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Evinrude & Johnson E75DPLSCB, Service Manual

The Evinrude & Johnson E75DPLSCB is a reliable and powerful outboard motor, perfect for avid boaters and fishing enthusiasts. To ensure proper maintenance and performance, make sure to have the Service Manual on hand. You can easily download this manual for free from our website, manualshive.com, to keep your E75DPLSCB running smoothly.

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

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
  1 SPECIAL TOOLS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
  2 INSTALLATION AND PREDELIVERY   . . . . . . . . . . . . . . 25
  3 MAINTENANCE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
  4 ENGINE COVER SERVICE   . . . . . . . . . . . . . . . . . . . . . . 81
  5 ENGINE MANAGEMENT MODULE (EMM)  . . . . . . . . . . 85
  6 SYSTEM ANALYSIS  . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
  7 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 117
  8 FUEL SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
  9 OILING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10 COOLING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
12 MIDSECTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
13 GEARCASE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
SAFETY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1
INDEX  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I–1
TROUBLE CHECK CHART   . . . . . . . . . . . . . . . . . . . . . . . . T–1
DIAGRAMS

EMM

 SERVICE CODE CHART

Summary of Contents for E75DPLSCB

Page 1: ...2008 SC E TEC 75 90 P N 5007527 75 90 HP 5007527 Service Manual ...

Page 2: ......

Page 3: ...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 registered trademark of the National Marine Electronics Association Oetiker is a registered trademark of Hans Oetiker AG Maschinen Packard is a registered trademark of Delphi Automotive Systems Permatex is a ...

Page 4: ...4 ENGINE COVER SERVICE 81 5 ENGINE MANAGEMENT MODULE EMM 85 6 SYSTEM ANALYSIS 103 7 ELECTRICAL AND IGNITION 117 8 FUEL SYSTEM 153 9 OILING SYSTEM 175 10 COOLING SYSTEM 189 11 POWERHEAD 199 12 MIDSECTION 235 13 GEARCASE 257 14 TRIM AND TILT 287 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1 DIAGRAMS EMM SERVICE CODE CHART ...

Page 5: ...NE EMISSIONS INFORMATION 7 MANUFACTURER S RESPONSIBILITY 7 DEALER S RESPONSIBILITY 7 OWNER S RESPONSIBILITY 7 EPA EMISSION REGULATIONS 7 MODEL DESIGNATION 8 MODELS COVERED IN THIS MANUAL 9 IDENTIFYING MODEL AND SERIAL NUMBERS 9 SERVICE SPECIFICATIONS 10 STANDARD TORQUE SPECIFICATIONS 12 PRODUCT REFERENCE AND ILLUSTRATIONS 12 ...

Page 6: ... never rush or guess a service pro cedure Human error is caused by many factors carelessness fatigue overload preoccupation unfamiliarity with the product and drugs and alco hol use to name a few Damage to a boat and outboard can be fixed in a short period of time but injury or death has a lasting effect When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalen...

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 cables at the battery Twist and remove all spark plug leads The electrical system presents a serious shock hazard DO NOT handle primary or secondary ignition components while outboard is running or fly...

Page 8: ...Direct Current ABYC American Boat Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft position sensor EMM Engine Management Module ICOMIA International Council of Marine Industry Associations MCA marine cranking amps MWS modular wiring system NMEA National Marine Electronics Assoc NTC ne...

Page 9: ...board maintenance performed to maintain emission lev els within prescribed certification standards The owner operator is not to and should not allow anyone to modify the outboard in any manner that would alter the horsepower or allow emis sions levels to exceed their predetermined factory specifications Tampering with the fuel system to change horse power or modify emission levels beyond factory s...

Page 10: ...3 R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex SC 2008 MODEL RUN or SUFFIX DESIGN FEATURES AP Advanced Propulsion B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injection G Graphite Paint H High Output J Jet Drive M Military P Power Trim and Tilt R Rope Start w Tiller Steering S Saltwater Edition T Tiller Steering TE Tiller Electric V White Paint W Commercial Model ...

Page 11: ...TEC models Identifying Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead Model Number Shaft Color Gearcase E75DPLSCB 20 BL S E75DSLSCS 20 WH S E90DPLSCB 20 BL S E90DSLSCM 20 WH S E90DPXSCB 25 WH O E90WDELSCS 20 BL S E90WDEXSCS 25 WH O 1 Model and serial number 002147 1 Serial number 002226 1 1 ...

Page 12: ...d Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journals 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 to 1 3762 in 34 94 to 34 96 mm Piston Ring End Gap Both 0 011 to 0 023 in 0 28 to ...

Page 13: ...800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC10WEP 0 028 003 in 0 71 mm GEARCASE Gear Ratio 20 in L Models 13 26 500 25 in X Models 12 27 444 2 1 2 25 1 Lubricant HPF XR Gearcase Lube Capacity 20 in L Models 31 6 fl oz 935 ml 25 in X Models 32 8 fl oz 970 ml Shift Rod Height 20 in L Models 21 25 539 75 mm one half turn 25 in X Model...

Page 14: ... in all marketing areas All service technicians must be familiar with nauti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 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 36 48 3 4 4 0 5 4 1 4 in 60 84 5 7 7 9 5 5 16 in 120 144 10 12 13 5 16 5 3 8 in 216 240 18 20 24 5 27 7 16 in 336 384 28 32 38 43 ...

Page 15: ...S 13 1 SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS 14 UNIVERSAL TOOLS 14 ELECTRICAL IGNITION TOOLS 16 FUEL OIL SYSTEM TOOLS 17 POWERHEAD TOOLS 17 GEARCASE TOOLS 18 TRIM AND TILT TOOLS 20 SHOP AIDS 21 NOTES 24 ...

Page 16: ...6 Interface cable P N 437955 45583 Universal Puller Set P N 378103 32885 Flywheel holder P N 771311 42938 Slide hammer adapter P N 340624 39435 Lifting eye P N 321537 23701 Slide hammer P N 391008 CO1577 Slide hammer adapter P N 390898 15356 Lifting ring assembly P N 396748 000669 Slide hammer P N 432128 15345 Puller Bridge 432127 23146 ...

Page 17: ...t tube nut wrench P N 342680 46879 Temperature gun P N 772018 45240 Large puller jaws P N 432129 23148 Tilt tube service kit P N 434523 33249 Fresh water flusher P N 500542 50110 Bearing puller jaws P N 432130 23149 Syringe P N 346936 50243 Oetiker pincers P N 787145 001081 ...

Page 18: ...tator Test Adapter P N 5005799 002273 Connector tool P N 342667 42004 Peak reading voltmeter P N 507972 49799 Crimping pliers P N 322696 30387 AMP connector tools Primary Lock Tool P N 777077 Secondary Lock Tool P N 777078 Release Tool P N 351413 Lock Installer P N 777079 002277 Test probe kit P N 342677 45241 Tachometer timing light P N 507980 49789 ...

Page 19: ...5 PSI P N 5006397 90 fitting P N 353322 004560 Injector test fitting kit P N 5005844 002465 Cylinder bore gauge P N 771310 45303 Piston stop tool P N 342679 Replacement tip P N 5006098 46543 Rod cap alignment fixture P N 396749 21596 Torquing socket P N 331638 000797 Crankshaft bearing and sleeve installer P N 338647 21953B Wrist pin bearing installer P N 336660 41029 ...

Page 20: ...veshaft Shimming Tool P N 5005925 1 Lower Driveshaft Shimming Bolt S2 gearcase P N352878 002601 Gearcase filler P N 501882 49790 1 Universal Pinion Bearing Remover and installer kit P N 5005927 002805 1 Pinion nut holder P N 334455 2 Wrench retainer P N 341438 40371 1 2 Gearcase pressure tester P N 507977 Stevens P N S 34 Gearcase vacuum tester P N 507982 Stevens P N V 34 49794 Universal shift rod...

Page 21: ...ft Puller P N 390706 32884 Lower Driveshaft Puller P N 342681 47257 Driveshaft seal protector P N 318674 23692 Driveshaft socket P N 311875 23261 Pinion nut starting tool P N 342216 40372 Bearing Installer P N 326562 32962 Prop shaft bearing installer P N 339750 32880 Prop shaft housing seal installer P N 326551 P N 336311 32973 Seal installation tool P N 330268 32924 ...

Page 22: ...20 SPECIAL TOOLS TRIM AND TILT TOOLS TRIM AND TILT TOOLS Tilt cylinder end cap remover P N 352932 for single piston tilt systems 005340 Spanner wrench P N 912084 32213 ...

Page 23: ...ti Purpose Lubricant P N 777192 Oil XD100 P N 777118 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 777225 Anti Corrosion Spray P N 777193 Silicone spray P N 775630 Oil XD30 P N 777219 HPF XR Gear Lube P N 778755 HPF PRO Gearcase Lube P N 778755 Moly Lube P N 175356 ...

Page 24: ...8298 Needle Bearing Grease P N 378642 Power Trim Tilt and Power Steering Fluid P N 775612 Black Neoprene Dip P N 909570 Starter Bendix Lube P N 337016 Biodegradeable TNT Fluid P N 763439 Electrical Grease P N 503243 2 4 Fuel conditioner P N 775613 Gel Seal and Gasket Remover P N 771050 Permatex No 2 P N 910032 ...

Page 25: ...t Sealing Compound P N 317201 Pipe Sealant with Teflon P N 910048 Locquic Primer P N 772032 Adhesive 847 P N 776964 Thermal Joint Compound P N 322170 Instant Bonding Adhesive P N 509955 1 Screw Lock P N 500417 Loctite Purple 222 equivalent 2 Nut Lock P N 500421 Loctite Blue 242 Equivalent 3 Ultra Lock P N 500423 Loctite Red 271 Equivalent 1 2 3 ...

Page 26: ...24 SPECIAL TOOLS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 27: ... ADJUSTMENTS 46 ELECTRICAL HARNESS CONNECTIONS 48 WATER PRESSURE GAUGE 48 CANBUS CONNECTIONS 49 FUEL AND OIL PRIMING 51 FUEL REQUIREMENTS 51 FUEL SYSTEM PRIMING 52 OIL REQUIREMENTS 52 OIL INJECTION RATE 53 BREAK IN OILING 54 OIL SUPPLY PRIMING 54 BEFORE START UP 55 RUNNING CHECKS 56 ENGINE MONITORING SYSTEM 56 FUEL SYSTEM 56 EMERGENCY STOP KEY SWITCH 56 REMOTE CONTROL OPERATION 56 START IN GEAR PR...

Page 28: ...ng System IMPORTANT Outboards with remote controls must be equipped with an I Command system a SystemCheck gauge or an equivalent engine monitor Operating the outboard without an engine monitor will void the warranty for failures related to monitored functions Refer to ENGINE MONITORING SYSTEM on p 93 WARNING The remote control used must have start in gear prevention This feature can pre vent inju...

Page 29: ...or exceeds the mini mum requirements Minimum 12 Volt Battery Recommendations Location and Preparation Proper installation will prevent battery movement while underway Secure all batteries in protected locations Place battery as close to the outboard as possi ble Battery location must provide access for peri odic maintenance Use battery mounting trays or battery boxes on all battery installations C...

Page 30: ...llations with extended length battery cables require an increased wire size Refer to the following table IMPORTANT Inadequate battery cables can affect the performance of an outboard s high amperage start circuit and the cranking speed of the outboard DO NOT use aluminum wire cables Use ONLY AWG stranded copper wire cables Battery Switches and Multiple Batteries A multiple battery setup including ...

Page 31: ...or each outboard installed Use the appropriate sized wire and terminals for all connections Use AWG stranded copper wire Battery Switch Location Always locate battery switch as close to the bat teries as possible Locate switch so that it cannot be accidently bumped or switched Refer to the battery switch manufacturer s installation instructions for specific information related to the installation ...

Page 32: ...d OFF ON PRIMARY 1 S 000135rev1 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 000136rev2 One outboard Battery disconnect One outboard One primary starting battery one secondary battery SECONDARY PRIMARY S 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 1 1 1 2 2 000134rev2 1 2 OFF BOTH 2 Positive Battery cables Negative Battery cables A h i P N 5006253 ...

Page 33: ...ION AND PREDELIVERY BOAT RIGGING 31 2 Two outboards One primary starting battery for each outboard PRIMARY 1 PRIMARY 2 S S 000086rev2 1 2 OFF BOTH 1 2 OFF BOTH 1 2 Positive Battery cables Negative Battery cables ...

Page 34: ...talled fuel hoses should be as short and horizontal as possible Use corrosion resistant metal clamps on perma nently installed fuel hoses Multi outboard applications require separate fuel tank pickups and hoses A fuel selector switch may be used for kicker motors as long as it has enough flow capacity for the larger out board Fuel System Primer Outboards require a priming system capable of refilli...

Page 35: ...esult in serious powerhead damage Outboard Fuel System Recommendations 0070 Typical Fuel Supply Configuration 1 Primer bulb 2 Water separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC6797 1 2 3 Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5 16 in 7 9 mm min I D 3 8 in 9 5 mm min I D Fuel fittings 1 4 in 6 4 mm min I D 9 32 in 7 1 mm min I D Fuel suppl...

