...

Page 172: ...vinrude Diagnostic software Static Test screen to activate the oil pump IMPORTANT This test is operating the pump with 12 V battery power on the system voltage 55 V circuit The oil injection pump will...

Page 173: ...unction Test Remove oil distribution hose from fitting at oil dis tribution manifold Do not lose the brass hose sup port Clean up any spilled oil with shop towels Temporarily install a length of oil h...

Page 174: ...rn ing should stop after the oil pump cycles 3 times Oil Component Servicing Oil Distribution Hoses The oil distribution hoses to each cylinder MUST be the same length DO NOT alter the length of any h...

Page 175: ...ld end of hose IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully inserted into manifold Insertion depth is 5 8 in 16 mm Visually inspect for hos...

Page 176: ...ock to threads Install screws and tighten to 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 oi...

Page 177: ...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 oil pump flange 2 Cylinder Models Install...

Page 178: ...ent inter ference with the LOW OIL switch All Models Install oil pump retainer screw s Tighten securely IMPORTANT Turn self tapping screws counter clock wise to start the threads and clockwise to tigh...

Page 179: ...182 Pressure Relief Valve 183 Thermostat 183 Block Venting 184 Water Pressure Connection 184 Operation 185 Cylinder Block Cylinder Head Cooling 1 85 EMM and Vapor Separator Cooling 185 Engine Tempera...

Page 180: ...1 9 2 4 5 6 8 7 1 3 10 Incoming water cool Outgoing water warm hot 1 Water intake screens 2 Water pump 3 Exhaust housing 4 Cylinder block 5 Pressure relief valve 6 Thermostat 7 Water supply to EMM 8 W...

Page 181: ...01818 1 Water intake screens 2 Water pump 3 Water tube 4 Adapter housing 5 Cylinder block 6 Pressure relief valve 7 Thermostat 8 Water supply to EMM 9 Water supply EMM to vapor separator 10 Overboard...

Page 182: ...et This hole provides cooling water for the tip of the exhaust passage Be sure to use the correct parts when replacing the water pump Exhaust Housing 2 Cylinder Models The water pump outlet connects w...

Page 183: ...ts in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing completely Thermostat The thermostat controls water flow and operating temperature at lower speeds below 1800 RPM Ove...

Page 184: ...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 185: ...out of the outboard At higher speeds water pressure opens the pressure relief valve at approximately 1800 RPM Water flows through the valve to the cylinder head and bypasses the thermostat All water f...

Page 186: ...display indicates a WATER TEMP warning refer to WATER TEMP HOT Cir cuit Test on p 114 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature sensor readin...

Page 187: ...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 188: ...of Thermal Joint Compound P N 322170 Sensor cavity should be filled to 1 inch 25 mm below the top edge of the cavity Install sensor DO NOT use gasket sealing com pound SLOWLY tighten temperature sens...

Page 189: ...mostat Refer to Cylinder Head Installation on p 214 Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly Assembl...

Page 190: ...f corrosion Replace damaged parts Clean debris from housing and parts Assembly Assembly is the reverse of disassembly Pay close attention when performing the following additional tasks Install a new p...

Page 191: ...4 Cylinder Block Cleaning 207 Powerhead Inspection 208 Powerhead Assembly 210 Crankshaft Assembly 210 Pistons and Connecting Rods 211 Cylinder Head Installation 214 Crankshaft and Connecting Rod Insta...

Page 192: ...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 B 18 20 ft lbs 24 5 27 N m 002283 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue N...

Page 193: ...H H H B A D 002284 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 M RTV Sealant P Permatex No 2 Q Gel Seal I...

Page 194: ...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 002281 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G...

Page 195: ...m 110 130 Ft lbs 149 176 N m H H B A D 002282 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 M RTV Sealant P...

Page 196: ...n Pin Retainer Tool Use the drawing below to modify a pair of needle nose pliers to remove piston pin retaining rings 0 09375 in 2 38125 mm 0 03125 in 0 79375 mm 0 03125 in 0 79375 mm 0 0625 in 1 5875...

