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Evinrude E-TEC 200, Service Manual

The Evinrude E-TEC 200 Service Manual is a comprehensive guide for owners looking to maintain and repair their outboard motor. This manual covers everything from troubleshooting to maintenance procedures, ensuring your Evinrude E-TEC 200 runs smoothly. Download your free manual from manualshive.com.

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238

POWERHEAD

POWERHEAD ASSEMBLY

Throttle Linkage Installation

Apply 

Nut Lock

 to threads of throttle lever screw.

Insert spring into cavity of throttle lever.

Install lever, screw, and washer on crankcase and
hook spring on rib as shown. Tighten screw to a
torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

Apply 

Nut Lock

 to threads of throttle cam screw.

Install cam, screw, and washer on cylinder block
and tighten screw to a torque of 120 to 144 in. lbs.
(13.5 to 16.5 N·m).

IMPORTANT:

Do not lubricate throttle levers or

shoulder screws.

Final Powerhead Assembly

Install the reed plate and throttle body assemblies.
Refer to 

Intake Manifold Service

 on p. 151.

Install oil recirculating hoses and check valves.
Refer to 

OIL RECIRCULATION DIAGRAMs

 on

p. 162, or 

POWERHEAD VIEWS

 on p. 242.

Install pressure valve assembly. Refer to 

PRES-

SURE RELIEF VALVE SERVICING

 on p. 192.

Install shift linkage. Refer to 

Shift Linkage Instal-

lation

 on p. 237.

Install throttle linkage. Refer to 

Throttle Linkage

Installation

 on p. 238.

Install fuel injectors and ignition coils. Refer to
Fuel Injector 

Installation

 on p. 149.

IMPORTANT:

All injectors must be reinstalled in

their original location. Improper injector installation
can result in powerhead failure.

Install oil pump, rear oil manifold, and oil injection
hoses. Refer to 

OIL COMPONENT SERVICING

on p. 178.

Install stator. Refer to 

Stator Service

 on p. 109.

Install electrical harness and 

EMM

. Refer to 

EMM

SERVICING

 on p. 70.

Install fuel pump assemblies, fuel manifolds, and
filter. Refer to 

FUEL COMPONENT SERVICING

on p. 143.

Install the electric starter. Refer to 

Starter Instal-

lation

 on p. 121.

1.

Throttle lever spring

006966

1.

Throttle cam screw

006866

1

1

WARNING

To prevent fire and explosion hazard,
make sure all electrical and ignition wiring
is routed and clamped in original posi-
tions.

Summary of Contents for E-TEC 200

Page 1: ...Main Menu...

Page 2: ......

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

Page 4: ...REMOTE CONTROL SYSTEM 193 11 POWERHEAD 213 12 MIDSECTION 257 13 GEARCASE 279 GEARCASE STANDARD ROTATION 294 GEARCASE COUNTER ROTATION 317 14 TRIM AND TILT 329 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART...

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

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

Page 7: ...edly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery c...

Page 8: ...merican Boat Yacht Council ATDC after top dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CFR Code of Federal Regulations CPS cr...

Page 9: ...changes such as altitude adjustments for exam ple Owner s Responsibility The owner operator is required to have outboard maintenance performed to maintain emission lev els within prescribed certifica...

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

Page 11: ...Stainless Steering Arm Standard Styling DE250PXIIC 3 3 L 200 1 ci 542 M2 25 White ICON Control Stainless Steering Arm Std Styling E250DCXIID 3 3 L 200 1 ci 542 M2 CR 25 White Stainless Steering Arm S...

Page 12: ...mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 1 6199 to 1 6204 in 41 15 to 41 16 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom...

Page 13: ...ssion Control Information Label Champion QC8WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 L2 Type Gearcase 200 HP 14 26 538 1 86 1 L2 Type Gearcase 225 HP 14 24 583...

Page 14: ...ize add piston oversize dimension to standard bore Top Crankshaft Journal 1 6199 to 1 6204 in 41 15 to 41 16 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Crankshaft Journ...

Page 15: ...sor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC8WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 Refer to GEARCASE TYPES on p 283 L...

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

Page 17: ...ING UNIT ADJUSTMENT 29 TRIM TAB ADJUSTMENT 30 DUAL OUTBOARD ALIGNMENT 31 OPERATIONAL CHECKS 32 COOLING SYSTEM 33 ENGINE FLUSHING 34 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 35 LUBRICATIO...

Page 18: ...teners tighten any loosened components Water intake screens check condition Cooling system check water pump indicator water pressure Anticorrosion anodes check condition Gearcase check condition Prope...

Page 19: ...dentify control cable function before rigging outboard Identify each control cable Put the control handle into NEUTRAL position The throttle cable casing guide will retract com pletely and the shift c...

Page 20: ...Hose and Wire Routing Refer to Control Cable Identification on p 17 Remove two screws and bracket that fasten the grommet to lower motor cover Route all hoses control cables and wiring through a prot...

Page 21: ...for all cables to avoid binding or chafing through all engine steering and tilting angles Control Cable Installation Refer to Control Cable Identification on p 17 Remove control cable trunnion covers...

Page 22: ...hten screw to a torque of 60 to 80 in lbs 7 to 9 N m Throttle Cable Installation and Adjustment With remote control lever in NEUTRAL pull firmly on throttle cable casing to remove slack Place throttle...

Page 23: ...ound stud SystemCheck Harness Connections Remove harness connector cover Before installing electrical connectors check that the seal is in place Clean off any dirt from con nectors Apply a light coat...

Page 24: ...CON Remote Control System Installation Guide If using a mechanical control system connect the I Command Engine Interface Cable to the EMM CANbus connector Use an I Command Ignition and Trim Harness to...

Page 25: ...rs Carefully align pins and sockets of connectors Do NOT force connectors together Tighten locking rings of buss connectors finger tight Do NOT use locking rings to force connec tors together Do not r...

Page 26: ...ied with gauge Route the water pressure hose around the star board side of the powerhead along the same path as the battery cables For an I Command water pressure display sev eral water pressure senso...

Page 27: ...to the battery negative post LAST Install a starwasher on the threaded battery post Stack cables from the outboard then cables from accessories Finish this connection with a hex nut Do not use wing n...

Page 28: ...The clamp identification numbers appear on the side of the clamp near the top of the ear Refer to Clamp Selection chart for dimensions Clamp Selection To select the correct size Oetiker clamp measure...

Page 29: ...r stepless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accessories Catalog Position correct size clamp over hose Install hose on fitting Close clamp ear fully with O...

Page 30: ...tion 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 equ...

Page 31: ...e engine is trimmed to the full down position the bow of the boat goes deeper into the water If the trim limiter rod is left out the bow could plow into the water causing the boat to bow steer resulti...

Page 32: ...to the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw as follows 115 200 HP 35 to 40 ft...

Page 33: ...nts 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 o...

Page 34: ...ear Prevention Start outboard and shift to FORWARD Turn outboard OFF while control is in FORWARD Try to restart the outboard Outboard should not start Shift back to NEUTRAL and restart outboard Shift...

Page 35: ...utboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use COOLING SYSTEM Check the cond...

Page 36: ...on Run outboard at IDLE only until full operating tem perature is reached Reinstall plug and nozzle Position the plug and nozzle to allow the water stream to be seen from the helm Leave the outboard i...

Page 37: ...ough water travels to the powerhead Water can drain from auxil iary inlets resulting in engine overheat A steady stream of water should flow from the overboard indicator while the engine is running Mo...

Page 38: ...lering bracket with Triple Guard grease Throttle and Shift Linkage Disconnect the battery cables at the battery Remove cable trunnion cover Carefully remove throttle and shift cables from trunnion blo...

Page 39: ...r Gearcase Lubricant Draining IMPORTANT Always check the fill level of the gearcase lubricant at the upper plug before removing the lower drain fill plug A tie strap can be used to check lubricant lev...

Page 40: ...is recommended when lubricant is contaminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 16 for service frequency and recommended lubricants Secure the ge...

Page 41: ...the fill plug threads Install the filler cap and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the unit at least five complete cycles to purge all air from the system...

Page 42: ...e 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 Appl...

Page 43: ...d Serviceable oil filters are located in the oil injec tion tank and in the oil supply line before the oil lift pump s Air Silencer The air silencer on Evinrude outboards maximizes air flow while mini...

Page 44: ...g for restric tion With key ON outboard NOT running the exhaust pressure sensor reading should be close to zero With the outboard running make sure the exhaust pressure reading changes with throttle s...

Page 45: ...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...

Page 46: ...d then start the outboard All four System Check lights will turn on and the outboard will run at idle speed After approximately 15 seconds the System Check lights will go off Move throttle to IDLE pos...