Page 36: ...or kit Cable and Wire Harness Routing Remote control cables wiring and hoses must follow a similar path into the lower motor covers Select the best routing for the specific application All cables wiring and hoses must be long enough to provide adequate slack Check clearances at all possible combinations of trim angles and steering positions Typical outboard installation 1 Oil tank 2 Anti siphon va...

Page 37: ...y cables be sure to Route cables through the protective sleeve Use the most direct path to route the battery cables to the battery or battery switch Fuel Hose The fuel hose may be routed outside of the pro tective sleeve or conduit Electric primers or man ual primers may not require this consideration Route fuel hoses with enough slack to allow the primer bulb arrow to point up during use Install ...

Page 38: ...e clamping range of the clamp Oetiker Stainless Steel Stepless Clamps WARNING DO NOT re use Oetiker clamps Fuel leak age could contribute to a fire or explosion 1 Clamp identification numbers 000093 1 CLAMP NO NOMINAL O D INCHES MILLIMETERS Replacement Clamp I D Inches MM Open Closed Open Closed 346930 95 3 8 9 5 0 374 0 307 9 5 7 8 348838 105 13 32 10 5 0 413 0 346 10 5 8 8 349516 113 7 16 11 3 0...

Page 39: ...epless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accesso ries Catalog P N 787145 Position correct size clamp over hose Install hose on fitting Close clamp ear fully with Oetiker pincers pli ers Clamp Removal Method 1 Position Oetiker pincers across clamp ear and cut clamp Method 2 Lift end of stepless clamp with screw driver Method 3 Use Oetiker pincers pliers ...

Page 40: ...Refer to ABYC Standards to determine the maximum horsepower capacity for boats with out certification labeling Mounting Surface Inspect transom surface prior to drilling mounting holes The transom should meet ABYC Standards The transom must be flat The transom angle should be approximately 14 degrees Check transom strength and height The stern brackets must contact the flat surface of the transom ...

Page 41: ... of bottom strakes on dual outboard installations Transom Brackets and Jack Plates When mounting an outboard on boats equipped with transom brackets or jack plates refer to the manufacturer s recommendations Confirm maximum weight and horsepower capacities Jack plate assemblies must provide a one piece mounting surface to support the outboard Mounting Hardware The required outboard mounting bolts ...

Page 42: ...ering systems may require additional spacing Refer to steering sys tem manufacturer for recommendations The top edge of the transom should be more than twice the width of the dual outboard centerline spacing dimension Bracket installations may not require this consideration Measure the transom for dual outboard spacing after the centerline of the hull is established Divide the spacing dimension by...

Page 43: ...line The indicators are affected by the squareness of the top edge of the transom If either side of the fixture must be raised more than in 6 mm above the transom s top surface to make both indicators align the transom must be modified IMPORTANT DO NOT assume that the top edge of the transom is straight Position the drill fixture based on measurements aligning it to the bottom of the hull IMPORTAN...

Page 44: ... 2 327053 3 in 76 mm 3 1 2 Bolt Hole Locations 7 318273 Retainer 2 318573 3 1 2 in 89 mm 4 Outside of Transom 8 319886 Screw 4 313327 4 in 102 mm 9 307238 Washer 2 336676 4 1 2 in 114 mm 10 320248 Washer 4 331578 5 in 127 mm 11 313623 Nut 4 321577 6 in 152 mm 12 318572 Cap 4 000133m 2 2 50 8mm 2 50 8mm 8 203 2mm 8 203 2mm 4 15 16 125 4mm 4 15 16 125 4mm 6 7 16 163 5mm 6 7 16 163 5mm 2 3 1 3 3 3 1 ...

Page 45: ...h mechanical steer ing systems that meet ABYC Standard P 17 Sin gle cable mechanical steering systems can be used on single or dual outboard installations if an ABYC approved steering link is used Dual cable mechanical steering helps provide firm steering control at high speeds Extend the steering cable and lubricate the inner core before installation IMPORTANT Install steering cable through tilt ...

Page 46: ... ufacturer s recommendations and to Dual Outboard Centerlines on p 40 Drag Links Use the correct drag link to allow full steering travel Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm For single motor single cable applications the drag link should be installed in the rear hole TYPICAL Manual Hydraulic Steering 004948 Model Drag Link 75 90 HP ...

Page 47: ...nting height of the outboard Mounting Bolt Installation IMPORTANT Use a marine sealant rated for above or below waterline use RTV silicone is not approved for below waterline use Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces Apply marine sealer under hex heads of bolts on the mounting plates and to the bolt shanks Assemble transom mounting plates on...

Page 48: ...ments IMPORTANT DO NOT attach cables to throttle and shift levers until all cables wires and hoses have been routed and grommet has been placed into the lower engine cover Pull firmly on shift cable casing to remove slack With outboard in NEUTRAL place the cable trun nion into the lower anchor pocket Adjust the trun nion nut so the casing fits onto the shift lever pin If there are not enough threa...

Page 49: ...eps Place washer on pin Position retainer clip with straight section on the bottom and angled section on the top Use long nose pliers to insert straight section of clip into linkage pin hole Push the clip towards the hole while lifting on the curved end with the pliers Be sure retainer clip fully engages the pin Lock the retainer by moving the angled section behind the straight section Make sure r...

Page 50: ...al Arrange connectors in flywheel cover Install electrical cover and secure with screws IMPORTANT BE SURE all harnesses and wires are not pinched cannot contact flywheel and do not interfere with moving throttle or shift linkages Water Pressure Gauge If a mechanical water pressure gauge is used install the water pressure hose fitting in the cylin der block Use Pipe Sealant with Teflon P N 910048 o...

Page 51: ... cap is clipped to EMM cooling water hose Remove clip from cap and install on CANbus harness connector Install clip and connector to hose Adjust harness routing as needed and secure tie straps Use a CANbus Ignition Harness in place of the standard MWS harness to connect the outboard to the key switch and trim tilt control Seal unused SystemCheck connector with 6 Pin Connector Seal P N 586076 If in...

Page 52: ... is not pinched behind air silencer Make sure both harnesses are in front of tab and CAN bus ignition harness is in wire channel Use Evinrude Diagnostics software to activate CANbus control functions in the EMM From the Settings screen select Engine Options 1 Trim Tilt connector 2 CANbus Ignition connector 3 SystemCheck connector with seal 4 Deutsch style harness power connector 006734 1 Electrica...

Page 53: ...deposits which can 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 can result in poor performance or engine damage Evinrude Johnson 2 4 Fuel Conditioner will help prevent gum and varnish deposits from form ing in fuel system components and will remo...

Page 54: ...with the starter Oil Requirements Evinrude Johnson XD100 XD50 or XD30 out board oils are recommended for use in Evinrude E TEC outboards If these oils are not available you must use a TC W3 certified oil Evinrude Johnson XD100 outboard oil is highly recommended for all conditions and applications Engine Lubricant Below 32 F 0 C If the outboard will be operated in temperatures below freezing 32 F 0...

Page 55: ... Conventional use runabouts cruisers Moderate applications Powerhead oil programming labels are provided to identify EMM oil programming Install the cor rect label to alert user to specific oil requirements An XD100 Outboard Oil Decal P N 352369 is available to label boats equipped with outboards that have been programmed for the reduced oil injection ratio Install decals in a highly visible locat...

Page 56: ...type of oil being used Start the outboard and use the oil priming function in the software for a minimum of 90 seconds to make sure the system is completely primed Observe oil flow through the oil distribution hoses Small bubbles are acceptable Large bubbles must be eliminated through continued priming IMPORTANT All clear blue oil distribution hoses on the powerhead should fill with oil as the air...

Page 57: ...een tested Refer to Oil Requirements on p 52 When starting the outboard for the first time refer to Oil Supply Priming on p 54 Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run ning outboard Tilt the motor up and engage the tilt support Remove filler cap and check fluid level Single Ram System Add Evinrude Johnson Biodegradable TNT Fluid as needed to bring level to the botto...

Page 58: ...t back to NEUTRAL 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 Confirm accuracy of tachometer reading Adjust dial on back of tachometer to required setting the outboard should not be running WARNING DO NOT run outboard without a water sup ply to the outboard s cooling system Cool ...

Page 59: ...CE SPECIFICA TIONS on p 10 Idle Speed Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use Break In When the outboard is delivered refer the cus tomer to the break in information in the Opera tor s Guide The Engine Management Module EMM auto matically supplies extra ...

Page 60: ...r to determine the engine s full throttle RPM The outboard should be trimmed for top speed Select a propeller that suits the customer s application and allows the engine to run near the midpoint of the full throttle operating range when the boat has a normal load Occasionally one propeller will not cover a wide range of boat applications water skiing to high speed performance boating In such cases...

Page 61: ...to 80 ft lbs 95 to 109 N m Without Keeper 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the propeller nut Without Keeper and propeller shaft are not aligned tighten the nut until they are in line Do not loosen Insert a new cotter pin through the propeller nut and shaft or propeller nut keeper and shaft Bend its ends over the nut to secure the assembly IMPORTANT After fastening propelle...

Page 62: ... the maximum tilt position Check the adjustment by tilting the outboard fully Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it con tacts the motor well To prevent damage to equipment provide addi tional motor well clearance when needed Con sider either changing the outboard mounting position or modifying the boat if the possibility for interference and...

Page 63: ...just the sending unit by pivoting it up or down Lower the outboard against the thrust rod to check adjustment Repeat adjustment if necessary After adjustment is correct tilt the outboard up tighten the two sending unit screws and remove the thrust rod 29072 1 Screws 27339 1 1 Needle at center position 000662 WARNING When the outboard is returned to the cus tomer the trim limiter rod must be instal...

Page 64: ... the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m Test the boat and if needed repeat the procedure until steering effort is as equal as possible Outboards with High Transom Heights The trim tab may be above the surface of the water when the o...

Page 65: ...rd alignments Each applica tion must be thoroughly tested until the ideal combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small amount of toe out and adjust inward until best results are achieved A typical set up with 2 stroke outboards mounted directly on the transom often runs best with a slight amount of toe in Outboards ...

Page 66: ...64 INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 67: ... GEARCASE LUBRICANT 71 TRIM AND TILT 73 BATTERY AND BATTERY CONNECTIONS 74 FUEL AND OIL SYSTEMS 74 FUEL FILTER 74 OIL FILTERS AND OIL RESERVOIR 74 AIR SILENCER 75 HOSES AND CONNECTIONS 75 SPARK PLUGS 76 REMOVAL 76 INDEXING 76 STORAGE 77 FUEL SYSTEM TREATMENT 77 INTERNAL ENGINE TREATMENT 77 ADDITIONAL RECOMMENDATIONS 78 PRE SEASON SERVICE 78 OUTBOARD MOUNTING BOLTS 78 GEARCASE LUBRICANT 78 BATTERY ...

Page 68: ...3 Cooling system check water pump indicator water pressure 3 Anticorrosion anodes check condition 3 Gearcase check condition 3 Propeller check condition 3 Fuel and oil systems inspect and repair leaks 2 2 Emission related component 3 Check battery connections and condition 3 Access EMM information resolve any service codes 3 Electrical and ignition wires inspect for wear or chafing 3 Fuel filter r...

Page 69: ...ased antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no resistance If resistance is high check the following Remove the anode and clean the area where the anode is installed Clean the mounting screws Install the anode and test again Metallic Component Protection Protect metal compo...

Page 70: ...between 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 59 Place outboard in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Shift the outboard to NEUTRAL with the propeller removed Turn water supply on START outboard Run it at IDLE only Shut OFF the outboard Turn off water supply and remove garden hose Leav...

Page 71: ...vapor separator flow water freely Replace water pump LUBRICATION Steering System Grease the stainless steel output end of the steer ing cable with Triple Guard grease Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease Make sure wiper nut is installed and not damaged 1 Water intake screen 2 Overboard indicator DSC02220a drc4952a...

Page 72: ... lever pins Carefully remove casing guides from pins IMPORTANT DO NOT disturb cable trunnion adjustments Shift remote control into FULL THROTTLE REVERSE position to fully extend the plastic cas ing guides Apply Triple Guard grease to Cable attachment pins of both the throttle and shift levers Brass inner casings of both the throttle and shift cables Shift the remote control to the NEUTRAL IDLE pos...

Page 73: ...er plug before removing the lower drain fill plug A tie strap can be used to check lubricant level Remove the lubricant level plug then the lubricant drain fill plug and drain the lube from the gear case into a container Inspection Inspect the lube and the magnets on the plugs for metal chips The presence of metal fuzz can indi cate normal wear of the gears bearings or shafts within the gearcase M...

Page 74: ...taminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 66 for service frequency and recommended lubricants Secure the gearcase in a vertical position Remove the lubricant level plug and the lubricant drain fill plug Slowly fill the gearcase with gearcase lube through the drain fill hole until it appears at the oil level hole Filling the gearcase too quick...

Page 75: ...ug threads Install the fill plug and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the unit at least five complete cycles to purge all air from the system When cycling the unit hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the oppo site direction 1 Tilt support bracket 002279 1 Sin...