Page 197: ...oken 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 43 Powerhead Removal 2 Cylinder Mode...

Page 198: ...olding the exhaust water valve to the exhaust housing Move water valve aside and remove the eight exhaust housing to powerhead screws Use a suitable tool to carefully separate the pow erhead from exha...

Page 199: ...riate chain hook to eye of tool and support weight of powerhead with hoist WARNING Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure R...

Page 200: ...bly Label connectors for reassembly locations Refer to EMM Servicing on p 77 Remove flywheel and stator Refer to Flywheel and Stator Servicing on p 116 Remove ignition coils and fuel injectors Refer t...

Page 201: ...r 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 Thr...

Page 202: ...PORTANT Do not use a tapered punch or any other tool that could jam in or damage the ta per bore when removing the pin Remove crankcase flange screws Loosen in stages and remove the main bearing nuts...

Page 203: ...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 204: ...ssing 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 of...

Page 205: ...scard seal Inspect housing and replace if necessary Remove the O ring from crankshaft sleeve and inspect it Replace the O ring if it is not in good condition Inspect the crankshaft sleeve and replace...

Page 206: ...ower bearing retaining ring IMPORTANT If the lower main bearing is re moved from the crankshaft it must be discarded DO NOT reuse it Use a bearing separator to support the bearing and press off the cr...

Page 207: ...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 208: ...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 and main bearing jo...

Page 209: ...asure 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 cylinder bore d...

Page 210: ...e 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 not...

Page 211: ...Pack lip of upper oil seal with Moly Lube Place seal on crankshaft with lip down and enclosed face up Do not apply sealer to outside edge of the seal Pistons and Connecting Rods New pistons are stamp...

Page 212: ...st pin Place connect ing rod with bearings washers and tool into the piston with the alignment dots facing the top of the piston Install wrist pin through piston and connecting rod pushing bearing too...

Page 213: ...appro priate ring compressor with outboard lubricant Center connecting rod in piston and locate piston rings on dowel pins Place appropriate ring com pressor on piston Slide piston and rod assembly i...

Page 214: ...nstall 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 Install cylind...

Page 215: ...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 bearing...

Page 216: ...ot on rod and that both dots face fly wheel Install Rod Cap Alignment Fixture P N 396749 before tightening rod cap screws Align the flat marked SET on the rod engagement stop with the arrow on the fra...

Page 217: ...Tighten the forcing 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 t...

Page 218: ...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 replac...

Page 219: ...llow at least two hours for Gel Seal II to cure before running outboard Apply Gasket Sealing Compound to both sides of a new water cover gasket Place gasket and cover on cylinder block Apply Nut Lock...

Page 220: ...cotter pin and washer on the shaft 2 cylin der models Install shift rod lever and tighten retaining screw to a torque of 60 to 84 in lbs 7 to 9 5 N m Apply Triple Guard grease to shoulder of shift ar...

Page 221: ...nal Powerhead Assembly Install the reed plate and throttle body assemblies Refer to Intake Manifold Service on p 156 Install oil recirculating hoses and check valves Refer to Oil Recirculation Diagram...

Page 222: ...nstalled in their original location Improper injector installation can result in powerhead failure Install stator and flywheel Refer to Flywheel and Stator Servicing on p 116 Install electrical harnes...

Page 223: ...otor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position with flats fac ing away from each other Apply Moly Lube to all sides of reta...

Page 224: ...t 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 powe...

Page 225: ...ck to threads of exhaust water valve screws 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 v...

Page 226: ...slowly lower powerhead onto exhaust housing 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...

Page 227: ...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 228: ...al Tighten adjustment screws to 60 to 84 in lbs 7 to 9 5 N m Final Adjustments Adjust timing pointer Index all spark plugs Refer to Spark Plug Indexing on p 43 Use Evinrude Diagnostics software to sta...

Page 229: ...229 Powerhead Powerhead Views 10 Powerhead Views 006490 2 Cylinder Port Hose Routings 006491 2 Cylinder Starboard Hose Routings...