Page 47: ...ON IS COM PLETE message Press EXIT to return to BUS DEVICES menu Repeat steps 3 through 8 for other engines multi engines set up only Additional Recommendations Top off oil reservoir inspect the fuel...

Page 48: ...rhead bearings IMPORTANT If outboard cannot be started or serviced immediately it should be resubmerged in fresh water to avoid exposure to the atmosphere Engine Dropped Overboard Not Running Disconne...

Page 49: ...hour Engine Dropped Overboard Running Follow the same procedures as Engine Dropped Overboard Not Running However if there is any binding when the flywheel is rotated it may indicate a bent connecting...

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

Page 51: ...SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 50 LATCH HOOK INSTALLATION 50 UPPER COVER CAP REPLACEMENT 50 LOWER COVER SERVICE 51 LOWER COVER REMOVAL 51 LOWER COVER INSTALLATION 51 LATCH HANDLE INSTA...

Page 52: ...to position on bracket Apply Ultra Lock to screw threads Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Upper Cover Cap Replacement Place new upper cap into position Tighten self tapping s...

Page 53: ...de cover slightly and disconnect trim tilt switch connector Then remove port and starboard covers Lower Cover Installation Install the lower engine covers and tighten all screws to a torque of 24 to 3...

Page 54: ...k to screw threads Place spring washer and hook into position and tighten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on switch...

Page 55: ...NSOR 60 NEUTRAL SHIFT INTERRUPT SWITCH 60 INTERNAL EMM FUNCTIONS 61 START ASSIST CIRCUIT SAC 61 ROM VERIFICATION 61 IDLE CONTROLLER 61 RPM LIMITER 61 NEUTRAL RPM LIMITER 61 ENGINE MONITOR AND WARNING...

Page 56: ...ours Oiling ratios Shift interrupt function Anti knock compensation EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections can damage the EMM DO...

Page 57: ...er 13 Trim Tilt Sending Unit 14 Water Pressure Sensor w adaptor harness 15 LED indicators 16 Fuel Pump high pressure 17 Starter Solenoid 18 Oil Injection Pump and Manifold 19 Rear Oil Injector and Man...

Page 58: ...sor circuit fault is detected and the EMM 55 V Circuit Sensor Monitors the EMM s 55 V alternator circuit If system voltage exceeds 57 volts the EMM If system voltage is less than 45 V between 500 and...

Page 59: ...Exhaust Pressure Sensor The exhaust pressure sensor monitors exhaust pressure during all running conditions to compen sate for engine loads If the sensor reads less than 85 in water or greater than 85...

Page 60: ...seconds the EMM If cylinder head temperature exceeds 248 F 120 C for 3 seconds the EMM The outboard will not restart until the engine tem perature returns to normal Refer to SHUTDOWN MODE on p 63 If s...

Page 61: ...EMM If the outboard is started the code is stored If the key ON voltage is greater than 0 78 V when the engine is started speed is limited to idle If code 11 is present as both a Hard Fault and a Stor...

Page 62: ...cylinder If knock continues the EMM If the sensor circuit is OPEN the EMM Neutral Shift Interrupt Switch A switch mounted on the powerhead signals the EMM when the shift linkage is moved from FOR WARD...

Page 63: ...ings are altered to maintain a specific RPM when engine is cold or warm The controller is inactive when TPS is advanced from idle position RPM Limiter This feature of EMM programming prevents engine d...

Page 64: ...by the EMM Refer to the EMM Service Code Chart at the back of this manual for a complete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position T...

Page 65: ...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 relat...

Page 66: ...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 ON Switched B 12 V enters the EMM at pin 21 purple...

Page 67: ...d and operating hours of first and last occurrences Hard Faults A hard fault is a service code that currently exists Hard faults become stored faults only if the out board is running Persistent Faults...

Page 68: ...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...

Page 69: ...njection rate This set ting REQUIRES the use of Evinrude XD100 out board lubricant and is not recommended for all applications Use the XD100 setting for Conventional use runabouts cruisers Moderate ap...

Page 70: ...tments TPS Calibration TPS Calibration synchronizes throttle plate open ing with throttle position sensor voltage Refer to TPS CALIBRATION on p 113 Perform TPS Calibration after replacing or adjust in...

Page 71: ...computer file Software Replacement Engine Management Software is loaded into the EMM at the factory Periodically a new program may be available to enhance the operation of an outboard Select Engine So...

Page 72: ...T Whenever the EMM is replaced EMM timing must be synchronized to crankshaft position Refer to TIMING ADJUSTMENTS on p 112 EMM SERVICING IMPORTANT If a new EMM is being installed refer to EMM Transfer...

Page 73: ...mounts on cylinder block Slide EMM into position Install two EMM retaining screws Tighten screws 12 to 16 in lbs 1 5 to 2 N m Install J1 A J1 B and J2 connectors Install exhaust pressure hose and coo...

Page 74: ...72 ENGINE MANAGEMENT MODULE EMM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 75: ...INDUCTIVE AMP METER TEST 77 EMM LED INDICATORS 78 KEY ON 78 STARTING 78 RUNNING 79 IGNITION OUTPUT TESTS 80 REQUIRED IGNITION SYSTEMS 80 WIRING INSPECTION 80 CRANKSHAFT POSITION SENSOR CPS TEST 81 SYS...

Page 76: ...spark plugs Check the fuse and the emergency stop switch lanyard Diagnostic Software Inspections Before running the outboard use Evinrude Diag nostics software to review historical information stored...

Page 77: ...ach new record is added the oldest record is removed The Engine Identity Report provides a snap shot of current engine and sensor conditions From the Identity screen press the Print button Next press...

Page 78: ...o EMM LED INDICA TORS on p 78 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...

Page 79: ...s IMPORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to maintain a constant IDLE speed The Dynamic Tests screen includes a function to tem porarily disab...

Page 80: ...nsor circuit fault Code 8 STBD Knock sensor circuit fault Code 12 TPS circuit fault Code 13 TPS below expected range Code 14 TPS above expected range Code 23 EMM temp sensor circuit fault Code 24 EMM...

Page 81: ...cylinder excessive knock Code 5 No 5 cylinder excessive knock Code 6 No 6 cylinder excessive knock Code 7 PORT Knock sensor circuit fault Code 8 STBD Knock sensor circuit fault Code 12 TPS circuit fa...

Page 82: ...ge from EMM white red provides 55 VDC to the oil injection pump the fuel injec tors and the ignition module of EMM Capacitor Connected to 55 V circuit white red to stabilize current on 55 V circuit Ne...

Page 83: ...oftware Monitor screen to check system voltage Results EMM ON not running 30 V 2 system volt age is GOOD EMM ON not running less than 30 V 2 check 12 V power to EMM Repair connection or wiring Possibl...

Page 84: ...Connect timing light pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test and observe timing light strobe for consistent flash IMPORTANT You may need to remove s...

Page 85: ...ltage and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 85 Check for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace s...

Page 86: ...l connector Refer to engine wiring diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil tests available Before replacing an ignition coil be sure 55 V is sup...

Page 87: ...r to check continuity between pin 2 of fuel pump connector and ground Refer to Circulation Pump Resistance Test on p 141 If the pump runs Refer to Fuel System Pressure Test on p 139 Refer to Running F...

Page 88: ...eing switched by the EMM The Dynamic Tests screen allows the control signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always...

Page 89: ...T 97 AUXILIARY BATTERY CHARGE WIRE 98 55 V ALTERNATOR CIRCUIT 98 ELECTRIC START CIRCUIT 99 ELECTRIC START TESTS 101 REMOTE CONTROL SWITCH TESTS 103 TILT TRIM RELAY TEST 105 SYSTEMCHECK CIRCUIT TESTS 1...

Page 90: ...m 30 42 In lbs 3 5 4 7 N m F F 30 42 In lbs 3 5 4 7 N m F J 30 42 In lbs 3 5 N m 60 84 In lbs 7 9 5 N m 30 42 In lbs 3 5 N m Apply to inner flywheel taper 15 30 Ft lbs 20 41 N m T 10 16 In lbs 1 2 N m...

Page 91: ...le Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock N Starter Bendix Lube T Liquid Neoprene N 60 84 in lbs 7 9 5 N m 168 192 in lbs 19 21 5 N m F 60 8...

Page 92: ...Main harness ground 12 V from battery FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 7 2 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 1 2 3 4 5 6 7 8 9 1 2 3...

Page 93: ...iagnostic connector White 4 Ground water in fuel digital Black 5 Oil level switch Tan Black 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Bootstrap connector programming Blk Ora...