Page 76: ...Triple Guard grease and insulate to prevent shorts or spark arcing FUEL AND OIL SYSTEMS Routine replacement of filters reduces the possi bility of foreign material restricting the incoming fuel or oil supplies Replacement filter elements are available through Evinrude Johnson Genuine Parts Fuel Filter Evinrude E TEC 40 90 HP outboards are equipped with an in line fuel filter Refer to FUEL COMPONEN...

Page 77: ...ove any accumulation of debris Hoses and Connections Check condition of all hoses and connections in both the fuel and oil systems Visually inspect all components Observe all clamps hoses and connections while outboard is running Replace all damaged components Repair all leaks 002158 WARNING Failure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion ...

Page 78: ... spark plug opposite the fuel injector nozzle Put an ink mark on the ceramic of the spark plug in line with the OPEN side of the ground elec trode This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector Apply Triple Guard grease to the gasket surface of the spark plug Install spark plug and tighten to a torque of 15 ft lbs 20 N m If the m...

Page 79: ...econds the System Check lights will go off Move throttle to IDLE position SystemCheck lights will light again Wait another 15 seconds SystemCheck lights will go off At this point advance throttle to FULL in neutral SystemCheck lights will flash indicating that outboard is in winterize mode Outboard will automatically go to fast idle and fog itself Allow outboard to run until it shuts itself off ab...

Page 80: ...orage make sure it is reinstalled with factory specified hardware Refer to the INSTALLATION AND PREDELIVERY section for proper set up Outboard Mounting Bolts Check and re tighten outboard mounting bolts to a torque of 40 ft lbs 54 N m Gearcase Lubricant Check the lubricant level Inspect gearcase for leaks If leak is apparent pressure and vacuum test gearcase Repair gearcase as needed Battery s Rep...

Page 81: ...onnect oil supply hose and oil return hose from outboard Drain and clean all oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil system and fuel system Refer to FUEL AND OIL PRIMING on p 51 Make sure all oil injection hoses are clean and filled with oil Make sure high pressure fuel system does not contain water Flush as needed In...

Page 82: ...80 MAINTENANCE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 83: ...1 4 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 82 LATCH HOOK INSTALLATION 82 LOWER COVER SERVICE 82 LOWER COVER REMOVAL 82 LOWER COVER INSTALLATION 83 LATCH HANDLE INSTALLATION 84 TRIM SWITCH INSTALLATION 84 ...

Page 84: ...osition with opening toward the front Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m LOWER COVER SERVICE Lower Cover Removal Remove lower engine cover screws Loosen port side cover slightly and disconnect trim tilt switch connector Then remove port and starboard covers 1 Bracket 006468 006469 1 1 Lower cover screws 002168 1 Trim tilt switch connector 002151 1 1 1 ...

Page 85: ... cover Connect trim tilt switch connector Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enough to hold the grommet in place Start the top front screw next and draw cover halves together Install remaining cover screws and tighten all screws to a torque of 24 to 36 in lbs 3 to 4 N m 1 Trim cable grommet 2 Trim tilt switch connecto...

Page 86: ... Place spring washer and hook into position and tighten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on switch Tighten nut to a torque of 10 to 16 in lbs 1 to 2 N m Install electrical connector Refer to CONNEC TOR SERVICING on p 148 1 Triple Guard grease 006470 1 Spring washer 2 Hook 3 Screw 006471 1 3 2 1 006746 006747 006748...

Page 87: ...SWITCH 90 THROTTLE POSITION SENSOR 90 CRANKSHAFT POSITION SENSOR 91 NEUTRAL SWITCH 91 INTERNAL EMM FUNCTIONS 92 ENGINE MONITORING SYSTEM 93 S A F E WARNING SYSTEM 94 SHUTDOWN MODE 94 DIAGNOSTIC SOFTWARE FUNCTIONS 95 COMMUNICATION 95 STATIC INFORMATION 95 DYNAMIC INFORMATION 96 STORED SERVICE CODES FAULTS 96 HARD FAULTS 96 PERSISTENT FAULTS 96 STATIC TESTS 96 DYNAMIC TESTS 97 OIL CONTROL SETTINGS 9...

Page 88: ...ng 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 with loose or disconnected wiring Make sure EMM connections are clean and tight Engine wire harness to EMM connectors J1 A J1 B J2 Stator to EMM connections one 6 pin AMP and J2 connector LED Indicators The EMM has four LED indicators lo...

Page 89: ...3T 1 Engine Management Module EMM 2 Battery 12 volt 3 Stator 4 Crankshaft Position Sensor CPS 5 Throttle Position Sensor TPS 6 Neutral Switch 7 Air Temperature Sensor AT 8 Oil Pressure Switch component of 11 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fuel Injector 14 Tachometer SystemCheck Gauge 15 Diagnostic Connector 16 LED Indic...

Page 90: ...EMM 55 V Circuit Sensor Monitors the EMM s 55 V alternator circuit If system voltage exceeds 57 volts the EMM If system voltage is below 45 volts with outboard running 500 to 1000 RPM or is below 52 volts with outboard running above 1000 RPM the EMM 12 V Circuit Sensor Monitors the EMM s 12 V alternator circuit If battery voltage exceeds 15 5 volts the EMM If battery voltage is below 12 volts with...

Page 91: ...e EMM provides a 5 V DC signal for sensor cir cuits It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges Inputs that fall outside of the acceptable range create service codes Air Temperature Sensor Monitors the air temperature at the throttle body The air temperature sensor is a negative tempera ture coefficient NTC thermistor As temperature increases the resi...

Page 92: ... has been run for more than 3 hours with NO OIL faults codes 34 117 the EMM Throttle Position Sensor The throttle position sensor is connected to the throttle plate shaft The sensor receives a voltage signal from the EMM As the throttle lever is rotated the EMM receives a return voltage signal through a second wire This signal increases as the TPS lever is advanced A third wire provides a ground c...

Page 93: ...Monitor screen to check CPS operation The software should show an RPM reading while the outboard is cranking If the CPS or its circuit fails no RPM reading will appear and the outboard cannot run Neutral Switch The powerhead mounted neutral switch controls a ground signal from the EMM to indicate shift link age position This allows the EMM to control idle speed variations for NEUTRAL or IN GEAR Ti...

Page 94: ...when TPS is advanced from idle position RPM Limiter This feature of EMM programming prevents engine damage due to excessive RPM At 6250 RPM fuel and ignition to the cylinders is shut off Normal operation resumes 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 18...

Page 95: ...he EMM Service Code Chart at the back of this manual for a complete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position The horn self tests by sound ing a half second beep SystemCheck gauges self test by turning the indicator lights on simulta neously then off in sequence Service Mode SystemCheck goes into a service mode if the key is left O...

Page 96: ...ir the cause Perform Fuel System Pressure Test on p 161 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 vent hose Recovery To recover from shutdown mode the EMM must NOT detect the related fault at start up The out board will not restart until the cause of the st...

Page 97: ...e computer s serial port The EMM must turn ON before it will communicate with the computer Power is normally supplied to the EMM when the key switch is turned ON Switched B 12 V enters the EMM at pin 28 purple of the EMM J1 B connector The EMM is also turned ON when it begins to receive AC voltage from the stator while the out board is being cranked Static Information Static information is viewed ...

Page 98: ...ed and operating hours of first and last occurrences Hard Faults A hard fault is a service code that currently exists Hard faults become stored faults only if the out board is running Persistent Faults The Persistent Faults screen keeps a history of all previously stored codes including code number the number of times the event occurred and oper ating hours of the last occurrence Persistent faults...

Page 99: ...he NO OIL circuit of the Engine Monitoring system Check Engine This test is used to check the CHECK ENGINE circuit of the Engine Monitoring system Tachometer This test is used to check operation of the tachom eter circuit Dynamic Tests Dynamic tests are performed with the outboard running Ignition Test This test momentarily disables the ignition and fuel injection circuits to one cylinder By dropp...

Page 100: ...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 oiling program runs for two hours of outboard operation above 2000 RPM Tiller Remote Programming This feature controls the start in gear protection function of the neutral switch Tiller operated mod els ...

Page 101: ...the outboard reaches operating tempera ture before making adjustments TPS Calibration TPS Calibration synchronizes throttle plate open ing with throttle position sensor voltage Refer to TPS Calibration on p 143 Perform TPS Calibration after replacing or adjust ing any throttle body or throttle linkage parts Idle Speed Control Use the Idle Adjust function to increase or decrease IN GEAR IDLE speed ...

Page 102: ...ick the Replace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Fuel Injector Service on p 169 Reports Engine reports provide service records and can be 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 ...

Page 103: ... 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 be replaced Select EMM Data Transfer from the Utilities menu Select the Collect EMM data to FILE option and follow the instructions provided with the program IMPORTANT Whenever the EMM is replaced EM...

Page 104: ...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 into position Apply Nut Lock to threads of EMM retaining screws Tighten to a torque of 30 to 42 in lbs 4 to 5 N m Install harness connectors and cooling hoses Secure hoses with tie straps 1 Cooling h...

Page 105: ...EMM LED INDICATORS 107 KEY ON 107 STARTING 107 RUNNING 108 IGNITION OUTPUT TESTS 109 IGNITION SYSTEM REQUIREMENTS 109 WIRING INSPECTION 109 CRANKSHAFT POSITION SENSOR CPS TEST 110 SYSTEM VOLTAGE TEST 110 STATIC IGNITION TEST 111 RUNNING IGNITION TESTS 112 IGNITION CONTROL CIRCUIT TESTS 113 IGNITION COIL TESTS 113 CAPACITOR TEST 113 FUEL DELIVERY TESTS 114 FUEL PUMP STATIC TEST 114 FUEL INJECTOR ST...

Page 106: ...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 Inspection should include the following Make sure the outboard can be cranked easily with no mechanical binding Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 107 Check...

Page 107: ...ion test indicates steady spark refer to FUEL DELIVERY TESTS on p 114 Outboard runs low on power misfires Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 107 Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS volt ages System voltage should be steady and TPS voltage should be between 0 2 and 4 85 V Use the diagnostics sof...

Page 108: ...PORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to maintain a constant IDLE speed The Dynamic Tests screen includes a function to tem porarily disable the idle controller Fuel Control Adjustment Use this test is to help identify a cylinder that may be too rich or too lean This feature should not be used by itself to identify a faulty injector Evinrud...

Page 109: ... and then go off in sequence LED 1 CHARGING OKAY Stator signal 30 V or higher LED 2 CRANK POSITION OKAY input from CPS EMM powered ON For NO LIGHT check for Code 16 CPS intermittent loss of sync LED 3 SENSORS OKAY 5 V For NO LIGHT 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...

Page 110: ...LT For 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 circuit fault Code 24 EMM temp below expected range Code 41 temp sensor circuit fault Code 42 temp below expected range Code 47 AT sensor circuit fault Code 48 AT sensor below expected range Code 49 ...

Page 111: ...stem voltage from EMM white red provides 55 VDC to the high pressure fuel pump the oil injection pump the fuel injectors and the igni tion coils Capacitor Connected to 55 V circuit white red to stabilize current on 55 V circuit Negative terminal of capacitor must be grounded Ignition Coil Primary circuits are powered by system 55 V voltage EMM provides control signal to ignition coil Output from i...

Page 112: ...ostics software Monitor screen to check system voltage Results KEY ON not running approximately 1 V less than battery voltage system voltage is GOOD KEY ON not running no voltage check 12 V power to EMM Repair connection or wiring RUNNING 55 V 2 system voltage is GOOD RUNNING less than 55 V 2 check stator output to EMM Repair connection or wiring Possible faulty stator or EMM Refer to STA TOR TEST...

Page 113: ...ondary cir cuit spark plug lead of the cylinder being tested Activate test and observe timing light strobe for consistent flash IMPORTANT This test is operating the ignition coil with 12 V battery power on the system voltage 55 V circuit An inductive probe with low sensitiv ity may not be able to detect the signal Results No spark on one or more cylinders Inspect or replace spark plugs Refer to Ig...

Page 114: ...ge and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 114 Inspect for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace spark plugs Check CPS air gap and resistance Refer to Ignition Control Circuit Tests on p 113 Refer to Ignition Coil Tests on p 113 Voltages fluctuate engine misfires Inspect battery and connections Te...

Page 115: ... diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil tests available Before replacing an ignition coil be sure 55 V is supplied to the white red wire of the igni tion coil connector A control signal is present on the orange wire of the ignition coil connector Refer to Ignition Control Circuit Tests on p 113 The black wire of the ignition coil connector p...

Page 116: ...inuity 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 to Circulation Pump Resistance Test on p 163 If the pump runs Refer to Fuel System Pressure Test on p 161 Refer to Running Fuel System Tests on p 115 Fuel Injector Static Test Use the Evinrude Dia...

Page 117: ...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 orientation of the timing light pickup and the oper ation of the timing light Results No light activation on any injector wires outboard cranks and starter turns flywheel Check stator input to EMM CP...