Page 230: ...Powerhead Powerhead Views 230 2 Cylinder Port Dressed Powerhead 2 Cylinder Starboard Dressed Powerhead 010510 010508...

Page 231: ...231 Powerhead Powerhead Views 10 2 Cylinder Port Rope Start Models 2 Cylinder Starboard Rope Start Models 008370 008185...

Page 232: ...Powerhead Powerhead Views 232 2 Cylinder Front 008160...

Page 233: ...Powerhead Powerhead Views 233 10 2 Cylinder Rear 010509...

Page 234: ...Powerhead Powerhead Views 234 2 Cylinder Top 010511...

Page 235: ...235 Powerhead Powerhead Views 10 2 Cylinder Top Rope Start Models 008186...

Page 236: ...Powerhead Powerhead Views 236 3 Cylinder Port Hose Routings 3 Cylinder Starboard Hose Routings 006760 006761...

Page 237: ...237 Powerhead Powerhead Views 10 3 Cylinder Port Dressed Powerhead 3 Cylinder Starboard Dressed Powerhead 010514 010516...

Page 238: ...Powerhead Powerhead Views 238 3 Cylinder Front 008166...

Page 239: ...239 Powerhead Powerhead Views 10 3 Cylinder Rear 010515...

Page 240: ...Powerhead Powerhead Views 240 3 Cylinder Top 010517...

Page 241: ...5 Exhaust Housing Assembly 256 Stern Bracket 2 Cylinder Models with Power Tilt 258 Stern Bracket Disassembly 258 Stern Bracket Assembly 259 Stern Bracket 3 Cylinder Models 260 Stern Bracket Disassembl...

Page 242: ...tra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant M RTV Sealant P Permatex No 2 Q Gel Seal II X See Service Manual Procedure Y Extreme Pressure Grease Z Thermal Joint Compound F 60...

Page 243: ...4 In lbs 7 9 5 N m E 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m E 60 84 In lbs 7 9 5 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Loc...

Page 244: ...In lbs 1 2 N m 45 50 Ft lbs 61 68 N m A A 45 50 Ft lbs 61 68 N m A A A 010308 A A IMPORTANT Use Triple Guard grease on all pivot points A Triple Guard Grease B Gasket Sealing Compound E Red Ultra Loc...

Page 245: ...A A U A 216 240 In lbs 25 27 N m F 38 45 Ft lbs 52 61 N m A B 130 150 Ft lbs 176 204 N m A 170 190 In lbs 19 22 N m 45 50 Ft lbs 61 68 N m 40 50 In lbs 4 5 5 5 N m 216 240 In lbs 25 27 N m 010309 A A...

Page 246: ...6 19 N m F 144 168 In lbs 16 19 N m X 40 45 Ft lbs 54 61 N m A A A 144 168 In lbs 16 19 N m IMPORTANT Use Triple Guard grease on all pivot points A Triple Guard Grease B Gasket Sealing Compound E Red...

Page 247: ...lbs 24 5 27 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 5 27 N m 20 30 In lbs 2 3 3 4 N m 36 48 In lbs 4 5 4 N m A 36 40 Ft lbs 49 54 N m F 18 20 Ft lbs 24 5 27 N m 24 36 In lbs 2 7 4 N m F F A A D D 0...

Page 248: ...se from the 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 R...

Page 249: ...t tube 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...

Page 250: ...the exhaust housing Remove the gearcase Refer to Gearcase Removal and Installation on p 46 Remove the powerhead Refer to Powerhead Powerhead Removal on p 197 Remove the three lower mount cover screws...

Page 251: ...that all water passages are clear Install hoses to fittings on exhaust housing Place water valve and bracket in position Apply Nut Lock to screws install and tighten 60 to 84 in lbs 7 to 9 5 N m Exhau...

Page 252: ...ead under the center screw Tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N m Place lower thrust washer on the steering shaft and place the lower front mount into position Install lower side m...

Page 253: ...owerhead Removal on p 197 Remove and discard four lower mount screws Remove the exhaust housing Lower Mount Service Remove lower mount covers and inspect the lower mounts If replacement is necessary l...