Page 94: ...cylinder 2 Orange Blue 20 Injector cylinder 4 Purple 21 Switched B 12V Purple 22 Injector ground Black 23 Oil solenoid Blue 24 Rear oil injector 12 V Red Yellow 25 Ignition cylinder 6 Orange Green 26...

Page 95: ...16 and 22 of the EMM J1 B connector and the main harness ground Sensor circuit grounds Check continuity between terminal pins 4 and 11 of the EMM J1 A connector and the appropriate sensor ground conne...

Page 96: ...e 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 r...

Page 97: ...erature 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 measur...

Page 98: ...to read 1 ohm or less To check for a grounded winding connect one meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no continuity If meter reads c...

Page 99: ...501 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 pile acro...

Page 100: ...If there is no increase turn the key switch to OFF and test red black wire between the EMM and auxiliary battery connection Continuity indicates faulty output from EMM Check 12 V alternator output be...

Page 101: ...8 9 J2 J1 A J1 B M A S C M B 1 2 3 4 5 6 2 5 3 4 1 6 A B FUSE B A 004112 NEG 8 13 15 9 5 10 9 1 2 3 4 6 11 12 13 16 3 14 17 7 POS 1 Marine battery 10 26 pin J1 B EMM connector 2 RED wire POS 11 34 pin...

Page 102: ...s Contains the following circuits Red purple output wire from fuse provides 12 V to instrument harness Purple wire provides switched 12 V to solenoid terminal A and EMM Yellow red wire provides switch...

Page 103: ...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 t...

Page 104: ...ative lead to starter motor terminal Activate starter motor and observe voltage reading No Load Current Draw Test Securely fasten starter in a vise or suitable fixture before proceeding with this chec...

Page 105: ...terminal S Meter should indicate continuity IMPORTANT The choke function or terminal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or continuity light to test the continu...

Page 106: ...ts are incorrect Emergency Stop Switch Test This switch can be part of the key switch or installed as a separate switch Either style con nects the M terminals of the key switch The emergency stop swit...

Page 107: ...d B con nection to TNT motor Terminals 87 and 30 are normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diag...

Page 108: ...urn on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the key switch ON Test for battery voltage between instrument harness terminal 1 purple wire an...

Page 109: ...wire of the SystemCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and t...

Page 110: ...yellow wire of the Sys temCheck connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits TACHOMETER CIRCUIT TESTS Check voltage at the battery U...

Page 111: ...y P N 307636 Screw P N 307637 Handle P N 307638 Three screws P N 309492 Three washers P N 307640 Apply Moly Lube grease to the threads of the puller pressing screw P N 307637 and the center hole of th...

Page 112: ...er This prevents Nut Lock from migrating into upper seal of crankshaft Align the flywheel keyway and install the flywheel Coat the threads of the flywheel nut with Gasket Sealing Compound Install the...

Page 113: ...racket with four screws Tighten screws to a torque of 60 to 84 in lb 7 to 9 5 N m Install spark plug leads with ground screw Tighten screw securely Ignition Coil Installation Connect ignition coil ele...

Page 114: ...rmly against the tool Mark the flywheel directly across from the pointer Label this mark A Rotate the flywheel clockwise until the piston contacts the tool Mark the flywheel directly across from the p...

Page 115: ...TANT Make sure the timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS CALIBRATION Use Evinrude Diagnostics software to tell the EMM what thr...

Page 116: ...it stops The Measured TPS Calibration field on the screen will increase Click the Working button in the software to cali brate the TPS MODELS WITH ICON ELECTRONIC SHIFT AND THROTTLE Use Ball Socket In...

Page 117: ...o the starter bearings and commutator Disconnect the battery cables at the battery Remove the starter positive cable from post on starter Remove the four frame and bracket mounting screws Lift and rem...

Page 118: ...ring under the spacer Remove the retaining ring spacer and spring from pinion shaft Remove pinion and plastic weather cover from pinion shaft Remove the driven gear and thrust washer Using No 2 exter...

Page 119: ...e with a rubber mallet to loosen it Find the insulator cap end of the shaft or inside the end cap Inspect and replace if necessary Note the alignment marks by the positive terminal stud Hold the armat...

Page 120: ...maged windings Clean off any carbon deposits or foreign matter which could contribute to failure of wind ings Check permanent magnets Make sure they strongly attract any steel or iron object held insi...

Page 121: ...ushes could damage the starter or cause reverse rotation Apply Moly Lube to the armature bushing Install the thrust washer and armature Align the starter frame and make sure the long alignment mark ma...

Page 122: ...the retaining ring flat side up with No 2 external retaining ring pliers Lightly coat the gear housing bearing with Moly Lube Lightly coat the driven gear with Triple Guard grease Install the thrust...

Page 123: ...t Lock to the thru bolts Install the nuts and tighten to a torque of 50 to 65 in lbs 5 6 to 7 3 N m To test the assembly and operation of the starter refer to No Load Current Draw Test on p 102 Starte...

Page 124: ...ently 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 lat...

Page 125: ...ock Tool P N 777077 to release locking tab of connector housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push c...

Page 126: ...seated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 connector of the EMM is a AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull connector from...

Page 127: ...y releas ing the tab and then pushing the terminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gasket...

Page 128: ...126 ELECTRICAL AND IGNITION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 129: ...PRIMING 138 VENT LINE CLAMP 138 PRIMING THE FUEL SYSTEM 138 FUEL SYSTEM TESTS 139 FUEL SYSTEM PRESSURE TEST 139 PRESSURE REGULATOR TEST 140 VAPOR SEPARATOR VENT CHECK 140 FUEL INJECTOR PRESSURE TEST 1...

Page 130: ...tighten to seal contact then 1 2 1 turn 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m L 100 110 In lbs 11 12 N m P Lower screw only L L L A Triple Guard Grease B Gasket Sealin...

Page 131: ...8 11 N m F 96 120 in lbs 11 13 5 N m 10 18 in lbs 1 2 N m 60 84 in lbs 7 9 5 N m C F K B B A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G...

Page 132: ...sive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Engine Lubricant S STP Oil Treatment 004101 R R R R R R R R S S S S S S S S S S R 60 84 in lbs 6 8 9 5 N m H 24...

Page 133: ...or separator Vent hose to throttle body 8 9 10 11 12 13 14 Electric fuel circulation pump 20 to 35 psi Fuel supply manifold Fuel injector s Fuel return manifold Pressure regulator high pressure Test f...

Page 134: ...gh pressure fuel pump Fuel filter water separator 007109 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 1 3 5 2 4 6 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 2 3...

Page 135: ...age NOTE A small amount of fuel may be released when the fuel connector is dison nected Store portable fuel tanks in well ventilated areas away from heat sources and open flames Close the vent screw o...

Page 136: ...amage the out board Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other fuel additives ca...

Page 137: ...ump pressure forces the fuel from the pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure components of the fuel sy...

Page 138: ...vapor separator decreases the fuel level begins to increase An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps maintain consi...

Page 139: ...he injector by serial number The EMM is programmed to compensate for vari ations in fuel flow Each injector and its location on the outboard is identified by the EMM DO NOT install an injector without...

Page 140: ...ric fuel primer until fuel flows from the fuel hose Once fuel flow is observed connect fuel supply hose from fuel tank to hose fitting on outboard Secure hose with Oetiker clamp Use the primer to fill...

Page 141: ...p 142 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying adequate fuel to vapor separa...

Page 142: ...lace vapor separator if the venting of fuel is continuous Fuel Injector Pressure Test This test requires Injector Test Fitting kit P N 5005844 Disconnect the battery cables at the battery Relieve fuel...

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

Page 144: ...ps to prevent fuel or air leaks Do not use fuel primer bulb manual fuel primer or electric fuel pump primer to restart outboard A positive pressure in the fuel supply could damage some vacuum gauges S...

Page 145: ...uel pump electrical connector If outboard runs start and run at IDLE for 5 seconds and STOP out board If outboard does NOT run crank for 10 seconds Disconnect the battery cables at the battery 1 Anti...

Page 146: ...filter s contents Inspect contents for any presence of water If water is present identify the source and correct the problem Take additional fuel samples and drain fuel tank s if necessary Installati...

Page 147: ...an assembly Installation Place fuel pump bracket with rubber isolator mounts in front of the throttle body Apply Nut Lock to screws and install screws into throttle body Tighten screws to a torque of...

Page 148: ...unts Install forward iso lator of vapor separator on mounting stud and secure with retainer clip Install all hoses and manifolds in original locations and secure with appropriate clamps Squeeze primer...

Page 149: ...lled in the correct cylinder locations Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning The Injector Coefficients screen displays injector serial number...

Page 150: ...mounting cup Thread adaptor and stud into face of injector Hold mounting cup securely Work slide hammer to separate injector from mount housing Remove adaptor from injector Remove crush ring and O rin...