Page 118: ...116 SYSTEM ANALYSIS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 119: ... SWITCH TEST 133 NEUTRAL START CIRCUIT TEST 133 NEUTRAL START SWITCH TEST 134 EMERGENCY STOP SWITCH TEST 134 TILT TRIM RELAY TEST 135 SYSTEMCHECK CIRCUIT TESTS 136 GAUGE SELF TEST CHECK 136 CHECK ENGINE CIRCUIT TEST 137 WATER TEMP HOT CIRCUIT TEST 137 LOW OIL CIRCUIT TEST 138 NO OIL CIRCUIT 138 TACHOMETER CIRCUIT TESTS 138 FLYWHEEL AND STATOR SERVICING 139 FLYWHEEL REMOVAL 139 STATOR SERVICE 141 F...

Page 120: ...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 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m N A T IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock N Starter Bendix Lube T Liquid Neoprene 002248 ...

Page 121: ...bs 2 7 to 4 N m 60 to 84 in lbs 7 to 9 5 N m F 30 to 42 in lbs 3 4 to 4 8 N m 24 to 36 in lbs 2 7 to 4 N m B 15 to 30 ft lbs 20 to 41 N m X J A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock J Thermal Grease T Liquid Neoprene X See Service Manual Text 002249 ...

Page 122: ...nnector Connect to a pre wired remote control or to a dash mounted key switch Black purple white tan wires Connect to the trim gauge 8 pin connector Connect to a 2 in System Check gauge or to a 3 1 2 in SystemCheck tachometer 2 pin connector Must connect to the warning horn in all installations Black purple gray wires Connect to a con ventional tachometer when a SystemCheck tachometer is not used ...

Page 123: ...75 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 Bootstrap connector programming Blk Orange 9 Stop circuit Blk Yellow 10 Throttle position sensor TPS 5 V Red 11 vacant 12 vacant 13 CANbus NET L Blue 14 CANbus NET H White 15 12 V to EMM fused Red Purple ...

Page 124: ...ant 17 vacant 18 vacant 19 Ignition cylinder 2 Orange Purple 20 Injector ground Black 21 Injector ground Black 22 vacant 23 Oil solenoid Blue 24 vacant 25 vacant 26 Ignition cylinder 1 Orange Blue 001877 Pin No Description of Circuit Wire Color 1 Stator winding 1S Yellow 2 Stator winding 2S Brown 3 Stator winding 3S Orange 4 Fuel pump control Brown 5 System Ground Black 6 12 V out Red 7 System Gro...

Page 125: ...ctor 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 Refer to wiring diagrams Additional Ground Tests Check connections and continuity at the following locations Starter solenoid terminal B and main harness ground Trim and Tilt module ground at main harness ground CPS connect...

Page 126: ...digital multimeter to measure sensor resis tance between the yellow and white wires The complete circuit can be tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mounted to throttle body housing and requires no adjustment Air gap or clearance to flywheel is fixed at approximately 0 073 in 1 85 mm The acceptable clearance is 0 036 to 0 110 in 1 to 2 8 mm ThrottlePosition...

Page 127: ...stance reading must change evenly as the sensor lever is moved Engine Temperature Sensor Test Remove the electrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperature Sensor AT Test Remove the electrical connector from the air tem perature sensor Use a digital multimeter to measure sensor resis tance Engine Temperature Sensor Resista...

Page 128: ...ck for a grounded winding connect one meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no continuity If meter reads continuity replace stator Stator Voltage Output Test Use a digital multimeter to check stator output voltage Set meter to read 110 VAC output Disconnect CPS Disconnect stator 6 pin connector from the engine harness 6 pin connecto...

Page 129: ...0 A ammeter in series between the red wires of engine wire harness alternator output from EMM 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 Reconnect the battery cables Following the manufacturer s directions connect the variable load tester carbon pil...

Page 130: ...126 55 V Alternator Circuit Check battery ground cable for continuity With the key switch ON check battery voltage at battery 12 V then check voltage on white red wires at J2 connector of EMM Use Electrical Test Probe Kit P N 342677 and a multimeter set to read 55 VDC Voltage at EMM connector should be 0 5 to 1 V less than battery With outboard running at 1000 RPM voltage on white red wires should...

Page 131: ... 6 M A S C M B 1 2 3 4 5 6 8 13 15 9 12 17 34 33 32 31 30 29 28 27 26 006403 1 Marine battery 10 26 pin J1 B EMM connector 2 RED wire POS 11 34 pin J1 A EMM connector 3 BLACK wire NEG 12 Engine Management Module EMM 4 Starter solenoid 13 YELLOW RED wire start 5 Fuse 10 amp 14 BLACK wire start signal ground 6 RED PURPLE wire 15 Neutral Safety Switch remote control 7 6 pin connectors 16 RED starter ...

Page 132: ...g 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 V to sole noid terminal A Black wire provides ground NEG to starter solenoid terminal B Instrument Wire Harness Contains the following circuits Red purple wire provides 12 V to key switch ter minal ...

Page 133: ...d the other lead on the battery positive cable terminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to 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 battery cable terminal The solenoid must close with an audible click Meter must show...

Page 134: ...eter or connect a 0 to 100 amp ammeter in series with a heavy jumper between the battery positive terminal and the starter positive terminal Fluke model 334 or 336 Snap On model MT110 or EETA501 and various other ammeters should be available through local tool suppliers Attach or hold a vibration tachometer such as a Frahm Reed tachometer to the starter Complete the circuit with a heavy jumper bet...

Page 135: ...and 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 continuity of the circuit while positioning the remote control in NEUTRAL FORWARD and REVERSE IMPORTANT Turn propeller shaft or discon nect shift cable to allow proper remote control shift action while ou...

Page 136: ...lts are incorrect Emergency Stop Switch Test This switch can be part of the key switch or installed as a separate switch Either style con nects the M terminals of the key switch The emergency stop switch function grounds the stop circuit wire black yellow when the lanyard clip is removed One M terminal is the ground wire black and one M terminal is the stop circuit wire black yellow Install the cl...

Page 137: ...con nection to TNT motor Terminals 87 and 30 are considered normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure red and black wires are connected to 12 V battery power supply Set voltmeter to 12 VDC scale Connect test leads to terminals A and B of TNT motor connector Use a wi...

Page 138: ...turn on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the key switch ON Test for battery voltage between instrument harness terminal 1 purple wire and terminal 2 black wire If battery voltage is present replace the gauge If there is no battery voltage check that 12 V is present at terminal B of the key switch Check condition of the instrument har...

Page 139: ... wire of the SystemCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and the MWS har ness receives a signal from the EMM The EMM receives information from the temperature sensor on the cylinder head Using a jumper wire connect tan wire pin 6 of the engine harness connector...

Page 140: ...n yellow wire of the Sys temCheck connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits TACHOMETER CIRCUIT TESTS Check voltage at the battery Use this reading as a reference for battery voltage Connect the red meter lead to the tachometer pur ple wire and the black meter lead to the tachome ter black wire key ON outboard NOT running If mete...

Page 141: ...nnecessary parts replacement An accurate test of alternator output can help determine the flywheel s condition Refer to CHARGING SYSTEM TESTS on p 127 Flywheel Removal Remove the electrical cover from flywheel cover Disconnect wiring harness and remove wiring from cover Remove fuse holder from flywheel cover Lift flywheel cover to remove WARNING To prevent accidental starting while ser vicing disc...

Page 142: ...ankshaft 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 washers P N 307640 Put the puller on flywheel with body flat side up Attach the puller body with the three shoulder screws and washers Hold puller body with han dle and tighten pressing screw until flywheel releases Turn the center screw ...

Page 143: ...r edge of flywheel key parallel with centerline of crankshaft Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry Align the flywheel keyway and install flywheel Coat the threads of a new flywheel nut with Triple Guard grease Install the washer and nut and tighten to a torque of 100 to 115 ft lbs 136 to 156 N m Replace flywheel cover and recoil starter rope start m...

Page 144: ...ter Label this mark A Rotate the flywheel clockwise until the piston contacts the tool Mark the flywheel directly across from the pointer Label this mark B Rotate fly wheel counterclockwise slightly to release tool then remove it from spark plug hole Use a flexible measuring device to find the exact center between marks A and B Measure along the edge of the flywheel Mark and label the cen ter poin...

Page 145: ...e timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS Calibration Use Evinrude Diagnostics software to tell the EMM what throttle position sensor voltage is when the throttle plates begin to open Remove the air silencer On the Settings screen of the diagnostics soft ware click the Set TPS Calibration button While holding the throttle plate...

Page 146: ...ables at the battery Remove lower motor covers and air silencer Refer to Lower Cover Removal on p 82 Remove the starter positive cable from post on starter Remove the battery negative cable from the double ended stud Remove two starter mounting screws and double ended stud Remove the starter Starter Disassembly Remove the retaining ring spacers spring and starter pinion from pinion shaft Mark the ...

Page 147: ...ve 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 windings Clean off any carbon deposits or foreign matter which could contribute to failure of wind ings Check permanent magnets and make sure they strongly attract any steel or iron object held inside ...

Page 148: ...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 orientation of the brushes could damage the starter or cause reverse rotation Compress the brushes and springs with a modi fied putty knife Align and place brush holder cap firmly on arma ture and slide putt...

Page 149: ...ed to cover clip completely To test the assembly and operation of the starter refer to No Load Current Draw Test on p 132 Starter Installation Apply Triple Guard grease to the threads of the two starter screws the double ended stud and also to the washers Position the starter and install the screws and washers Tighten screws to a torque of 168 to 192 in lbs 19 to 21 N m Attach starter positive cab...

Page 150: ...ntly pull on wire Terminal Installation Push terminal through seal until it locks into place Fill connector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push wedge in until latched Wedge in 2 pin receptacle is not symmetrical position latch shoul ders next to terminals Crimping Terminals Strip insulation back 3 16 in 5 mm Place termi nal in 18 gauge notch of Crimping Pliers ...

Page 151: ...ector housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push con nector and seal into housing until seated Align anti backout device with connector housing and terminals Use Secondary Lock Installer P N 777079 to seat device in connector Crimping Terminals Crimping Superseal 1 5 terminals requires the PRO CRIMP...

Page 152: ...on nector housing Close lock mechanism POWER TIMER SERIES The J2 connector of the EMM is a AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull connector from plug Connect Push connector until seated in plug Close latch completely Terminal Removal Use Terminal Release Tool P N 351413 to release BOTH locking mechanisms of connector Pull terminal from housing 1 J1 A conn...

Page 153: ...l into connector housing until seated Packard Connectors IMPORTANT Always use the appropriate meter test probes and adapters when testing com ponents fitted with these terminals Disconnect Lift latch s Remove connector Connect Confirm the seal is in place Push connector onto housing until latched 1 Latch 2 Terminal with seal 002456 1 2 ...

Page 154: ...tall wire gasket on wires and feed wires through the correct terminal position of the con nector housing 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 strands in terminal past the wire crimp area and the end of insulation in the insulation crimp a...

Page 155: ... TEST 161 PRESSURE REGULATOR TEST 162 VAPOR SEPARATOR VENT CHECK 162 FUEL INJECTOR PRESSURE TEST 162 FUEL INJECTOR RESISTANCE TEST 163 CIRCULATION PUMP RESISTANCE TEST 163 LIFT PUMP PRESSURE TEST 163 LIFT PUMP VACUUM TEST 164 LIFT PUMP DIAPHRAGM TEST 165 ANTI SIPHON VALVE TEST 165 FUEL COMPONENT SERVICING 166 RELIEVING FUEL SYSTEM PRESSURE 166 FUEL FILTER SERVICE 167 FUEL LIFT PUMP SERVICE 167 VAP...

Page 156: ... 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant S STP Oil Treatment Tighten in 3 stages 002154b ...

Page 157: ...n lbs 7 14 n m 10 14 in lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m F F IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease ...

Page 158: ...el lift pump 2 to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel injector s Fuel return manifold Vent hose to intake manifold Pressure regulator high pressure 5 2 3 Fuel Supply Fuel Return 1 2 7 10 6 8 11 4 12 9 9 9 ...

Page 159: ... Fuel circulation pump 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 11 PURPLE GREEN 2 BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B J1 A J2 4 1 2 3 4 5 6 2 3 4 5 6 1 006756 3 1 2 4 1 7 2 5 1 2 3 1 2 3 1 2 6 J2 9 10 11 8 ...

Page 160: ...l from the pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure components of the fuel system from contaminants Refer to INSPECTION AND MAIN TENANCE SCHEDULE on p 66 for service fre quency Vapor Separator The vapor separator Serves as a water cooled fuel reservoir to accu mulate incoming fuel from the fuel lift pum...

Page 161: ...fuel level begins to increase An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps maintain consis tent fuel pressure in the fuel system Fuel returning from the injectors enters the fuel chamber of the vapor separator through a pres sure regulator The pressure regulator maintains approximately 20 to 30 psi 138 to 207 kPa of f...

Page 162: ...injector by serial number Then the EMM is programmed to compensate for variations in fuel flow Each injector and its loca tion on the outboard is identified by the EMM DO NOT install an injector without updating the com pensation software Each service injector includes its fuel flow infor mation on a 3 5 in floppy disk This software allows the EMM to be reprogrammed for this injec tor s unique fue...