Page 254: ...er mount screws with lock patch Tighten screws to a torque of 38 to 45 ft lbs 51 to 61 N m Install gearcase Refer to Gearcase Removal and Installation on p 46 Install powerhead Refer to Powerhead Inst...

Page 255: ...upper and lower thrust mounts and replace if deteriorated or damaged Before checking the exhaust housing for distor tion thoroughly clean the top and bottom mating surfaces and remove all sealer and...

Page 256: ...housing Apply Ultra Lock to the threads of the screws and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Place a new grommet on the water tube and coat the outside edge with Adhesive 847 Install...

Page 257: ...pply Gel Seal II sealant to the adapter flange of the exhaust housing Place the adapter inner exhaust housing into the exhaust housing Guide the water tube through the hole in the outer housing and th...

Page 258: ...crews upper mount and ground lead from the bracket Pull the steering arm out of the swivel bracket Use an appropriate tool to pry the upper seal from the swivel bracket Use an appropriate tool to pry...

Page 259: ...Lubricate the swivel bracket bushings with Triple Guard grease Place the bushings in the swivel bracket Position the swivel bracket between the stern brackets Place a thrust washer between each of the...

Page 260: ...n Bracket Disassembly Before servicing the stern bracket Remove gearcase Refer to Gearcase Removal and Installation on p 46 Remove powerhead Refer to Powerhead Removal on p 197 Remove exhaust housing...

Page 261: ...scard Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to Tilt Tube 3 Cylin der Models on p 248 Remove the two tilt tube washers Remove the anode Remove the swivel bracket...

Page 262: ...g from the swivel bracket and inspect the detent roller and spring Stern Bracket Assembly IMPORTANT Before proceeding make sure all components have been thoroughly cleaned Re place any seals that have...

Page 263: ...f 216 to 240 in lbs 25 to 27 N m Install the trail lock and bushings in the swivel bracket Tighten to a torque of 216 to 240 in lbs 25 to 27 N m Install the trail lock spring in the swivel bracket and...

Page 264: ...als 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 with...

Page 265: ...nd stern brackets through the two forward grease fit tings Install the exhaust housing Refer to Exhaust Housing Installation on p 254 Stern Bracket 2 Cylinder Manual Tilt Clamp Screw Service Inspect c...

Page 266: ...eering 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 re...

Page 267: ...wo stern bracket flange screws and separate the stern brackets from the swivel bracket Place the tilt run lever in the RUN position Loosen the bellcrank setscrew Remove the tilt run lever port stop li...

Page 268: ...rse 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 reverse lock assembly In...

Page 269: ...he 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 screw...

Page 270: ...ering 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 surfa...

Page 271: ...nd the 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 option...

Page 272: ...r 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 the throttl...

Page 273: ...Remove handle Disassembly Loosen throttle friction control so there is no restriction on grip IMPORTANT Do not back screw out completely Nut is under spring tension Use Twist Grip Remover P N 390767...

Page 274: ...e Remove the throttle cable retaining clip Pry the cable trunnion out of the steering handle and remove cable IMPORTANT DO NOT remove the inner handle except to replace it Use a punch and mallet to dr...

Page 275: ...on Inspect the throttle cable for kinks and wear Replace if necessary Inspect the steering handle components for wear cracks or damage Replace parts if necessary Assembly Install the throttle cable se...

Page 276: ...through the end of the throttle cable Lubricate end of the pin guides rollers helix grooves and inner handle guide slot with Moly Lube Place the guides over the roller pin and into the slots of the in...

Page 277: ...the bushings into the steering bracket Attach the steering handle to the bracket Tighten screw to a torque of 36 to 40 ft lbs 49 to 54 N m Route throttle cable and electrical harness through grommet...

Page 278: ...ttle cam is against idle stop when anchor screw aligns with throttle body boss Then rotate anchor four turns toward the end of the cable Install washer cable anchor and cable anchor screw on throttle...

Page 279: ...m shift cable Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove shift and throttle cables and wire harness from grommet in lower engine cover Remove lo...