Page 151: ...Files to EMM Use the Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM Select the Injectors tab Select the cylinder tab for injector being replaced Select the Rep...

Page 152: ...stall 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...

Page 153: ...assembly All reed plate assembly and reed valve assem blies must be cleaned before reassembly DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning Remove the reed valve ret...

Page 154: ...n lbs 3 5 to 4 7 N m Installation Install gasket on reed plate assembly DO NOT use sealer on the gasket Place reed plate assembly on cylinder crankcase Apply Nut Lock to screws Install all screws Tigh...

Page 155: ...to throttle shaft surface Install oil fuel pump bracket Tighten screws 30 to 42 in lbs 3 5 to 4 7 N m Position clamps as shown Refer to TPS CALIBRATION on p 113 1 Throttle linkage 2 TPS electrical con...

Page 156: ...154 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 157: ...SE 167 OIL RECIRCULATION SYSTEM 167 OIL CONTROL SETTINGS 168 OIL INJECTION RATE 168 BREAK IN OILING 169 OIL SUPPLY PRIMING 170 OIL HOSE PRIMING 170 OIL PUMP PRIMING 170 250 300 HP 3 4 L MODELS 170 200...

Page 158: ...e Johnson Refer to the Operator s Guide for Oil Requirements P N 351520 TCW3RL OIL XD 30 XD 50 Yellow XD 100 Blue IMPORTANT This outboard has been programmed for the use of Evinrude Johnson XD100 outb...

Page 159: ...4 5 2 1 1 2 3 6 5 4 1 2 3 4 5 J2 J1 B J1 A 26 27 28 29 30 31 32 33 34 4 7 8 9 10 11 12 13 14 15 2 A B 1 2 3 4 5 6 7 8 Crankcase Oil Injection Pump Cylinder Oil Injection Pump EMM 55 V Circuit WHITE R...

Page 160: ...nder 3 4 Cylinder 4 5 Cylinder 5 6 Cylinder 6 7 Rear oil manifold 7 1 2 3 4 5 6 1 Cylinder 2 2 Cylinder 4 3 Cylinder 6 4 Cylinder 1 5 Cylinder 3 6 Cylinder 5 Rear oil manifold delivers oil to cylinder...

Page 161: ...OILING SYSTEM OIL SUPPLY DIAGRAMS 159 8 008208 Starboard View Port View...

Page 162: ...inder 5 6 Cylinder 6 7 Rear oil manifold 6 5 4 7 2 1 8 6 6 7 2 3 4 5 6 1 1 Cylinder 2 2 Cylinder 4 3 Cylinder 6 4 Cylinder 1 5 Cylinder 3 6 Cylinder 5 Rear oil pump delivers oil to cylinder sleeves 1...

Page 163: ...OILING SYSTEM OIL SUPPLY DIAGRAMS 161 8 008432 Starboard View Port View...

Page 164: ...162 OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMs 008205 1 Recirculation fitting 008206 2 4 6 1 3 5 Complete View 1 Top View...

Page 165: ...OILING SYSTEM OIL RECIRCULATION DIAGRAMS 163 8 008207 Starboard View Port View...

Page 166: ...t least one quar ter capacity The LOW OIL warning should not display Failure to follow these recommen dations could void the outboard warranty if a lubrication related failure occurs COMPONENTS The oi...

Page 167: ...the specified range open circuit the EMM Oil Pressure Sensor The oil pressure sensor reacts to changes in oil manifold pressure The EMM supplies and moni tors electrical current to the sensor The sens...

Page 168: ...ors the oil injection pump electri cal circuit If the circuit is open the EMM LOW OIL Warning A sending unit in the oil tank pick up assembly monitors the oil level in the oil tank If the oil level fa...

Page 169: ...ulate any accumulation of oil from various locations in the powerhead The movement of oil is controlled by check valves Cylinder Recirculation Internal powerhead oil drain passages connect the lowest...

Page 170: ...Module EMM controls the oil injection rate based on engine RPM This rate can be adjusted for the type of oil being used and also for powerhead break in Use Evinrude Diagnostics software to access thes...

Page 171: ...ing IMPORTANT DO NOT add oil in the fuel tank on Evinrude E TEC models The EMM automatically supplies extra oil to the engine as follows 90 V6 First two hours above 2000 RPM Follow these steps for out...

Page 172: ...d for the type of oil being used 250 300 HP 3 4 L MODELS Start the outboard Use the oil priming functions in the software to make sure the system is com pletely primed IMPORTANT The outboard should be...

Page 173: ...il flow through all oil distribution hoses Air must be purged during the priming procedure Small bubbles are acceptable Large bubbles must be eliminated through continued priming Repair any fuel or oi...

Page 174: ...that oil flows through the rear oil distri bution manifold to the cylinder block fittings Small bubbles are acceptable Large bubbles must be eliminated through continued priming Repair any fuel or oil...

Page 175: ...hen it is activated Use an inductive timing light to monitor current flow through the ground circuit blue wire at the oil pump connector pin 2 If the light flashes the EMM and oil injection cir cuits...

Page 176: ...istance Test IMPORTANT The complete oil injection pump electrical circuit includes EMM alternator output the engine wire harness the injection pump wind ing and connectors and the oil injector control...

Page 177: ...l multimeter to the Hertz Hz scale Meter should read approximately 2 Hz Results If voltage and control signal readings Hz at pin A are within range the EMM and wiring are not at fault If voltage at pi...

Page 178: ...lly remove the pickup filter and flush with a mild solvent to remove any contamination Rein stall filter Carefully remove the oil hose from the oil pickup and remove the oil supply hose from the oil i...

Page 179: ...e to oil flow at other distribution hoses If one or more hoses fail to discharge oil check for a kinked or restricted hose before replacing the oil injection pump assembly Oil Injection Fittings Flow...

Page 180: ...to rear manifold hose does not use a hose support IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully inserted into manifold Insertion depth is 5...

Page 181: ...nifold Remove oil distribution hoses from the crankcase fittings Remove oil injection pump clamp screw Remove the oil injection pump assembly IMPORTANT The oil injection pump and mani fold is an assem...

Page 182: ...MING on p 170 Run the outboard and check for leaks Repair any oil leaks and any kinked or misrouted hoses Rear Oil Pump Removal Disconnect the battery cables at the battery Remove engine cover Remove...

Page 183: ...bution hoses from the oil distribu tion manifold to the crankcase oil delivery fittings as they were before removal Refer to OIL SUP PLY DIAGRAMS on p 158 Connect oil hoses to cylinder sleeve oil fitt...

Page 184: ...tem is primed Check oil flow through oil distribution hoses Check oil system operation and routing of oil hoses Refer to OIL SUPPLY PRIMING on p 170 Run the outboard and check for leaks Repair any oil...

Page 185: ...186 OPERATION 187 CYLINDER BLOCK CYLINDER HEAD COOLING 187 EMM AND VAPOR SEPARATOR COOLING 188 ENGINE TEMPERATURE CHECK 188 SOFTWARE METHOD 189 PYROMETER METHOD 189 IDLE OPERATING TEMPERATURE TROUBLES...

Page 186: ...off valve to starboard cylinder head 9 2 7 5 4 11 8 10 12 3 7 8 5 Port Rear Hose Routing Water Flow Diagram 200 250HP 90 V6 Evinrude E TEC 5 Outgoing water warm hot Incoming Water cool 6 004109 6 REA...

Page 187: ...HIGHER speeds Refer to WATER PUMP SERVICE on p 290 for water pump servicing Water Supply Tube The water pump outlet connects with the water supply tube located in the outboard s midsection Grommets s...

Page 188: ...event the valve from closing completely Thermostats Thermostats control water flow and operating temperature at lower speeds below 1200 RPM Overheating A restricted or faulty thermostat typ ically res...

Page 189: ...ows 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 1200 RPM Water flows through the valve and by...

Page 190: ...g ENGINE TEMPERATURE CHECK IMPORTANT The engine temperatures listed below are based on an intake water temperature of 70 10 F 21 3 C Install correct test propeller and place outboard in a test tank or...

Page 191: ...Check temperature on both sides of powerhead Typical pyrometer readings at IDLE speed should be 143 F 15 F 62 C 8 C IMPORTANT If you get low or inaccurate read ings with a digital pyrometer coat the...

Page 192: ...eliminating water flow to the cylinder heads pressure relief valve is leaking Replace pressure relief valve If IDLE temperature is still below operating range with hoses pinched off inspect thermostat...

Page 193: ...ed air to bleed from cav ity Thermal compound may seep past threads Retighten sensor THERMOSTAT SERVICING Disassembly Remove the thermostat cover and O ring from cyl inder head Remove spring thermosta...