Page 163: ...st on p 164 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying enough fuel to vapor separator Refer to Lift Pump Pressure Test on p 163 If the above tests are good and vapor separator remains full of fuel check for damaged circula tion pump Replace vapor separator assembly No pressure C...

Page 164: ...Replace vapor separator if the venting of fuel is continuous Fuel Injector Pressure Test This test requires Injector Test Fitting kit P N 5005844 Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 166 IMPORTANT Perform test with injector mounted to cylinder head and fittings installed with manifold retainer Use cap and tie strap t...

Page 165: ...t being tested Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter to measure the fuel pump circuit and coil resistance Lift Pump Pressure Test Install a 0 to 15 psi 0 to 103 kPa Fuel Pressure Gauge P N 5006397 or equivalent to the lower fuel pressure test fitting Prime the fuel system and check for leaks START outboard and run at idle speed Hold ...

Page 166: ...ift pump Temporarily install a vacuum gauge T fitting and 8 in 20 3 cm of clear vinyl hose between the fuel supply hose and fuel lift pump inlet Secure con nections with tie straps to prevent fuel or air leaks IMPORTANT Do not use fuel primer bulb man ual fuel primer or electric fuel pump primer to restart outboard A positive pressure in the fuel supply could damage some vacuum gauges START outboa...

Page 167: ...ove anti siphon valve from fuel tank Install adapter fittings and a 36 in 91 4 cm length of clear hose to the inlet side tank end of valve Fill clear hose with water to a height of 20 in 500 mm Water must NOT flow through valve An occasional drip is acceptable Replace valve if water drips continuously Increase height of water to 25 in 630 mm Water should flow through valve as water level reaches 2...

Page 168: ...a suitable con tainer Slowly open gauge s venting valve Clean up any spilled fuel with shop towels WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use caution when working on any part of the fuel system Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure Alw...

Page 169: ... fuel leaks Connect battery cables Run outboard and check for fuel leaks Fuel Lift Pump Service The fuel lift pump is serviceable as a complete assembly or can be repaired with a fuel pump repair kit Refer to parts catalog for service parts Removal Disconnect the battery cables at the battery Disconnect the fuel hoses from the fuel pump housing Disconnect the fuel lift pump pulse hose at the crank...

Page 170: ... vapor separator housing retainer clip Remove vapor separator fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts Installation Installation is the reverse of removal Pay close attention when performing the following additional tasks Install all hoses and manifolds to original locations and secure with appropriate clamps Squeeze primer bulb to ...

Page 171: ...ssembly on p 187 Fuel Injector Service Mark fuel injectors to show cylinder locations IMPORTANT Fuel injectors must be installed in the correct cylinder locations Use Evinrude Diag nostics Software to make sure that EMM program ming matches injector positioning The Injector Coefficients screen displays injector serial num bers Use caution when handling fuel injectors Prevent dirt and debris from e...

Page 172: ...ctor from mounting cup Thread 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 injector Inspect and clean injec tor filter Install new crush ring and O rings Lubri cate O rings with STP Oil Treatment Install injector into mount housing Press on injec tor face u...

Page 173: ...le Guard grease Install washers one per screw on injec tor retaining screws Install screws and washers through mounting flange of injector and into cylin der head Tighten screws in stages starting with the lower screw First torque is 5 ft lbs 7 N m Second torque is 10 ft lbs 14 N m Final torque is 24 to 26 ft lbs 33 to 35 N m Reconnect fuel injector electrical connectors Install the ignition coil ...

Page 174: ...ed plate assembly and reed valve assem blies must be cleaned prior to reassembly DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning Remove the reed valve retainer screws and remove the assembly Use caution to prevent damaging reed valve assemblies IMPORTANT DO NOT disassemble reed valve assemblies Damaged reed plates are not ser viceable and are replaced as an assembl...

Page 175: ...Surface must be flat 0 004 in 0 10 mm Assembly Remove old adhesive from reed valve retaining screws Install gasket on reed plate assembly DO NOT use sealer on the gasket Prime screw threads with Locquic Primer and let dry Apply Nut Lock to threads Position reed valve on reed plate and install screws Tighten screws to a torque of 25 to 35 in lbs 2 8 to 4 0 N m Installation Place reed plate assembly...

Page 176: ...install screws Tighten the center screws first and expand out ward Final torque is 60 to 120 in lbs 7 to 13 5 N m Install upper main bearing vent hose and secure with tie strap Connect throttle linkage and electrical connectors IMPORTANT Refer to TPS Calibration on p 143 DO NOT lubricate throttle linkages 002329 ...

Page 177: ...RNING 181 CYLINDER AND CRANKCASE 181 OIL RECIRCULATION SYSTEM 182 OIL CONTROL SETTINGS 182 OIL PRIMING 182 OILING RATES 182 BREAK IN OILING 182 OILING SYSTEM TESTS 183 OIL INJECTION PUMP STATIC TEST 183 OIL INJECTION PUMP VOLTAGE TEST 183 OIL INJECTION PUMP CIRCUIT RESISTANCE TEST 184 OIL INJECTION PUMP FUNCTION TEST 184 OIL INJECTION FITTINGS FLOW TEST 185 LOW OIL SENDING UNIT TEST 185 OIL COMPON...

Page 178: ... 30 42 in lbs 3 5 5 N m 60 84 in lbs 7 9 5 N m 30 42 in lbs 3 5 5 N m 30 42 in lbs 3 5 5 N m F F 002213a A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant S STP Oil Treatment ...

Page 179: ...STEM OIL SUPPLY DIAGRAMS 9 OIL SUPPLY DIAGRAMS 006645 1 3 4 6 2 4 5 5 5 6 6 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard ...

Page 180: ...178 OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM 002223 Starboard view Port view ...

Page 181: ... injector control BLUE Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK No oil signal to SystemCheck gauge TAN YELLOW 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 13 12 11 10 9 8 7 6 5 4 3 2 1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34 33 32 31 30 29 28 27 26 24 25 23 22 21 20 19 18 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B J1...

Page 182: ...lectric 55 V actua tor style pump It draws oil from the oil tank and supplies pressurized oil to the oil manifold The EMM supplies 55 V and controls activation of the pump The oil manifold distributes the oil supplied by the pump Electrical Circuit 55 V The oil injector is powered by the 55 V electrical circuit The EMM controls pump operation by rap idly connecting and disconnecting the pump s int...

Page 183: ... 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 Cylinder and Crankcase The oil distribution manifold provides crankcase lubrication through oil distribution hoses and pressed in fittings on the crankcase and cylinder block Engine Monitor LOW OIL display ON Activates S A F E Stores ...

Page 184: ...ting in crankcase cover at upper main bearing hose routed to reed plate fitting This circuit vents the upper main bearing cavity to promote oil flow Refer to the OIL RECIRCULATION DIAGRAM on p 178 OIL CONTROL SETTINGS Oil Priming The oiling system of the outboard must be primed When the outboard is first installed Whenever the oil supply to the oil lift pump is disconnected or disrupted Whenever a...

Page 185: ...he ground circuit blue wire at the oil tank connector pin 2 If the light flashes the EMM and oil injection cir cuits are not at fault Refer to Oil Injection Pump Voltage Test on p 183 Oil Injection Pump Voltage Test Check voltage at pin 1 white red wire of oil tank electrical connector Acceptable voltage readings Key switch ON slightly less than 12 V Outboard running 55 V Results If voltage is not...

Page 186: ...faulty wiring or replace faulty component and retest For a higher than expected reading test resis tance of the injection pump If injection pump resistance reading is approximately 22 Ω injec tion pump winding is good Isolate faulty com ponent Repair faulty wiring or replace faulty component and retest Oil Injection Pump Function Test Remove oil distribution hose from fitting at oil dis tribution ...

Page 187: ... manifold Use a Syringe P N 346936 filled with isopropyl alcohol to force fluid through hose and fitting LOW OIL Sending Unit Test Remove the oil from the oil tank Turn the key switch ON The dash mounted Engine Monitor system should show a LOW OIL warning Once the warning has been confirmed refill the oil tank and start the outboard The LOW OIL warn ing should stop after the oil pump cycles 3 time...

Page 188: ...rom the manifold make sure hose support is in end of the hose Installation Cut Replacement Oil Hose P N 778708 to the correct length Insert hose support in manifold end of hose IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully inserted into manifold Insertion depth is 5 8 in 16 mm Visually inspect for hose supports WARNING To prevent accident...

Page 189: ...rews and tighten to a torque of 30 to 42 in lbs 3 5 to 5 N m Install nut 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 oil delivery fittings Refer to OIL SUP PLY DIAGRAMS on p 177 Secure oil hoses to crankcase fittings with tie straps Run outboard and check for leaks Use Evinru...

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

Page 191: ... 192 BLOCK VENTING 192 WATER PRESSURE CONNECTION 192 OPERATION 193 CYLINDER BLOCK CYLINDER HEAD COOLING 193 EMM AND VAPOR SEPARATOR COOLING 193 ENGINE TEMPERATURE CHECK 194 SOFTWARE METHOD 194 PYROMETER METHOD 194 IDLE OPERATING TEMPERATURE TROUBLESHOOTING BELOW RANGE 195 THERMOSTAT SERVICING 196 DISASSEMBLY 196 INSPECTION 196 ASSEMBLY 196 PRESSURE RELIEF VALVE SERVICING 197 DISASSEMBLY 197 INSPEC...

Page 192: ...Incoming water cool 6 4 8 9 10 5 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply EMM to vapor separator Overboard indicator outgoing water from vapor separator Incoming water cool Outgoing water warm hot ...

Page 193: ...ugal pump at HIGHER speeds Refer to WATER PUMP SERVICE on p 263 for servicing Water Supply Tube The water pump outlet connects with the water supply tube located in the outboard s midsection Grommets seal the water tube to the water pump housing and the adaptor housing The water tube fastens to the base of the adapter housing with a retainer plate and screws Water supplied to the water tube provid...

Page 194: ... Overheating A restricted or faulty thermostat typ ically results in LOW SPEED overheating Overcooling Debris may prevent the thermostat from closing completely Block Venting A fitting and hose connected to the top of the exhaust cover allows the constant movement of water and or air from the block Circulated water flows through the EMM and vapor separator before exiting through the overboard indi...

Page 195: ...in the cyl inder block Water flows through the block to the exhaust housing and then out of the outboard At higher speeds water pressure opens the pressure relief valve at approximately 1800 RPM Water flows through the valve to the cylinder head and bypasses the thermostat All water flows through the cylinder head to the outlet passage of the block and then exits through the exhaust housing This p...

Page 196: ...t the SystemCheck gauge indicates a WATER TEMP warning refer to WATER TEMP HOT Circuit Test on p 137 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature displays at IDLE speed should be 155 F 5 F 68 3 C 3 C Typical temperature displays at WOT speed should be 160 F 40 F 71 C 22 C Operating temperature must not exceed 212 F 100 C Pyrometer Method Use a...

Page 197: ...re 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 temperature is too low check pressure relief valve plunger and seal for damage or debris that could prevent the valve from closing com pletely If IDLE temperature is still below operating range replace p...

Page 198: ...ing thermostat Refer to Cylinder Head Installation on p 217 Inspection Inspect all parts for cracks heat damage or signs of 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 Coat threads of thermostat cover with Gasket Sealing Compound and install new O ring Install ...

Page 199: ... of 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 plunger seal squarely over ridge in housing Apply a light coat of Triple Guard grease to a new cover o ring and place in groove in housing Install valve assembly into housing Tighten cover screws to ...

Page 200: ...198 COOLING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 201: ... PISTON RINGS 212 BEARINGS 213 POWERHEAD ASSEMBLY 213 CRANKSHAFT ASSEMBLY 213 PISTONS AND CONNECTING RODS 215 CYLINDER HEAD INSTALLATION 217 CRANKSHAFT AND CONNECTING ROD INSTALLATION 218 CRANKCASE ASSEMBLY 221 SHIFT LINKAGE INSTALLATION 223 THROTTLE LINKAGE INSTALLATION 223 FINAL POWERHEAD ASSEMBLY 224 UPPER MOUNT SERVICING 225 REMOVAL 225 INSTALLATION 225 POWERHEAD INSTALLATION 226 POWERHEAD MOU...

Page 202: ...cedure Q Apply to crankcase mating flange M Apply to water passages F 60 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 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 J Thermal Grease M RTV Sealant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease ...

Page 203: ...ool H G D H H H H B A D D D 15 20 Ft lbs 20 27 N m 110 130 Ft lbs 149 176 N m A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease 002282 ...

Page 204: ...re to use only the 1 1 8 in short screws P N 398067 included with the tool to avoid damage to electronic components under the flywheel Fasten appropriate 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 Refer to Relieving Fuel System Pressure To prevent ac...

Page 205: ...rge powerhead screws and the upper mount screws Use a suitable tool to carefully separate the pow erhead from exhaust housing IMPORTANT Do not damage the powerhead or exhaust housing mating surfaces 1 Rear small powerhead screw 002160 1 Small powerhead screws 2 Large powerhead screws 3 Upper mount screws 002153 1 1 2 3 1 002161 ...