Page 280: ...crews and bottom cover of tiller handle Remove stop switch cover screws unplug stop switch electrical connector and remove stop switch assembly Disconnect trim switch connector Remove con nector from...

Page 281: ...le cable retaining clip Pry the cable trunnion out of the steering handle and remove cable The trim switch wiring can now be removed from the inner handle Remove the screw and washer retaining the inn...

Page 282: ...hift cable retainer from shift cable trun nion Remove cotter pin from shift handle pin Remove shift cable Remove shift handle screw and washer Remove shift handle bushing and washer Remove shift handl...

Page 283: ...nstall shift pin into shift handle Tighten to a torque of 18 to 22 ft lbs 24 5 to 29 N m Coat detent ball spring and guide with Triple Guard grease and install into shift handle Place one washer on sh...

Page 284: ...ab must be flush with top of flange Apply Nut Lock on the screw threads install the washer and screw IMPORTANT Turn self tapping screw counter clock wise until threads of screw engage threads of screw...

Page 285: ...ner steering handle Wire guide should slide easily into place If any binding is felt inspect trim switch wiring for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Make...

Page 286: ...bricate 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 the ends...

Page 287: ...e Snap the grip into place Install stop 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 angl...

Page 288: ...nstall the electrical cover Use tie strap to secure harness to throttle body bracket Control Cable Installation IMPORTANT DO NOT complete final attach ment of cables to shift and throttle levers until...

Page 289: ...engages the pin Lock the retainer by moving the angled section behind the straight section Throttle Cable Adjustment Place throttle cable in position Use Ball Socket Installer tool P N 342225 to snap...

Page 290: ...e body boss Tighten screw securely IMPORTANT Rotate twist grip Make sure throt tle cam goes to full throttle without bending cable and still returns to IDLE stop 1 Cable anchor 2 Boss 3 Cable retainer...

Page 291: ...eral 295 Reservoir Fluid 295 Manual Release Valve 295 Stern Brackets 295 Troubleshooting 296 Electrical Circuit Tests 296 Relay Testing 296 Trim and Tilt Motor Current Draw Tests 296 Trim and Tilt Mot...

Page 292: ...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 010326 A Triple Guard Grease E Red Ultra Loc...

Page 293: ...0 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 010327 A Triple Guard...

Page 294: ...ugh the tilt range IMPORTANT When in tilt range make sure wa ter is available to gearcase water pickups Manual Adjustment The outboard can be manually raised or lowered through its entire trim and til...

Page 295: ...fluid leakage Correct causes as necessary Check the battery to be sure it is in good operating condition Reservoir Fluid Check reservoir fluid level at least every three years or 300 operating hours S...

Page 296: ...erminal The green trim motor wire remains grounded When the button is released the blue trim motor wire returns to a grounded position When the trim DOWN button is pressed the DOWN relay is energized...

Page 297: ...rrent draw slow operating speed Check for Manual release valve damaged Trim and Tilt Motor No Load Test IMPORTANT Securely fasten motor in a suit able fixture before proceeding with this test Use a ba...

Page 298: ...he trim gauge S terminal With key switch ON gauge should indicate full trim DOWN position Now connect a jumper wire between terminals S and G Gauge should indicate full trim UP position If results are...

Page 299: ...ise the outboard and engage the tilt support Remove the rubber grommet from the blue green trim tilt cable connector Remove the terminals from the connector by using a suitable tool to depress the tab...

Page 300: ...mer P N 391008 Screw the adapter into the cylinder pin and remove the pin Remove one of the locknuts from the angle adjust ment rod Remove the rod from the stern brack ets Remove the unit from the ste...

Page 301: ...n and remove the trim tilt unit from the stern brackets Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw Installation 2 Cylinder Models L...

Page 302: ...install the pin Secure the cylinder pin with cotter clip 3 Cylinder Models Install the ground lead Place trim tilt unit into position Apply Triple Guard grease to the lower pin and install the pin In...

Page 303: ...prevent surface dirt from con taminating internal parts Always use a lint free shop cloth when handling power trim tilt components If painting the unit is required paint it after it is completely asse...