Page 194: ...ap from the hous ing Remove the pressure valve assembly Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly Ass...

Page 195: ...SHIFT ACTUATOR 195 THROTTLE ACTUATOR 196 ICON SYSTEM FAILSAFE MODE 196 ICON COMPONENT SERVICING 197 ELECTRONIC SERVO MODULE ESM 197 SHIFT ACTUATOR 200 THROTTLE ACTUATOR 202 ICON SYSTEM SETTINGS 205 S...

Page 196: ...4 in lbs 7 to 9 5 N m F 18 to 20 ft lbs 24 5 to 27 N m F 60 to 84 in lbs 7 to 9 5 N m ICON buss cable connector ESM to EMM connector ESM to trim tilt connector ESM power supply harness ESM to throttle...

Page 197: ...Actuator The shift actuator converts electronic signals from the ESM into the mechanical motion required to shift the outboard into and out of gear If the shift actuator sensor cannot determine gear...

Page 198: ...n gear position when fault occurred If the throttle cannot move toward closed position all LED indicators flash until control levers and shift actuators are in NEUTRAL Then the NEUTRAL indicator LED f...

Page 199: ...ly harness from solenoid and ground stud Remove the ESM from studs Installation Install grommets on ESM Apply soapy water to grommets and push assembly on to studs Route the CANbus harness from the ES...

Page 200: ...e as shown Connect to harness from ESM and attach to clip on mount ing plate Make sure the oil recirculation hose is not pinched during assembly Secure ESM to throttle actuator harness with tie strap...

Page 201: ...o 84 in lbs 7 to 9 5 N m Install copper crush washer over ESM positive ring terminal Then install star washer battery cable and nut Tighten nut to a torque of 60 to 84 in lbs 7 to 9 5 N m Connect ESM...

Page 202: ...et cover IMPORTANT Calibrate shift and throttle actua tors Refer to Calibrate Actuator Stroke on p 205 Shift Actuator Removal Disconnect the battery cables at the battery Remove electrical bracket cov...

Page 203: ...rew and shift actuator retaining screws Apply Nut Lock to the threads of the screws Install shift actuator on mounting plate with three long screws and one short screw Tighten screws to a torque of 60...

Page 204: ...on procedure has been completed Refer to Calibrate Actuator Stroke on p 205 Throttle Actuator Removal Disconnect the battery cables at the battery Remove the flywheel cover Remove the electrical brack...

Page 205: ...ift actuator retaining screws Apply Nut Lock on the threads of the screws Install throttle actuator on mounting plate with three long screws and one short screw Tighten screws to a torque of 60 to 84...

Page 206: ...torque of 60 to 84 in lbs 7 to 9 5 N m Route the throttle actuator harness behind and over the oil recirculation hose as shown Connect the throttle actuator harness Attach to clip on mounting plate Ma...

Page 207: ...EST Calibra tion tab of the Evinrude Diagnostics Settings screen In a multi engine application all outboards can be calibrated through one connection by changing the engine instance setting on the sc...

Page 208: ...orward button under Shift Calibration on the EST Calibration screen The actuator arm will move forward Use the Nudge buttons to move the actuator arm forward or backward until the shift link aligns wi...

Page 209: ...tor will move to the neutral position After forward and reverse strokes have been cali brated the ESM calculates neutral position Install the shift link and secure with retainer clips and washers Lock...

Page 210: ...r motor of outboard does not operate Remote control is ON Indicator LEDs are flashing Trim tilt system does not operate Outboard is not connected to ICON system ESM 30 Amp fuse has failed Check buss c...

Page 211: ...module is OFF Gateway power harness is not connected or faulty NMEA 2000 buss cable from gateway module to NMEA 2000 network is not con nected or faulty Buss cable from ICON hub to gateway module is...

Page 212: ...or is faulty ESM is faulty Check spark plug condition Gap and install new spark plugs Check harness from ESM to throttle actuator for damage Swap a known good throttle actuator Swap a known good ESM 1...

Page 213: ...ift actuator is not cali brated Shift linkage is dam aged Shift actuator is faulty Retry shifting Turn master power key switch OFF and then back to RUN position to reset system Check shift actuator ha...

Page 214: ...wer key switch OFF and then back to RUN position to reset sys tem Check harness from trim and tilt switch panel to remote control for damage Swap a known good trim and tilt switch panel 111 ESM Commun...

Page 215: ...PISTON RINGS 227 BEARINGS 228 POWERHEAD ASSEMBLY 228 CRANKSHAFT ASSEMBLY 228 PISTONS AND CONNECTING RODS 231 CYLINDER HEAD INSTALLATION 232 CRANKSHAFT AND CONNECTING RODS 233 CRANKCASE ASSEMBLY 236 S...

Page 216: ...In lbs 7 9 5 N m L 30 42 In lbs 3 5 5 N m L H H 84 108 In lbs 9 5 12 N m P X Q B X 120 144 In lbs 13 5 16 5 N m 120 144 In lbs 13 5 16 5 N m 144 168 In lbs 16 5 19 N m E 60 84 In lbs 7 9 5 N m F 7 10...

Page 217: ...3 5 N m 96 120 In lbs 11 13 5 N m F A A B F B D 96 120 In lbs 11 13 5 N m F B B X A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle B...

Page 218: ...attachment into spark plug hole 14 mm threads While cranking outboard with starter note maxi mum pressure reading on gauge Repeat proce dure for each cylinder If engine shows a variation greater than...

Page 219: ...us fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 143 To prevent accidental starting while ser vicing twist and...

Page 220: ...reads Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist Remove all powerhead retaining screws and nuts Remove the rear powerhead nut Use a suitable tool to carefu...

Page 221: ...RTANT 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 li...

Page 222: ...ch or any other tool that could jam in or damage the taper bore when removing the pin Remove crankcase flange screws Remove the upper crankcase head screws Remove the lower crankcase head screws IMPOR...

Page 223: ...crankshaft seal rings Cylinder Head Removal Loosen in stages and remove cylinder head retaining screws Remove the cylinder head Connecting Rods and Pistons Use a permanent marker to identify each con...

Page 224: ...rnal components so that if reused they can be reinstalled in their original positions Repeat steps for each remaining piston and con necting rod Use an appropriate ring expander to remove all piston r...

Page 225: ...remove the lower crankshaft seal Remove and discard two crankcase head O rings Remove the O ring from crankshaft sleeve and inspect it Replace the O ring if it is not in good condition Inspect the cra...

Page 226: ...DO NOT reuse it Use a bearing separator to support the bearing and press off the crankshaft Remove and inspect crankcase seal rings Iden tify each ring for installation in original location Remove cen...

Page 227: ...ket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block and crankcase Carefully remove any carbon accumulation from the tops and ring grooves of the pisto...

Page 228: ...page using a piece of bar stock or machinist s straightedge and a feeler gauge set Cylinder head warpage must not exceed 0 003 in 0 08 mm per inch of measurement Replace head if warpage exceeds this d...

Page 229: ...CATIONS on p 10 The cylinder must not be oversized by more than 0 003 in 0 08 mm Pistons Visually inspect pistons for signs of abnormal wear scuffing cracks or burning Piston Rings For new ring sets p...

Page 230: ...tly clean and lightly coated with outboard lubricant IMPORTANT Use new wrist pin retaining rings gaskets seals and O rings during assembly Crankshaft Assembly Place bearing retainer plate flat side do...

Page 231: ...be used if surface is damaged Use retaining ring pliers to install bearing retaining ring with sharp edge facing away from bearing Lubricate a new driveshaft O ring and lightly lubri cate crankshaft...

Page 232: ...N 383175 to align retainer plate with crankcase head Slide crankcase head onto crankshaft until seated around lower main bearing Install new seals on the four bearing retainer screws Apply Nut Lock to...

Page 233: ...piston will be located toward the flywheel and opposite the exhaust port It is also very important that the connecting rods are installed with the align ment dots and the diagonal oil hole facing up t...

Page 234: ...uld be misaligned Refer to CYLIN DER BLOCK CLEANING on p 225 Coat pistons rings cylinder walls and ring com pressor with outboard lubricant Center connecting rod in piston and locate piston rings on d...

Page 235: ...re seated in the block Push all pistons to the top of cylinders Remove the numbered connecting rod caps and hold the connecting rods to the outside with rubber bands Gently lower crankshaft into place...

Page 236: ...screws without Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent damage to the connecting rod and crankshaft To maintain accurate torque values keep torque wrench exte...

Page 237: ...3 in lbs 2 5 N m IMPORTANT Make sure that frame is squarely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Torquing Socket P N 346187 to tighten rod cap s...