Page 206: ... p 169 IMPORTANT Mark injectors for cylinder loca tion before removal All injectors must be installed in their original location Improper injector installa tion can result in powerhead failure Remove throttle linkage Refer to Throttle Link age Removal on p 204 Remove shift linkage Refer to Shift Linkage Removal on p 204 Remove the throttle body and reed plate assem blies Refer to Intake Manifold S...

Page 207: ... 1 8 in diameter pin punch to push crank case taper pin toward the front side of the engine IMPORTANT Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin Remove crankcase flange screws Loosen in stages and remove the main bearing nuts and washers 1 Shift detent assembly 002135 002124 WARNING Wear safety glasses to avoid injury 1 002136 0021...

Page 208: ...Remove the cylinder head Dis card thermostat seal and O rings Connecting Rods and Pistons Use a permanent marker to identify each connect ing rod cap connecting rod and piston by cylinder number Number 1 is closest to the flywheel Use Torquing Socket 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...

Page 209: ...ns Discard the rings Remove wrist pin retaining rings Discard retaining rings The wrist pin fit is loose on both sides Push the wrist pin through to free the piston from the con necting rod If necessary use Wrist Pin Pressing 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 If any of the bearings are worn or lost rep...

Page 210: ...he housing O ring Discard O ring Use a punch to remove the housing seal Discard seal Inspect housing and replace if necessary Remove O ring from crankshaft sleeve and inspect it Replace the O ring if it is not in good condition 1 Upper oil seal 2 Upper main bearing 002034 002042 002044 1 2 1 Punch 002053 002040 1 ...

Page 211: ...ds to be replaced Use external retaining ring pliers to remove the lower bearing retaining ring IMPORTANT If the lower main bearing is removed from the crankshaft it must be dis carded DO NOT reuse it Use a bearing separator to support the bearing and press off the crankshaft Remove center main bearings and split sleeves for inspection Do not mix parts Note location of bearings for reassembly 0020...

Page 212: ...Gasket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block and crankcase Carefully remove any carbon accumulation from the tops and ring grooves of the piston using Engine Tuner A ring groove cleaning tool can be made by breaking an old ring and grinding an angle on its end Do not damage ring grooves while cleaning Thoroughly wash entire cylinder block...

Page 213: ...ad warpage must not exceed 0 006 in 0 15 mm per inch of measurement Replace head if warpage exceeds this dimension Crankshaft Measure the diameter of each crankpin and main bearing journal The lower main bearing journal would only be measured if the bearing was removed for another reason Cylinder Bore Use Cylinder Bore Gauge P N 771310 to inspect each cylinder bore for an out of round oversize or ...

Page 214: ...square the ring in the cylinder Use a feeler gauge to measure the ring end gap Ring end gap should be 0 011 to 0 023 in 0 28 to 0 58 mm IMPORTANT Ring end gap increases approxi mately 0 003 in 0 076 mm for each 0 001 in 0 025 mm increase in cylinder bore diameter DO NOT exceed cylinder oversize dimension Use a machinist s straightedge to check for proper ring clearance Position piston rings on pis...

Page 215: ...icant IMPORTANT Use new wrist pin retaining rings gaskets seals and O rings during assembly Crankshaft Assembly Oil the end of the crankshaft Use Crankshaft Bearing Sleeve Installer P N 338647 and place a new lower main bearing onto crankshaft with let tered side facing the tool Install bearing until it seats on the crankshaft Oil the end of the crankshaft Use Crankshaft Bearing Sleeve Installer P...

Page 216: ...cant and install them in their original positions The split sleeve ring grooves must face toward driveshaft lower end of crankshaft when installed Lightly coat the outside edge of a new 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 Triple Guard grease Install a new O r...

Page 217: ...d direction New pistons are stamped EXH This marking should be turned toward the exhaust side of the block The splash bowl on the dome of the piston will be located toward the flywheel and opposite the exhaust port IMPORTANT It is also very important that the connecting rods are installed with the alignment dots and the diagonal oil hole facing up toward the flywheel Apply Needle Bearing Grease to...

Page 218: ...necting rod pushing bearing tool out through the piston Use Wrist Pin Cone P N 318600 and Driver P N 318599 to install new wrist pin retaining rings in each wrist pin hole Gap of retaining ring faces up away from notch in piston Installing Pistons When all pistons and connecting rods are assem bled install piston ring sets Be sure rings are installed in the cylinder used to test ring end gap Refer...

Page 219: ...ston and locate piston rings on dowel pins Place appropriate ring com pressor on piston Slide piston and rod assembly into the correct cyl inder as marked during disassembly Guide con necting rod through cylinder block to avoid scratching cylinder wall Cylinder Head Installation Install a new thermostat seal in cylinder head with side marked TO CYL HEAD facing toward ther mostat Refer to THERMOSTA...

Page 220: ...d Installation Rotate cylinder block so crankcase mating flange is facing up Apply Gasket Sealing Compound to lower oil seal groove in cylinder block DO NOT put any sealer in upper seal groove Check that main bearing alignment dowel pins are seated in the block Push all pistons to the top of cylinders Remove numbered connecting rod caps Gently lower crankshaft into place Align tab on lower bearing...

Page 221: ...MPORTANT Be sure alignment dot on rod cap matches dot on rod and that both dots face fly wheel IMPORTANT Tightening rod cap screws with out Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent dam age to the connecting rod and crankshaft To maintain accurate torque values keep torque wrench extension length to a minimum Install Rod Cap Alignment Fixture P N 396749 bef...

Page 222: ... rod cap The groove lines on the jaws must be centered on the rod crankpin diameter 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 turn Use Torquing Socket P N 331638 to tighten rod cap screws in three stages Apply first torque of 40 to 60 in lbs 5...

Page 223: ... sealer in upper seal groove Use a small brush with a tapping motion to apply a thin even coat of Gel Seal II sealant to the crank 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 replace it if the age of the tube cannot be determined Using old Gel Seal II...

Page 224: ...84 in lbs 7 to 9 5 N m Test that the crankshaft spins freely without bind ing IMPORTANT After powerhead has been assembled allow 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 Position gasket and cover on cylinder block Apply Nut Lock to cover screws and double ended stud Place star washer under J clamp and...

Page 225: ... a torque of 60 to 84 in lbs 7 to 9 5 N m Apply Triple Guard grease to shoulder of shift arm screw and Nut Lock to threads Install arm screw and washer and tighten screw to a torque of 120 to 144 in lbs 13 5 to 16 N m Throttle Linkage Installation Apply Nut Lock to threads of throttle lever screw Insert spring into cavity of throttle return lever Install lever screw and washer on crankcase and hoo...

Page 226: ...inkage Refer to Throttle Linkage Installation on p 223 Install fuel injectors and ignition coils Refer to Fuel Injector Installation on p 171 IMPORTANT All injectors must be installed in their original location Improper injector installation can result in powerhead failure Install stator and flywheel Refer to FLYWHEEL AND STATOR SERVICING on p 139 Install electrical harness then install EMM Refer ...

Page 227: ...d remove Inspect mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position with flats fac ing away from each other Apply Moly Lube to all sides of retainer and install between mounts Install the retainer screw and tighten to a torque of 15 to 20 ft lbs 20 to 27 N m 002069 002130 002132 ...

Page 228: ...reads and Gasket Sealing Compound to the shank of the powerhead screws Apply Triple Guard grease to upper mount screw threads Loosely install all powerhead screws and upper mount screws before tightening Tighten the six large powerhead screws to a torque of 18 to 20 ft lbs 24 to 27 N m in the sequence shown Tighten the five small powerhead screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Tighten...

Page 229: ...ase shifts solidly into both forward and reverse and that pro peller shaft spins freely in neutral Connect the power trim connectors Install the lower engine covers Refer to LOWER COVER SERVICE on p 82 IMPORTANT Perform the following procedures before returning outboard to service Index all spark plugs Refer to Spark Plug Indexing on p 76 Adjust timing pointer and check engine timing Refer to TIMI...

Page 230: ...usted the shift lever will be parallel with the vertical line of the outboard and the distance between the shift lever pin and the center of the shift cable trunnion pocket should be approximately 7 in 17 8 cm IMPORTANT The shift rod height is the most critical of these adjustments and should not be moved during this procedure Refer to SHIFT ROD ADJUSTMENT on p 266 Tighten adjustment screws to 60 ...

Page 231: ...POWERHEAD POWERHEAD VIEWS 229 11 POWERHEAD VIEWS Port Short Block Starboard Short Block ...

Page 232: ...230 POWERHEAD POWERHEAD VIEWS Port Dressed Powerhead Starboard Dressed Powerhead ...

Page 233: ...POWERHEAD POWERHEAD VIEWS 231 11 Front ...

Page 234: ...232 POWERHEAD POWERHEAD VIEWS Rear ...

Page 235: ...POWERHEAD POWERHEAD VIEWS 233 11 Top ...

Page 236: ...234 POWERHEAD NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 237: ... HOUSING REMOVAL 240 EXHAUST HOUSING DISASSEMBLY 241 CLEANING AND INSPECTION 242 EXHAUST HOUSING ASSEMBLY 242 EXHAUST HOUSING INSTALLATION 245 STERN BRACKET 246 STERN BRACKET REMOVAL 246 STERN BRACKET DISASSEMBLY 246 STERN BRACKET ASSEMBLY 248 SWIVEL BRACKET DISASSEMBLY MANUAL TILT 251 SWIVEL BRACKET ASSEMBLY MANUAL TILT 253 NOTES 256 ...

Page 238: ...40 In lbs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m A A A A A B 120 144 In lbs 13 5 16 5 N m A 110 130 Ft lbs 149 176 N m 216 240 In lbs 25 27 N m U F A 004105a IMPORTANT Use Triple Guard grease on all pivot points A Triple Guard Grease B Gasket Sealing Compound...

Page 239: ... N m E 60 84 In lbs 7 9 5 N m C C A B B 60 84 In lbs 7 9 5 N m F 150 180 In lbs 17 20 N m A A C B 18 20 Ft lbs 24 5 27 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex Number 2 Q Gel Seal II 002210 ...

Page 240: ...ar Remove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer from Tilt Tube Service Kit P N 434523 onto the starboard end of the tilt tube Remove steering cable wiper nut from tilt tube Thread the adapter from Tilt Tube Service Kit P N 434523 onto the port end of the tilt tube WARNING Support the outboard with a suitable hoist 1 Locking tabs 30749 30748 ...

Page 241: ...se a wood or leather mallet to tap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft lbs 61 to 68 N m Replace steering cable wiper nut on port end of tilt tube Apply one drop of instant bonding adhesive in receiving channels of tilt limit switch collar and install collar and tilt cam on...

Page 242: ...TALLA TION on p 261 The powerhead must be removed Refer to POWERHEAD REMOVAL on p 202 Remove and discard four lower mount screws Remove the exhaust housing Remove lower mount covers and inspect the lower mounts If replacement is necessary lubricate mount with soapy water and carefully pry at both ends to remove 20 Models 23036 25 Models 32590 001986 001970 001971 ...

Page 243: ...Remove the three upper screws and three lower screws securing the inner exhaust housing to the adapter housing Remove the water tube from the inner exhaust housing Discard water tube grommet Remove the seal from the bottom flange of the inner exhaust housing 1 Adapter retaining screws 001981 001980 1 1 1 Upper inner exhaust housing screws 001975 1 Lower inner exhaust housing screws 001974 1 Water ...

Page 244: ...sing on a surface plate Use a dial indica tor to check flatness by measuring the run out on the top edge of housing The maximum allowable run out is 0 009 in 0 228 mm If you do not have access to a dial indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a distorted housing replace it IMPORTANT A distorted exhaust housing will cause the upper driveshaft spl...

Page 245: ...sing Apply Ultra Lock to the screws Install the three lower screws and three upper screws and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Apply Adhesive 847 to the bottom flange of the inner exhaust housing Install a new seal Apply Triple Guard grease to outer seal surface 1 Water tube grommet 2 Flared end of water tube 001977 001982 1 2 1 Lower inner exhaust housing screws 001974 1 Upper ...

Page 246: ...ter housing and the alignment pin into the adapter housing Apply Gasket Sealing Compound to threads of the four retaining screws and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m If removed coat the lower mounts with soapy water and press into the exhaust housing with the OUTSIDE mark facing outward Install the mount covers Apply Nut Lock to screws install washers and screws and tighten to a...

Page 247: ...osition with the stern bracket Install four new lower 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 261 Install powerhead Refer to POWERHEAD REMOVAL on p 202 20 Models 23036 25 Models 32590 ...

Page 248: ...er to TRIM AND TILT on p 287 Stern Bracket Disassembly Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaft and thrust washer It may be necessary to tap the steering shaft out using a wood dowel and mallet Pry out upper and lower steering shaft seals and discard Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to...

Page 249: ...h the braided tube Remove the tilt limit switch and retainer from the swivel bracket Disconnect the trail lock spring and remove it from the swivel bracket Remove trail arm retainer Remove the trail lock arm and bushings from the swivel bracket 1 Anode 30762 1 Tilt tube bushing 30761 30760 1 1 1 Tilt limit switch 2 Retainer 30758 1 Trail lock spring 2 Trail arm retainer 30756 1 Trail lock bushing ...