Page 304: ...al release valve There may be pressure behind the valve wear safety glasses Clean up any spilled hydraulic fluid with shop tow els 2 Cylinder Models 002528 3 Cylinder Models 004279 2 Cylinder Models 0...

Page 305: ...oove Piston Seal and End Cap Trim and Tilt Seal Tool Kit P N 5008918 is required for service of the piston and end cap assemblies Removal Refer to Removal on p 299 for trim and tilt assembly removal p...

Page 306: ...in a vice as shown Remove fastener and washer from piston assem bly Note Use spanner wrench P N T 552 to remove fastener from piston of trim and tilt assembly P N 5005756 Remove springs valves and che...

Page 307: ...es Replace damaged tools Assembly IMPORTANT Always use the correct trim tilt flu id Some trim and tilt assemblies use Power Trim Tilt and Steering Fluid and some use Evin rude Johnson Biodegradable Tr...

Page 308: ...ice Charts on p 292 Assemble the piston as shown in the Service Charts on p 292 Tighten fasteners to specified torque Service Charts on p 292 Apply trim tilt fluid to the inside diameter of the resizi...

Page 309: ...dge 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 Use a piec...

Page 310: ...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 311: ...he 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 assembly Use end cap spanner wrench P N 352932...

Page 312: ...allation IMPORTANT 3 Cylinder models Use only Evinrude Johnson Biodegradable TNT Fluid to fill the hydraulic system Install drive coupler in pump assembly Install a new motor O ring Position the motor...

Page 313: ...ly extended Oil should be level with bottom of fill port Install and tighten the fill plug to a torque of 45 to 55 in lbs 5 to 6 N m Refer to Installation on p 301 for trim and tilt assembly installat...

Page 314: ...314 Trim and Tilt Notes Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 315: ...5 13 Manual Starter Table of Contents Service Chart 316 Recoil Starter Removal 317 Recoil Starter Disassembly 317 Recoil Starter Cleaning and Inspection 319 Recoil Starter Assembly 319 Recoil Starter...

Page 316: ...ervice Chart Service Chart 96 to 120 in lbs 11 to 13 5 N m V F 60 to 84 in lbs 7 to 9 5 N m F 120 to 144 in lbs 13 5 to 16 N m E 120 to 144 in lbs 13 5 to 16 N m V 003724 E Red Ultra Lock F Blue Nut L...

Page 317: ...emove 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 Remove the rope guid...

Page 318: ...ng 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 th...

Page 319: ...ay the starter rope File and polish to remove Examine the starter and starter lockout parts Replace any worn or damaged parts Recoil Starter Assembly Place starter spring shield and pulley bushing int...

Page 320: ...into the starter housing Locate the outer loop of the rewind spring on the pin in the starter housing Press down through the holes in the spring winder base to transfer the rewind spring into the star...

Page 321: ...er pawl plate return spring on the starter pawl plate Press the other end of spring on the boss of the pulley Position the starter pawl plate on the pulley Clean threads of the starter pawl plate reta...

Page 322: ...outlet in the starter handle bracket Seat the knotted end of the starter rope in the pul ley Tie a slip knot in the starter rope to hold rope in position Apply Triple Guard grease or Lubriplate 777 to...

Page 323: ...to 16 N m Place the starter assembly onto the outboard Install the starter housing retaining screws wash ers and lock washers Be sure to place washers between the starter housing and the flywheel cov...

Page 324: ...324 Manual Starter Notes Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 325: ...and Safety S 332 Outboard Mounting System and Safety S 335 If weakened parts could fail later on the water when not expected S 336 Outboard Hydraulic Tilt Trim Shock Absorption System and Safety S 33...

Page 326: ...S 326...

Page 327: ...e not had training related to common shop safety practices you should do so not only to protect yourself but also to protect the people around you It is impossible for this manual to cover every poten...

Page 328: ...IF NEUTRAL FORWARD REVERSE FORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted...

Page 329: ...UTRAL Operator must be able to STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How ca...