Page 238: ...l Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the tube cannot be determined Using old Gel Seal II could cause crankca...

Page 239: ...w threads and tighten to a torque of 7 to 10 in lbs 0 8 to 1 1 N m If removed install cam on shift arm Apply Ultra Lock to screw threads and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Lubrica...

Page 240: ...Refer to PRES SURE RELIEF VALVE SERVICING on p 192 Install shift linkage Refer to Shift Linkage Instal lation on p 237 Install throttle linkage Refer to Throttle Linkage Installation on p 238 Install...

Page 241: ...n crankshaft and driveshaft splines Apply Gasket Sealing Compound to the threads of all powerhead screws Loosely install all fasteners before tightening Tighten the 3 8 in diameter powerhead screws to...

Page 242: ...ns freely in neutral Install water hoses and exhaust back pressure hose Route power trim harness through clamp and con nect to engine harness 1 Rear powerhead nut 004252 1 Shift rod pin 004241 1 1 Por...

Page 243: ...exing on p 40 Use Evinrude Diagnostics software to start pow erhead break in oiling Refer to Powerhead Break In on p 67 Use Evinrude Diagnostics software to set TPS calibration Refer to TPS CALIBRATIO...

Page 244: ...242 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings 3 3 L models 007153...

Page 245: ...POWERHEAD POWERHEAD VIEWS 243 11 Starboard Hose Routings 3 3 L models 007154...

Page 246: ...244 POWERHEAD POWERHEAD VIEWS Port Hose Routings 3 4 L models 008503...

Page 247: ...POWERHEAD POWERHEAD VIEWS 245 11 Starboard Hose Routings 3 4 L models 008502...

Page 248: ...246 POWERHEAD POWERHEAD VIEWS Port 3 3 L models 008448...

Page 249: ...POWERHEAD POWERHEAD VIEWS 247 11 Starboard 3 3 L models 008449...

Page 250: ...248 POWERHEAD POWERHEAD VIEWS Port 3 4 L models 008441...

Page 251: ...POWERHEAD POWERHEAD VIEWS 249 11 Starboard 3 4 L models 008442...

Page 252: ...250 POWERHEAD POWERHEAD VIEWS Front 3 3 L models 008450...

Page 253: ...POWERHEAD POWERHEAD VIEWS 251 11 Front 3 4 L models 008439...

Page 254: ...252 POWERHEAD POWERHEAD VIEWS Rear 3 3 L models 007142...

Page 255: ...POWERHEAD POWERHEAD VIEWS 253 11 Rear 3 4 L models 008440...

Page 256: ...254 POWERHEAD POWERHEAD VIEWS Top 008438...

Page 257: ...POWERHEAD POWERHEAD VIEWS 255 11 Starboard ICON models 008504...

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

Page 259: ...SING SERVICE 264 EXHAUST HOUSING REMOVAL 264 LOWER MOUNT SERVICE 264 EXHAUST HOUSING INSTALLATION 265 EXHAUST HOUSING DISASSEMBLY 3 3 L MODELS 266 EXHAUST HOUSING DISASSEMBLY 3 4 L MODELS 267 CLEANING...

Page 260: ...N m 216 240 In lbs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m...

Page 261: ...7 9 5 N m 60 84 In lbs 7 9 5 N m B F F F 144 168 In lbs 16 19 N m B B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P B C See Assembly Instructions B C C C See Assembly Instructions A C C 60 84...

Page 262: ...19 N m 20 22 Ft lbs 27 30 N m 60 84 In lbs 7 9 5 N m B F F 144 168 In lbs 16 5 19 N m B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P C A C C B L 60 84 In lbs 7 9 5 N m Q E A Triple Guard Grea...

Page 263: ...MIDSECTION SERVICE CHART 261 12 Muffler 007117...

Page 264: ...r 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 ca...

Page 265: ...e a wood or leather mallet to tap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft lbs...

Page 266: ...werhead Refer to POWER HEAD REMOVAL on p 217 Remove and discard four lower mount screws Remove the steering arm ground lead and screw Remove two upper mount screws Remove the exhaust housing Lower Mou...

Page 267: ...washers and screws and tighten to a torque of 156 to 180 in lbs 18 to 20 N m Exhaust Housing Installation Bring the exhaust housing into position with the stern bracket Install four new lower mount s...

Page 268: ...ALLATION on p 287 Install powerhead Refer to POWERHEAD INSTALLATION on p 239 Exhaust Housing Disassembly 3 3 L models Remove two front adapter to outer exhaust hous ing screws Remove three nuts at rea...

Page 269: ...tube and grommet from the inner exhaust housing Discard the grommet Loosen retaining screws and remove the cover from water plate Loosen retaining screws and remove water plate from the adapter Exhaus...

Page 270: ...e if deteriorated or damaged Before checking the exhaust housing for distor tion thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion Check the exhaust housing for d...

Page 271: ...Apply Gasket Sealing Compound to threads of cover retaining screws Install with washers and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Coat the outside diameter of a new water tube grommet w...

Page 272: ...screws nuts and washers Lubricate the upper mount with soapy water and push into place in the adapter housing The mount radius must face aft with the TOP mark facing up Apply Locquic Primer and Nut Lo...

Page 273: ...seal Apply Triple Guard grease to outer seal surface Install grommet and water tube in the inner exhaust housing Clean and degrease the adapter housing and outer exhaust housing mating surfaces with...

Page 274: ...t plate screws and install the plate and screws loosely Install the ground lead and star washer under the forward starboard screw Align the outer exhaust housing and adapter by placing two powerhead m...

Page 275: ...wer trim tilt unit must be removed Refer to TRIM AND TILT SERVICE on p 347 Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaft and thrust wash...

Page 276: ...he braided tube Remove the tilt limit switch and retainer from the swivel bracket Disconnect the trail lock spring and remove it from the swivel bracket Remove trail arm retainer Remove the trail lock...

Page 277: ...e proceeding make sure all components have been thoroughly cleaned Replace any seals that have been removed Inspect all thrust washers and bushings for evi dence of deterioration Install the detent ro...

Page 278: ...he tilt limit switch and retainer on the swivel bracket Tighten screws to a torque of 40 to 50 in lbs 4 5 to 5 5 N m Route the trim sender wires through the braided tube and install the sender unit in...

Page 279: ...ly Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket Align...

Page 280: ...mbly connects to the exhaust relief hoses from the adaptor housing assembly The overboard indicator and flush port in the exhaust relief grommet connect to the adaptor housing assembly with a hose Thi...

Page 281: ...GEAR AND PROPELLER SHAFT INSTALLATION 310 PINION GEAR AND DRIVESHAFTINSTALLATION 311 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION L2 TYPE 313 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALL...

Page 282: ...bs 6 8 9 5 N m B A 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m A A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m A 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 27 N m A G A B B 108...

Page 283: ...40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m A 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 108 132 In lbs 12 15 N m A A E 18 20 Ft lbs 24 27 N m A G J 30 34 Ft lbs 41 46 N m...

Page 284: ...bs 61 68 N m A A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 60 84 in lbs 6 8 9 5 N m A 30 34 Ft lbs 41 46 N m C 70 80 Ft lbs...

Page 285: ...n propeller bearing housing performance gearset V6 14 26 538 90 V6 20 in 90 V6 25 in 90 V6 30 in M2 front water inlets and straight leading edge pressed in propeller shaft bearing housing with retaini...

Page 286: ...ad condi tions will allow the engine to run near the mid point of the RPM operating range at full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blades have too much pitch the engin...

Page 287: ...Propeller Hardware Installation IMPORTANT Depending on propeller style dif ferent thrust bushings spacers and cotter pin keepers are used See the Evinrude Johnson Genuine Parts and Accessories Catalo...

Page 288: ...ne source of leak If the gauge does not indicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leaks Make necessary repairs and repeat test Install Gearcase Vacuum Tester P N 5079...

Page 289: ...move 7 16 14 x 3 5 in screw and washer Remove the four 3 8 16 x 1 75 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being careful not to bend the shift...

Page 290: ...ase Some outboard models include hollow alignment pins between the exhaust housing and gearcase If outboard is not equipped with alignment pins use Gearcase Alignment Kit P N 5007231 to accurately ali...

Page 291: ...ith the index marks noted prior to disassembly Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m For adjustment refer to Trim Tab Adjustment on p 30 Standard rotation and counter...

Page 292: ...lting Make sure gasket surface is clean and smooth Assembly Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs IMPORTANT Do not allow any sealer to get into the air bleed gr...

Page 293: ...ater tube from exhaust housing and replace o rings Apply a light coat of Triple Guard grease to the o rings and install water tube in exhaust housing Apply Triple Guard grease to screw threads and ins...