Page 250: ...e proceeding make sure all components have been thoroughly cleaned Replace any seals that have been removed Inspect all thrust washers and bushings for evi dence of deterioration Install the detent roller and spring and the tilt sup port with bushing in the swivel bracket Tighten bushing to a torque of 28 to 30 ft lbs 38 to 41 N m 1 Trim rod roller 30754 1 Tilt support bushing 30753 1 1 30752 1 Ti...

Page 251: ... the tilt limit switch and retainer on the swivel bracket Tighten screws to a torque of 40 to 50 in lbs 4 5 to 5 5 N m Route the trim sender wires through the braided tube and install the sender unit in the port stern bracket Install the upper and lower steering shaft bushings and new seals in the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compoun...

Page 252: ...y Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket Align the bracket with the steering arm and tighten the nut to a torque of 130 to 150 ft lbs 176 to 204 N m Fill the swivel bracket with Triple Guard grease through the grease fitting on the bracket s port s...

Page 253: ... pins and locking lever Remove starboard reverse lock link Remove port reverse lock link Loosen bellcrank set screw remove bellcrank and handle link rod 1 Reverse lock release collar 2 Set screw 006697 1 Reverse lock springs 2 Reverse lock spring screws 006700 1 Locking lever 2 Pins 006699 1 2 2 1 2 1 1 Starboard reverse lock link 006696 1 Port reverse lock link 006695 1 Handle link rod 2 Bellcran...

Page 254: ...ock lever and reverse lock pivot shaft from swivel bracket Remove port trail lock lever and trail lock shaft as an assembly Remove port and starboard trail lock shaft bush ings from swivel bracket 1 Retaining ring 006693 1 Reverse lock pivot shaft 2 Trail lock lever 006692 1 1 2 1 Port trail lock lever and shaft 006704 1 Trail lock shaft bushings 006687 1 1 ...

Page 255: ...l in swivel bracket from port side DO NOT tighten screw at this time Refer to Reverse Lock and Trail Lock Refer ence on p 253 for correct orientation of reverse lock and trail lock components Assemble reverse lock pivot shaft reverse lock lever rod and bellcrank shaft spacer as shown 1 Component reference view 2 006686 1 Trail lock shaft bushings port side shown 006687 1 1 Port trail lock lever an...

Page 256: ...acer on reverse lock pivot shaft then install retaining ring Install the rod handle link to reverse lock lever and bellcrank Install bellcrank on reverse lock pivot shaft Tighten the setscrew Install the port reverse lock link on the swivel bracket Install washer screw Apply blue Nut Lock to screw threads and install washer and screw 1 Reverse lock pivot shaft and rod 2 Trail lock lever 3 Trail lo...

Page 257: ...screw Tighten screw to a torque of 60 to 84 in lbs 7 to 9 5 N m Install reverse lock release collar and tighten set screw Install locking lever pins and new cotter pins Install reverse lock springs on locking lever and reverse lock spring screws 1 Port reverse lock link 006695 1 Starboard reverse lock link 2 Reverse lock lever rod 006696 1 1 2 1 Reverse lock release collar 2 Set screw 006697 1 Loc...

Page 258: ...256 MIDSECTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 259: ...VAL 268 DRIVESHAFT SERVICE 270 SHIFT HOUSING GEAR AND PROPELLER SHAFT REMOVAL 271 WATER INTAKE SCREENS 271 GEARCASE HOUSING INSPECTION 271 INTERNAL GEARCASE SERVICE 272 PINION BEARING REMOVAL 272 PINION BEARING INSTALLATION 272 SHIFT HOUSING DISASSEMBLY 273 SHIFT HOUSING ASSEMBLY 275 DRIVESHAFT BEARING HOUSING SERVICE 277 PROPELLER SHAFT BEARING HOUSING SERVICE 278 DRIVESHAFT SHIMMING 280 GEARCASE...

Page 260: ... m G 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A A J 14 18 In lbs 1 5 2 N m X G A B 120 144 In lbs 13 5 16 5 N m A 006594 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut ...

Page 261: ... lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A J 14 18 In lbs 1 5 2 N m X G A B E E B 15 20 In lbs 1 7 2 3 N m 18 20 Ft lbs 24 27 N m A 70 80 Ft lbs 95 109 N m A A 006592 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra L...

Page 262: ...pressure gauge indicates leakage submerge the gearcase in water to determine source of leak If the gearcase pressure gauge does not indicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leakage Make necessary repairs and repeat test Install vacuum test gauge Apply 3 to 5 in of vac uum 76 to 127 mm Hg with pump Check for leakage If leakage occurs apply oil around suspected sea...

Page 263: ...move the four gearcase retaining screws Remove the gearcase assembly from the exhaust housing being careful not to bend the shift rod or damage the water tube The lower inner exhaust housing may come out with the gearcase WARNING To prevent accidental starting while ser vicing twist and remove all spark plug leads During service the outboard may drop unexpectedly Avoid personal injury always suppo...

Page 264: ...ages the crankshaft Water tube enters the water pump Lower inner exhaust housing installs correctly Shift rod does not turn and is positioned prop erly in shift shaft connection area Apply Gasket Sealing Compound to threads of the gearcase retaining screws Tighten the screws to a torque of 3 8 in screws 26 to 28 ft lbs 35 to 38 N m 7 16 in screws 40 to 50 ft lbs 54 to 68 N m Apply Gasket Sealing C...

Page 265: ...e impeller cam Remove the four impeller hous ing screws Slide the water pump off the driveshaft Remove the impeller drive cam O ring impeller plate and gasket Discard the gasket Remove all the parts from the housing Inspection Check impeller for overheating hub separation and other wear or damage Check liner and wear plate for scoring distortion and impeller material transfer Inspect the housing f...

Page 266: ...und Install the cup in the impeller housing Install the water tube grommet with the inside taper facing up Install the impeller housing cover and tighten screws to a torque of 24 to 36 in lbs 3 to 4 N m Apply Adhesive 847 to flat side of the impeller housing grommet Install the grommet flat side down Lightly coat the liner with Triple Guard grease With a counterclockwise rotation install the impel...

Page 267: ...nd slide water pump down over cam Be sure impeller cam does not fall out of position IMPORTANT Make sure the impeller engages the impeller cam Serious powerhead damage will result if impeller cam is not in place Align the impeller housing with the gearcase Apply Gasket Sealing Compound to threads of the four impeller housing screws Install the screws and tighten to a torque of 60 to 84 in lbs 7 to...

Page 268: ...TRAL rotate the shift rod up or down as necessary for correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTANT The NEUTRAL detent is a two step design Make sure the NEUTRAL detent ball is in the center step before checking shift rod height Shift Rod Heights COA6166 Model Type Height 20 in L S 21 25 in One Half Turn 25 in X O 26 25 in O...

Page 269: ...aged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase damage Hydrostatic Seal Grooves Must be in good condition to help prevent propeller ventilation Gearcase Anodes If anodes have eroded to two thirds their original size they must be replaced Drive Shaft Check splines for visible da...

Page 270: ...18 nuts obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing and reverse gear from gearcase Pinion Gear and Driveshaft Removal Adjust the shift rod to move the clutch dog as far forward as possible This will help ease removal of the pinion nut Use Driveshaft Holding Socket P N 311875 Pin ion Nut Holder P N 334455 and Wrench Reta...

Page 271: ... N 325867 to break the lock Install the tools as shown by clamping them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gearcase until the driveshaft pops loose from the pinion If upper driveshaft becomes separated from lower driveshaft use Lower Driveshaft Puller P N 342681 to remove Install puller into lower drivesha...

Page 272: ...riveshaft install new driveshaft retainer into the groove of the upper driveshaft Install the upper driveshaft into the lower drive shaft aligning the holes in the driveshaft retainer and the lower driveshaft S Type Gearcases Install the roll pin flush O Type Gearcases Install the roll pin to the specified dimension 29337 29338 29330 1 Roll pin DR4596 1 Roll pin DR4610 1 1 0 125 in 3 2 mm ...

Page 273: ...screens Replace if damaged GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection Inspect pinion bearing and forward thrust surface of gearcase housing Use Gearcase Alignment Gauge Kit P N 5006349 to check the condition of gearcase housing prior to reassembly Refer to instructions provided with kit Use additional Gauging Head as follows P N ...

Page 274: ...emble the following components of Pinion Bearing Remover and Installer P N 391257 as shown S Type Gearcases 1 Pinion bearing retaining screw 2 Water screen pocket 3 Seal DSC02370 DRC7416 DSC02313 1 1 4 20 x 1 2 in Hex Head Screw 2 1 in O D Flat Washer 3 Plate P N 391260 4 Rod P N 326582 5 Installer Remover P N 326574 6 1 4 20 x 1 1 4 in Hex Head Screw 824163 2 3 1 1 2 3 4 5 6 1 Flange nut P N 3265...

Page 275: ...into the gearcase Drive the bearing into the gearcase until the washer on the tool contacts the spacer Remove the tool Position new O ring on the pinion bearing retain ing screw Apply Gasket Sealing Compound to O ring Apply Nut Lock to screw threads Install the screw and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Shift Housing Disassembly IMPORTANT The shift housing and bearing are servic...

Page 276: ...o catch ball and spring Rotate the shifter detent 90 in either direction then pull the detent out of the housing Remove the detent ball and spring Remove needle bearings from bearing housing for cleaning and inspection O Type 1 Pin COA3561 1 Gear 2 Thrust bearing 3 Thrust washer COA3562 1 1 3 2 1 Shift lever pin 2 Shift shaft 3 Cradle 4 Shift lever 5 Shifter detent DSC02449 DSC02489 WARNING Wear s...

Page 277: ...he ball and spring with a suitable tool Once the shifter detent is past the ball remove the tool and position detent to engage NEUTRAL position Thoroughly grease 25 needle bearings with Nee dle Bearing grease and place in the bearing case O Type gearcases With shifter detent in NEUTRAL install arms of shift lever into detent slots Align the pivot holes and insert the retaining pin Push shifter det...

Page 278: ... the correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing rear of the shaft IMPORTANT The clutch dog is not symmetri cal If installed backward it will not fully engage and will immediately damage itself and the gears Slide the propeller shaft onto the shift shaft align the hole in the shaft with the hole in the clutc...

Page 279: ... O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage IMPORTANT Do not install the O ring in the bearing housing s bottom groove The bottom groove is an oil passage Gearcase damage could result Apply Gasket Sealing Compound to metal casings of new seals before installing Us...

Page 280: ...d Large Puller Jaws P N 432129 Place the puller plate on top of the housing to sup port the bridge and tighten jaws securely behind the bearing Inspect the bearing housing anode Replace anode if it is reduced to two thirds of original size Tighten screws to a torque of 108 to 132 in lbs 12 to 15 N m Discard the bearing housing O ring Clean the housing and bearings in solvent and dry thor oughly If...

Page 281: ...Type gearcases Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to install new seals back to back in bearing housing Seal installation tool P N 326551 S Type gearcases P N 336311 O Type gearcases Install inner seal with lip facing toward the bearing housing then outer seal with lip facing away from the bearing housing A...

Page 282: ...ring housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 100 to 110 ft lbs 136 to 149 N m IMPORTANT The original pinion nut may be used for shimming but must NOT be used in final assembly Select correct collar and shim gauge bar Collar P N 341440 Shim gauge bar P N 328367 Slide the collar onto the driveshaft with large end in contact with the bear...

Page 283: ...veshaft from the tool and add the required shims between the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 318674 Check clearance again The measurement between the gauge bar and pinion should be 0 020 in 0 508 mm Remove the nut and pinion from the driveshaft Discard the nut GEARCASE ASSEM...

Page 284: ...ushing it through the cover to avoid damaging the O ring Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket Place the gasket on the gearcase Thread the shift rod into the shifter detent about four turns Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the pin hole in the gearcase Apply ...

Page 285: ...lvent Use a shop towel free of grease and lint Place the pinion gear into the gearcase Insert the driveshaft into the gearcase and through the pin ion gear Using Driveshaft Seal Protector P N 318674 slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase Lightly coat the threads of a new pinion nut with outboard lubricant Use Pinion Nut Starting Tool P N 342216 t...

Page 286: ...sembly onto the propeller shaft until it engages the pinion gear Lightly apply Gasket Sealing Compound to a new bearing housing O ring Install O ring in groove in the housing Install housing into gearcase Align screw holes with retainer slots in gearcase Housing must be completely seated to install retainer tabs Install two retainers washers and screws Apply Ultra Lock to threads and tighten screw...

Page 287: ...Confirm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m To complete gearcase assembly refer to GEARCASE LEAK TEST on p 260 WATER PUMP SERVICE on p 263 SHIFT ROD ADJUSTMENT on p 266 GEARCASE REMOVAL AND INSTALLA TION on p 261 Gearcase Lubricant on p 71 Propeller Hardware Installation on p 59 Trim Tab Adjustment on p 62 During break in period of a reassembled gear case change the ge...