Page 330: ...arts here at the steering wheel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could b...

Page 331: ...that will not loosen rust or weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK ear...

Page 332: ...k What is most important Fuel leakage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is store...

Page 333: ...Metal Clamps Tie Straps Position as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark P...

Page 334: ...heck for leaks under engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is...

Page 335: ...must stay in position on boat s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits somethi...

Page 336: ...nsom is curved outboard may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken...

Page 337: ...rd must not trim in too far suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow w...

Page 338: ...ere at the clip and lanyard and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled f...

Page 339: ...or may drown and boat WILL run into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow wa...

Page 340: ...proper safety takes time Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damage...

Page 341: ...gravity Stand Clear It might hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly...

Page 342: ...ard to work on the outboard remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts l...

Page 343: ...ns and other boats Avoid exhaust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create...

Page 344: ...ng engine or operating boat Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propel ler can continue to turn even after the engine is off Always shut off th...

Page 345: ...ty when connecting these larger leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged...

Page 346: ...hem if fumes are smelled Matches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors...

Page 347: ...hurt people READ How and where to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle labe...

Page 348: ...rstand that the service manual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you rec...

Page 349: ...necting Rod 216 Crankshaft 205 206 210 211 Wrist Pin 204 212 Break In EMM Programming 170 228 Oiling 170 Procedure 73 C Capacitor Test 89 Clamp Screw 265 Connecting Rods Installation on Crankshaft 216...

Page 350: ...d Control 74 Oil Injector Test 172 Oil Priming 176 Oiling Rate 72 169 Reports 75 Sensor Monitoring 101 Static Ignition Test 87 Timing Verification 73 120 TPS Calibration 74 121 Dual Outboard Alignment...

Page 351: ...mum Octane 139 Pressure Tests 144 Priming 143 Recommended Fuels 12 14 Relieving Pressure 148 Requirements 138 Troubleshooting 83 90 144 Vapor Separator 140 150 Fuse 100 G Gearcase Installation 47 Lubr...

Page 352: ...Oil Injector Electrical Circuit 55 V 167 Electrical Tests 172 Functional Test 173 Oiling Rate 73 169 Oiling System Components 166 Electrical Circuits 165 Engine Lubricant 166 Low Oil Switch 64 New En...

Page 353: ...System 160 Shift Cable Adjustment Tiller 288 Shift Linkage Adjustment 228 Installation 220 Lubrication 39 Removal 201 Shift Rod Adjustment 13 15 Shutdown 68 No Oil 168 Spark Plugs Gap 13 15 43 Indexin...

Page 354: ...nter Adjustment 119 Tools Accessory Power Cable Kit P N 5008092 69 76 154 Ball Socket Installer tool P N 342225 278 289 Ball Socket Remover tool P N 342226 156 272 279 Battery Cable P N 584348 70 Boot...

Page 355: ...P N 318600 213 Wrist Pin Pressing Tool P N 326356 204 Wrist Pin Retaining Ring Driver P N 318599 213 Torque Charts see Service Charts TPS Calibration 121 Trailering Bracket 294 Lubrication 39 Trim and...

Page 356: ...I 356 Index Notes Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 357: ...ontents Outboard Will Not Start T 358 Outboard Will Not Start T 359 Outboard Hard to Start T 360 Outboard Will Not Shut Off T 361 Outboard Starts and Stalls T 361 Outboard Starts Low Maximum RPM T 362...

Page 358: ...iring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendix drive g...

Page 359: ...rking 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 alte...

Page 360: ...ck 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 Ca...

Page 361: ...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 362: ...is and Electrical and Ignition Fuel injector electrical circuit or control function Check voltage at injectors refer to System Anal ysis Restricted or leaking fuel injec tors Check injectors refer to...

Page 363: ...up check for fuel system air leaks Restricted or leaking fuel injec tor s Check injectors refer to Fuel System Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring...

Page 364: ...Trouble Check Chart Notes T 364 Notes Technician s Notes Related Documents Bulletins Instruction Sheets Other...

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