Page 294: ...h the impeller key Rotate the driveshaft to engage the key with the impeller and slide water pump down over key Be sure impeller key does not fall out of position Make sure the impeller engages the im...

Page 295: ...NT on p 293 SHIFT ROD ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge P N 389997 With the gearcase in NEUTRAL rotate...

Page 296: ...for twisted splines and damaged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase dam...

Page 297: ...eller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using Propeller Shaft Bearing Housing Puller Kit P N 354060 DO NOT use tools designed to push on the pro peller...

Page 298: ...the clutch dog as far forward as possible This will help ease removal of the pinion nut Use Driveshaft Holding Socket P N 311875 Pin ion Nut Holder P N 334455 and Wrench Retainer P N 341438 to loosen...

Page 299: ...7 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...

Page 300: ...holes in the driveshaft retainer and the lower driveshaft Install the roll pin to the specified dimension Shift Housing Gear and Propeller Shaft Removal Push down on the shift rod This will move the d...

Page 301: ...using 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 gea...

Page 302: ...ead If shaft does not slide into hole gearcase housing is damaged and must be replaced SHIFTER BEARING AND SEAL SERVICING Pinion Bearing Removal Remove pinion bearing retaining screw Assemble Pinion B...

Page 303: ...ing up Insert the tool with the bearing 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...

Page 304: ...with a shop cloth to catch ball and spring Rotate the shifter detent 90 in either direction then pull the detent out of the housing Remove the detent ball and spring Remove needle bearings from beari...

Page 305: ...wn while depressing the ball and spring with a suitable tool Once the shifter detent is past the ball remove the tool and position detent to engage NEUTRAL position Thoroughly grease 25 needle bearing...

Page 306: ...d in the correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing rear of the shaft The clutch dog is not symmetrical If i...

Page 307: ...e and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage Do not inst...

Page 308: ...32127 and Large Puller Jaws P N 432129 Rest the puller plate on top of the housing to sup port the bridge and tighten the jaws securely behind the bearing Inspect the bearing housing anode Replace ano...

Page 309: ...seats When installed the lettered end of the bearing should be visible STANDARD ROTATION HOUSING Bearing Installation Tool P N 354139 front and rear bearings COUNTER ROTATION HOUSING Bearing Installa...

Page 310: ...shim the assembly to restore factory clearance Use Driveshaft Shimming Tool P N 5005925 Shim gauge bars are precision made and should be handled carefully The length of each bar is stamped near the p...

Page 311: ...g housing and repeat check if variance is greater than 0 004 in 0 101 mm Check squareness of the pinion to the driveshaft Hold the shim gauge bar against the bearing housing between the screw holes wh...

Page 312: ...e while aligning shift housing pin with hole in forward end of gearcase housing Shift Rod Housing Installation Lubricate a new shift rod cover O ring with Triple Guard grease Install the O ring into t...

Page 313: ...proper alignment of the bearing housing locator pin into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 t...

Page 314: ...ace the pinion gear into the gearcase Insert the driveshaft into the gearcase and through the pin ion gear Lightly coat the threads of a new pinion nut with outboard lubricant Use Pinion Nut Starting...

Page 315: ...t engages the pinion gear Lightly apply Triple Guard Grease to a new bear ing housing O ring Install O ring in groove in the housing Grease the machined side surfaces of bearing housing Install housin...

Page 316: ...0 ft lbs 24 to 27 N m Propeller Shaft Bearing Housing and Gear Installation M2 Type IMPORTANT The propeller shaft bearing hous ing on the M2 type gearcases is PRESSED into the gearcase housing Oil and...

Page 317: ...Gearcase Fixture P N 354059 and an appropriate floor press 10 ton or greater to install housing into gearcase Align and level gearcase assembly in fixture as shown Secure fixture to floor press Housi...

Page 318: ...complete gearcase assembly refer to GEARCASE LEAK TEST on p 286 WATER PUMP SERVICE on p 290 SHIFT ROD ADJUSTMENT on p 293 GEARCASE REMOVAL AND INSTALLATION on p 287 Gearcase Lubricant on p 37 Propelle...

Page 319: ...ng on M2 type gearcases is PRESSED into gearcase housing Remove the two retaining screws holding the pro peller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using...

Page 320: ...s pulled out Unscrew the shift rod from the detent lever Remove screws cover and shift rod from the gearcase Discard the cover gasket Remove the shift rod O ring from inside of cover and discard Use a...

Page 321: ...h the pin out of the clutch dog Remove all parts Remove the gear thrust bearing and thrust washer from the shift housing IMPORTANT The shift housing supports the reverse gear on counter rotation gearc...

Page 322: ...coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent into the housing as shown while depressing the ball and spring with a s...

Page 323: ...grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the gear bearing and washer into the bearing housing Bearing and washer must be installed in the c...

Page 324: ...p 301 Propeller Shaft Bearing Housing and Forward Gear Disassembly Remove and discard the bearing housing O ring Remove the anode and discard if more than two thirds deteriorated Clamp the propeller...

Page 325: ...sure distance from flange of housing to flat surface as shown Add the appropriate shims to create a dimension of 0 140 in 3 556 mm To determine thickness of shims use the following example 1 389 in re...

Page 326: ...threads of the for ward gear bearing housing Install forward gear assembly with correct shims in bearing housing IMPORTANT To prevent damage to threads install forward gear bearing housing assembly by...

Page 327: ...the drive shaft Use Driveshaft Seal Protector P N 318674 when installing or removing the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of...

Page 328: ...embly Mea sure clearance between the gauge bar and the pinion at several locations If variance is greater than 0 002 in 0 050 mm replace the pinion or driveshaft as necessary and repeat check Subtract...

Page 329: ...bly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing Shift Rod Cover Refer to Shift Rod Housing Installation on p 310 Pinion Gear and Driveshaft In...

Page 330: ...install retainer screws Bearing housing is approximately level with gearcase Apply Ultra Lock to threads and install two retain ing screws Tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N m F...

Page 331: ...OOTING 338 SYMPTOMS CHART 339 SERVICE PROCEDURES 339 PRESSURE LEAKDOWN TEST 339 ELECTRICAL CIRCUIT TESTS 342 RELAY TESTING 342 TRIM AND TILT MOTOR CURRENT DRAW TESTS 342 TRIM AND TILT MOTOR NO LOAD TE...

Page 332: ...E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease 60 70 Ft lbs 81 95 N m DO NOT OVER TIGHTEN 84 108 In lbs 9 5 12 N m 58 87 Ft lbs 79 118 N m 35 52 In lbs 4 0 5 9 N m 60 84 In lbs 7 9 5 N m 45...

Page 333: ...t down to the top of the trim range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be manually raised or lowered through the ent...

Page 334: ...o the pump through the open DOWN check valve In the trim range fluid is pushed from the top of the trim cylinders by the pistons and returns to the reservoir Only fluid from the top of the tilt cylind...

Page 335: ...linders Fluid from the bottom of the cylinders returns through the open UP check valve to the pump In the tilt range all of the fluid from the bottom of the tilt cylinder returns through the UP check...

Page 336: ...er extends The fluid above the piston is com pressed producing high pressure This high pressure fluid passes through the impact relief valves in the tilt piston dissipating much of the energy of the i...

Page 337: ...filter valve opens and allows fluid to flow from the reservoir to the top of the tilt cylinder The outboard will tilt down to the top of the trim range Thermal Expansion Relief Ambient air temperature...

Page 338: ...ers Trimming Outboard OUT Pull gearcase out farther than the desired final position up into the tilt range if necessary Close the manual release valve Manually push the gearcase in or down until it is...

Page 339: ...ve Fluid flows from the bottom of the tilt cylinder in the tilt range to the top of the tilt cylinder The excess fluid equal to the volume of the piston rod is vented to the reservoir In the trim rang...

Page 340: ...determined the Symp toms Chart on p 339 should help locate the problem Keep a manual release valve and a valve body in stock for troubleshooting Use these parts when the Service Procedures on p 339 ca...

Page 341: ...ani fold assembly was faulty Remove temporary assembly and replace it with correct one STEP 6 Install replacement pump manifold assembly and retest If all symptoms are not corrected recon sider the pr...

Page 342: ...servoir cap one full turn Loosen the manual release valve three turns Some fluid will bypass the reservoir cap These steps will relieve the pressure in the unit Remove the manual release valve retaini...

Page 343: ...n and up several times to purge air With all rods fully extended run the unit down momentarily to reduce pressure Check fluid level again and add fluid if necessary Remember that all rods must be comp...

Page 344: ...ectric motor and certain mechanical components Use a battery rated at 360 CCA 50 Ah or higher that is in good condition and fully charged to per form this test IMPORTANT Specifications are for static...