Page 288: ...286 GEARCASE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 289: ... GENERAL 289 RESERVOIR FLUID 289 MANUAL RELEASE VALVE 289 STERN BRACKETS 289 TROUBLESHOOTING 289 ELECTRICAL CIRCUIT TESTS 290 RELAY TESTING 290 TRIM AND TILT MOTOR CURRENT DRAW TESTS 290 TRIM AND TILT MOTOR NO LOAD TEST 291 TRIM GAUGE TEST 291 TRIM SENDER TEST 292 SERVICING 292 REMOVAL 292 DISASSEMBLY 294 ASSEMBLY 295 INSTALLATION 296 ADJUSTMENTS 297 NOTES 298 ...

Page 290: ...t down to the top of the trim range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be manually raised or lowered through the entire trim and tilt range by opening the manual release valve a minimum of three turns The manual release valve must be closed and torqued 45 to 55 in lbs 5 to 6 N m to hold the outboard in position and...

Page 291: ...ve must be tightened to a torque of 45 to 55 in lbs 5 to 6 N m Stern Brackets Inspect the stern brackets for binding with the swivel bracket in the thrust rod area Retighten the tilt tube nuts as follows Tighten the tilt tube nuts to a torque of 45 to 50 ft lbs 61 to 68 N m TROUBLESHOOTING Use the following guidelines to check a single pis ton trim tilt unit that is not working correctly Cylinder ...

Page 292: ...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 hydraulic tests DO NOT attempt to perform the following tests while the boat is moving Connect a 0 to 100 A DC ammeter in series between the battery side of the starter solenoid and the red lead to the trim tilt relay module Observe ammeter and a stop...

Page 293: ...ected 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 the motor Trim Gauge Test STEP 1 Turn key switch ON Using a voltmeter check for voltage between the trim gauge I and G termi nals If no voltage check condition of instrument har ness key switch ...

Page 294: ...r must show a reading above 80 Ω With the outboard fully UP meter must show a reading below 10 Ω If results agree refer to Trim Gauge Test on p 291 If results are different replace trim sender TRIM AND TILT SERVICE Removal Remove lower engine cover and disconnect the trim tilt connectors Refer to LOWER COVER SERVICE on p 82 Remove the rubber grommet from the blue green trim tilt cable connector Re...

Page 295: ...nual release valve raise the unit and lock it in place with the tilt support Remove the external snap rings from the upper pin Use a punch to remove the upper pin Retract the tilt cylinder rod Remove the external snap rings from the lower pin Use a punch to remove the lower pin and remove the trim tilt unit from the stern brackets 25078 27381 25064 25065 25077 25076 ...

Page 296: ...es of paint to enter the hydraulic passages during assembly Tape the trim tilt piston rods before painting IMPORTANT Before removing manual release valve relieve pressure by fully extending cylinder Screw the manual release valve in Remove the retaining ring using a small pick or screwdriver Discard the retaining ring Slowly remove the manual release valve There may be pressure behind the valve we...

Page 297: ...Johnson Bio degradable TNT Fluid to fill the hydraulic system Install drive coupler in pump assembly Install a new motor O ring Position the motor on the manifold and install four new screws and lock washers Tighten the screws 35 to 50 in lbs 4 to 5 6 N m Oil O rings and install them on the manual release valve Oil and install the manual release valve Tighten the valve to a torque of 45 to 55 in l...

Page 298: ...nd tighten the fill plug to a torque of 45 to 55 in lbs 5 1 to 6 2 N m Installation Install the ground lead Place trim tilt unit into position Apply Triple Guard grease to the lower pin and install the pin If loosened tighten the tilt tube nut to a torque of 45 to 50 ft lbs 61 to 68 N m Install external snap rings on lower pin with sharp edge of ring facing out Extend tilt cylinder rod to match wi...

Page 299: ...he outboard Tighten the manual release valve to a torque of 45 to 55 in lbs 5 1 to 6 2 N m Install connector on trim tilt cable and reconnect trim connectors to engine wire harness Install lower engine cover Refer to LOWER COVER SERVICE on p 82 ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p 61 Refer to Tilt Limit Switch Adjustment on p 60 25079 ...

Page 300: ...298 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 301: ...S 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 SAFETY S 14 SUMMING UP S 16 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM S 17 HANDLING OUTBOARDS S 17 HANDLING LEAD ACID BATTERIES S 21 GASOLINE HANDLE WITH CARE S 22 HAZARDOUS PRODUCTS S 23 SAFE...

Page 302: ...S 2 ...

Page 303: ...self but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommendations contained in this manual and use of good judgment when servicing outboards will help promote safety Always be alert and careful a good foundation for safety First A word about parts Plain par...

Page 304: ...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 by operator How can loss of shift control be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemble parts carefully Make adjustments carefully T...

Page 305: ...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 can loss of speed control be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemble parts carefully Make adjustments carefully Test your work Do not...

Page 306: ...heel 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 operator may not be able to avoid obstacles Operator could panic If steering is loose boat may weave while operator tries to steer a straight course With some rigs at high speed loose steering could lead ...

Page 307: ... 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 one half inch run test again to make sure steering parts are free and clear During this procedure steering parts Must not bind and Must not touch other boat outboard or accessory parts in transom ar...

Page 308: ...akage 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 ignited by any open flame or spark furnace pilot light etc When boating fuel leaking under the engine cover could be ignited by a damaged or deteriorated electrical part or loose wire connection makin...

Page 309: ...ition 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 Fully pushed onto spark plug Spark Plugs Avoid rough handling that could crack ceramic part of plug Sparks may jump across outside of plug All Connections Clean Tight Prevents sparks Electric Cable ...

Page 310: ...der 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 and not in the hose where it might leak onto the floor if the hose deteriorates If gasoline tank is stored indoors do not put it in a room having an appliance with a pilot light or where electrical ap...

Page 311: ...t 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 the transom boat occupants may be injured from the outboard or its parts entering the boat Boat s transom could break away Outboard may be lost overboard Boat may SINK The mounting system includes o...

Page 312: ...rd 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 blow to the lower unit OR I was backing up and I think the outboard may have hit a tree or something Check for a slow heavy squash to the outboard Look for damaged parts and loosened nuts and bolts ...

Page 313: ... 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 your work whenever possible If oil leaks are seen in service areas determine source Keep reservoir filled If outboard is hydraulic tilt trim model always return rod to hole position determined by boa...

Page 314: ... 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 switch If switch fails If lanyard is caught engine will keep running engine will keep running when clip is pulled from the switch ...

Page 315: ...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 warnings marked closely Assemble parts carefully Inspect lanyard for cuts or fraying clip for wear Replace with original parts Do not substitute Locate control box and other items in area to keep lanyard from being caught ALWAYS ...

Page 316: ... 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 Replaced parts are like originals in every way Customer is told of things which need attention But do you really want the alternative ...

Page 317: ...ht 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 special hardened screws and washers from the set Outboard can drop suddenly if hoist or engine stand are in poor shape or too small for the job Make sure shop aids have extra capacity and keep them in go...

Page 318: ... 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 can shock you and may cause you to recoil into the rotating flywheel When you do things that turn the flywheel like Off season storage fogging oiling of outboard Removing propeller with a powered tool ...

Page 319: ...aust 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 concentrations CO can be fatal within minutes Lower concentrations are just as lethal over long periods of time DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fum...

Page 320: ...t Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water Eyes need protection when Grinding Spraying cleaners and paints Chiseling Tip When steel on steel use plastic or brass type hammers They don t chip off as easily as steel hammers Protect e...

Page 321: ...ger 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 Battery may EXPLODE While charging or discharging remember No smoking No flames No sparks DO NOT check battery charge by placing metal objects across posts You will make sparks and serious burns are po...

Page 322: ...atches 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 Loose wires on running outboards Other variables which may ignite fumes How many of these are in your repair area 20 Parts Air By Volume 1 Part Gasoline Gas Fumes If the air around you is calm the p...

Page 323: ...ere 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 children are very curious and will try to taste everything so keep containers away from children ...

Page 324: ...nual 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 common shop safety practices to protect your self and others around you 7 When replacement parts are required will you use Evinrude Johnson Genuine Parts or parts with equivalent characteristics inclu...

Page 325: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Batteries Battery Switches 28 Cable Routing 35 Cables 28 Charging System Tests 127 Connections 28 74 Instal...

Page 326: ...ivery Tests 114 Ignition Tests 109 LED Indicators 107 Strategy 104 Diagnostic Software Break In Programming 54 57 182 CANbus Activation 50 Communication with Outboard 95 Crankshaft Position Sensor 110 Cylinder Drop Tests 106 Fuel Injector Programming 100 169 Fuel Pump Test 114 Idle Speed Control 99 Oil Injector Test 183 Oil Priming 54 187 Oiling Rate 53 54 98 Reports 100 Sensor Monitoring 124 Serv...

Page 327: ...n n n n n n n n Flushing Cooling System 68 Flywheel Installation 141 Removal 139 Fuel Filter Requirements 33 Fuel Injectors Crush Ring Replacement 170 Electrical Circuits 157 EMM Programming 169 171 Installation 171 Removal 169 Tests 162 163 Fuel System Additives 10 51 Components 158 Filter 33 158 167 Fuel Circulation Pump 159 163 Fuel Filter 74 Fuel Lift Pump 158 163 165 167 Fuel Manifolds 168 Fu...

Page 328: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n LED Indicators 107 Lower Cover Installation 83 Removal 82 Lubrication Engine Oil 10 52 Gearc...

Page 329: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 330: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 331: ...r P N 336314 217 Rod Cap Alignment Fixture P N 396749 219 Seal Installation Tool P N 326551 279 Seal Installation Tool P N 330268 277 Seal Installation Tool P N 336311 279 Secondary Lock Installer P N 777079 149 Secondary Lock Tool P N 777078 149 Shim Gauge Bar P N 328367 280 Slide Hammer Adaptor Kit P N 390898 170 Slide Hammer P N 391008 170 214 269 Slide Hammer P N 432128 209 239 Small Puller Ja...

Page 332: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 333: ... 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 bendix drive gears Check starter inspect bendix drive gears Seized powerhead or gearcase Check and repair as needed Outboard turns slowly Discharged battery Check battery recharge or replace Battery cable...

Page 334: ...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 alternator output Check voltage on 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuits refer to SYSTEM ANALYSIS and ELECTRI...

Page 335: ...Check 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 Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit white red refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Restricted or leaking fuel injector s Check injectors refer to FUEL SY...

Page 336: ...ut 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 IGNITION Contaminated or poor fuel quality Check or replace fuel supply Low fuel pressure Check pressure refer to FUEL SYSTEM Air in fuel system Check for air in fuel supply manifold refer to FUEL S...

Page 337: ...ion Check ignition refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS Restricted or leaking fuel injectors Check injectors refer to FUEL SYSTEM Low fuel pressure Check circulation pump operation refer to FUEL SYSTEM EMM programming timing or operation Check EMM program and timing check inject...

Page 338: ... 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 Check CPS air gap Low alternator output 55 V Check voltage on 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION EMM program timing or operation Check EMM program and timing check inje...

Page 339: ...rm hot Incoming water cool 6 4 8 9 10 1 Intake water screens 2 Water pump 3 Water tube 4 Adaptor housing 5 Cylinder block 6 Pressure valve 7 Thermostat 8 Water supply to EMM 9 Water supply EMM to vapor separator 10 Overboard indicator outgoing water from vapor separator 5 001818 ...

Page 340: ...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 341: ...839 CANbus Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 1 4 watt resistor 10 Amp Fused B 12V ...

Page 342: ...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 343: ...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 344: ...V PUL REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 TO OUTBOARD WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASHBOARD ...

Page 345: ...tion Sensor 3 Neutral Switch 4 Stator 5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Connector 12 Temperature Sensor 13 Ignition Coil 14 Fuel Injector 15 Fuse 10 Amp 16 Starter Solenoid 17 Main Harness Ground 18 Electric Starter 19 EMM 20 Oil Injector 21 Low Oil Switch 22 Tilt Limit Switc...

Page 346: ...ation Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will not start Correct problem and clear codes Indicates 30V or higher on 55V circuit Indicates CPS working and EMM SYNC 1 2 3 4 Start assist circuit SAC OK V models only Stop circuit OK Sensor circuits ...

Page 347: ... Temperature ABOVE range 3 3 LED 4 ON Running WATER TEMP HOT 8 seconds EMM Temperature 176 F 80 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running LOW BATTERY 5 minutes Battery voltage 12 5 V Perform stator charging tests 27 12 V circuit ABOVE range 3 LED 1 ON Running LOW BATTERY 5 minutes Battery voltage 15 5 V Check battery connections and wiring 29 EMM Tempe...

Page 348: ...es 83 Ignition timing circuit 3 OPEN LED 2 ON Running 10 instances 90 Water injection solenoid SHORTED LED 2 ON Running 8 seconds Check circuit resistance 295 Ω 20 77 F 25 C 91 Fuel pump circuit OPEN LED 2 ON Running 8 seconds Check pump circuit resistance 2 to 3 Ω 77 F 25 C 93 Water injection solenoid OPEN LED 2 ON Running 8 seconds Check circuit resistance 295 Ω 20 77 F 25 C 94 Fuel pump circuit...

Page 349: ...2008 SC E TEC 75 90 P N 5007527 75 90 HP 5007527 Service Manual ...

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