Page 345: ...nnect a 0 to 50 A ammeter in series with the battery positive terminal ammeter red lead toward battery Attach or hold a vibration or mechanical tachome ter to the motor while performing this test Moni...

Page 346: ...rim UP position If results are different replace the trim gauge If results agree refer to Trim Sender Test Trim Sender Test IMPORTANT To avoid immediate meter dam age never apply a multimeter to an el...

Page 347: ...om the connector by using a suitable tool to depress the tab While the tab is depressed pull on the wire from the rear of the connector to release it from the connector Separate the trim tilt unit wir...

Page 348: ...allation Place trim tilt unit into position Apply Triple Guard grease to the lower pin and install the pin Install external snap rings on lower pin with sharp edge of ring facing out Loosen the manual...

Page 349: ...shop cloth when handling power trim tilt components If painting the unit is required paint it after it is completely assembled Painting of individual com ponents may cause flakes of paint to enter the...

Page 350: ...re damaged replace the manual release valve Remove reservoir cap and drain the fluid into a container Inspect the O ring in the cap Remove the three Pozidriv screws securing the reservoir to cylinder...

Page 351: ...achined surfaces on the manifold for nicks and scratches The pump manifold is not serviceable Do not remove the pump or any control valves from the manifold Clean the screen with a mild solvent and in...

Page 352: ...ew the tilt rod end cap Drain the fluid from above the piston Slowly pull the piston out with a rag wrapped around the rod and the top of the cylinder Drain the remaining fluid from the cylinder Inspe...

Page 353: ...ngers are identical Lubricate and install a new outer O ring on the tilt piston Place one ball one plunger and one spring in each hole in the piston as indicated The two five coil springs go in the la...

Page 354: ...end cap Use a wire brush to clean all thread locking mate rial from the threads on the tilt rod Lubricate the inside surface of the end cap Lubri cate and install Tilt Cylinder Seal Protector P N 326...

Page 355: ...rim Tilt Steering Fluid on top of the tilt piston Fluid should not leak past the impact relief balls while seated If fluid does leak disassemble the piston assembly and inspect the relief ball seats S...

Page 356: ...the rod tightly in a vise Remove the thrust pad from the trim rod then remove the end cap Remove the rod from the vise Use a small screw driver to carefully pry the scraper out of the end cap Discard...

Page 357: ...the rod and install thrust pad Tighten thrust pad to a torque of 84 to 108 in lbs 9 5 to 12 N m Manifold and Reservoir Installation Lubricate five new manifold body O rings Place them in the cylinder...

Page 358: ...ith three Pozidriv screws Tighten the screws to a torque of 35 to 52 in lbs 4 0 to 5 9 N m Trim Rod Installation Lubricate the trim rod pistons Place the rod assemblies into the body Push them in unti...

Page 359: ...id Failure to fill the cylinder could cause difficulty purging air from the unit Screw tilt cylinder end cap into cylinder body Use Tilt Cylinder End Cap Remover Installer P N 326485 or Universal Span...

Page 360: ...reservoir to the bottom of the fill hole with Power Trim Tilt Steering Fluid Install and tighten the reservoir cap Turn the manual release valve in until it seats Cycle the unit up and down several ti...

Page 361: ...ICE 14 Check the tilt rod bushings Replace them if they are worn excessively Check the bushings on the bottom of the manifold body Replace them if they are worn excessively Check system operation in b...

Page 362: ...360 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 363: ...6 OUTBOARD FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY S 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFET...

Page 364: ...S 2...

Page 365: ...elf but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommen...

Page 366: ...ORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of...

Page 367: ...o STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How can loss of speed control be mi...

Page 368: ...eel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams opera...

Page 369: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK earlier If moved up or down even...

Page 370: ...kage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is stored base ment or cottage could be i...

Page 371: ...tion as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked...

Page 372: ...er engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is trapped in tank a...

Page 373: ...s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Page 374: ...d may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken Check for a high speed...

Page 375: ...suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test...

Page 376: ...and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key s...

Page 377: ...un into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemb...

Page 378: ...Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Repla...

Page 379: ...t hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly P N 396748 use only the spec...

Page 380: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils ca...

Page 381: ...ust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In high con...

Page 382: ...Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in...

Page 383: ...er leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Ba...

Page 384: ...tches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters...

Page 385: ...re to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little childre...

Page 386: ...ual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to c...

Page 387: ...25 Requirements 11 13 Storage 45 Bearing Connecting Rod 233 Crankshaft 228 229 Pinion Gear 300 301 Break In EMM Programming 169 241 Gearcase 289 316 328 Oiling 169 Procedure 67 C Cable Hose and Wire R...

Page 388: ...73 Oiling Rate 67 170 Reports 69 Sensor Monitoring 94 Static Ignition Test 82 Timing Verification 68 113 TPS Calibration 68 113 Driveshaft Installation 311 Removal 296 318 Service 298 Shimming 308 Spe...

Page 389: ...35 Filter 135 144 Fuel Circulation Pump 136 Fuel Filter 41 144 Fuel Lift Pump 135 142 145 Fuel Manifolds 146 Fuel Requirements 134 Hose Routing 131 Injector Servicing 147 Intake Manifold 151 Minimum O...

Page 390: ...section Stern Bracket Servicing 273 Tilt Tube Servicing 262 Models Included Models 9 Model Designation 8 Serial Number Location 8 Motor Mounts Lower Mount Servicing 264 265 271 Upper Mount Servicing 2...

Page 391: ...ller Shaft Bearing Housing Bearing Installation 307 Bearing Removal 306 Installation 313 Rear Seal Installation 308 Rear Seal Removal 306 Propeller Shaft Bearing Housing Counter Rotation Assembly 323...

Page 392: ...System Lubrication 36 Steering Arm and Shaft 273 276 Steering Torque 30 Stern Bracket Assembly 275 Disassembly 273 Stop Circuit 104 Storage 44 Submerged Engines 46 Switches Key Switch 103 Swivel Brack...

Page 393: ...Pressure Tester P N 507977 286 Gearcase Vacuum Tester P N 507982 286 Guide Rods P N 383175 230 Hydraulic Cylinder Rod Holder P N 983213 354 355 Injector Test Fitting Kit P N 5005844 140 Installer Hand...

Page 394: ...it Tests 105 Inspection 338 Installation 346 Lubrication 39 Manifold and Reservoir Installation 355 Manual Release 336 Pressure Leakdown Test 339 Removal 345 Reservoir Fluid 338 Troubleshooting 338 Tr...

Page 395: ...on 33 Installation 310 327 Removal 299 318 Water Pressure Gauge 24 Water Pump Assembly 290 Description 185 Disassembly 290 Inspection 290 Water Supply Tube 185 Winterizing 44 Wiring Harness Connection...

Page 396: ...I 10 INDEX NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 397: ...A Check wiring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendi...

Page 398: ...g Check voltage at injectors Excessive fuel or oil engine flooded Check for leaking injectors leaking fuel or oil lift pump or leaking vapor separator vent refer to SYSTEM ANALYSIS Low or no 55 V alte...

Page 399: ...anti siphon valve and fuel pick up check for fuel system air leaks Low or no alternator output 55 V Check voltage on 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V...

Page 400: ...t 55 V Check voltage on 55 V circuits refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND...

Page 401: ...on Check ignition refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS Restricted or leaking fu...

Page 402: ...air leaks Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring Check CPS air gap Low al...

Page 403: ...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 404: ...51 I Command Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 5 w...

Page 405: ...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 406: ......

Page 407: ...ND 12V PUL REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASH...

Page 408: ...tion Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will...

Page 409: ...jector 6 27 Ignition Coil 6 28 Low Oil Switch 29 Trim Sending Unit 30 Tilt Limit Switch 31 Trim Tilt Motor 008332 FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 1 3 5 2 4 6 27 10 20 21 22 23 24...

Page 410: ......

Page 411: ...el Injector 6 28 Ignition Coil 6 29 Low Oil Switch 30 Trim Sending Unit 31 Tilt Limit Switch 32 Trim Tilt Motor 008331 FUSE 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 1 3 5 2 4 6 28 10 20 21 22 2...

Page 412: ......

Page 413: ...attery voltage 15 5 V Check battery connections and wiring 28 Shift switch malfunction LED 3 ON Running 10 seconds Check shift switch linkage and switch activation Check continuity of switch normally...

Page 414: ...ated wiring Check for pinched or chafed wiring 79 Starter solenoid circuit OPEN LED 3 OFF Key On CHECK ENGINE 10 seconds Check starter solenoid circuit for continuity key switch OFF and for 12 V with...

Page 415: ......

Page 416: ......

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