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Evinrude E-Tec 40 HP, Service Manual

The Evinrude E-Tec 40 HP outboard motor is reliable and efficient, perfect for a variety of water activities. Make sure to keep your motor running smoothly by downloading the free Service Manual from manualshive.com. This manual provides detailed instructions to help maintain and troubleshoot your outboard motor.

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184

COOLING SYSTEM

PRESSURE RELIEF VALVE SERVICING

Inspection

Inspect all parts for cracks, heat damage, or signs

of  corrosion. Re place dama ged p arts.  Clean

debris from housing and parts.

Assembly

Assembly  is the rever se of disassemb ly. Pa y

close attent ion when pe rforming 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  a torque of 60  to 84 in.

lbs. (7 to 9.5 N·m).

Pressure Relief Valve Assembly Components

002442

1.

Plunger seal

2.

Cover o-ring

002458

 

1

2

Summary of Contents for E-Tec 40 HP

Page 1: ......

Page 2: ......

Page 3: ...y GM is a registered trademark of The General Motors Corporation Locquic and Loctite are registered trademarks of The Henkel Group Lubriplate is a registered trademark of Fiske Brothers Refining Compa...

Page 4: ...185 11 MIDSECTION 233 12 GEARCASE 289 GEARCASE SERVICE 40 65 HP MODELS 296 GEARCASE SERVICE 75 90 HP MODELS 318 13 TRIM AND TILT 343 14 MANUAL STARTER 361 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1...

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: ...p atch screws be requ ired a lways replace with a new one When repla cement p arts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and...

Page 7: ...rd may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disc...

Page 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: ...scrib ed changes such as altitude ad justments for exam ple Owner s Responsibility The owner operator is required to have outboa rd maintenance performed to maintain emission lev els within prescribed...

Page 10: ...T 3 R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex IN 2012 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: ...Power Tilt Remote Steering Electric Start E50DSLINM 86 L 52 7 ci 12 32 0 375 F 20 White Power Tilt Remote Steering Electric Start E60DTLINM 86 L 52 7 ci 12 32 0 375 F 20 Blue Power Tilt Tiller Steeri...

Page 12: ...Bore 3 601 in 91 47 mm Stroke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1...

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

Page 14: ...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...

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

Page 16: ...ith nauti cal orientation This manual of ten identifies p arts 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...

Page 17: ...ENDING UNIT ADJUSTMENT 75 90 HP 30 TRIM TAB ADJUSTMENT 31 DUAL OUTBOARD ALIGNMENT 32 OPERATIONAL CHECKS 33 COOLING SYSTEM 34 ENGINE FLUSHING 35 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 3...

Page 18: ...components Water intake screens check condition Cooling system check water pump indicator water pressure Anticorrosion anodes check condition Gearcase check condition Propeller check condition Fuel a...

Page 19: ...ith the service manual set Common Practices All Models Control Cable Identification IMPORTANT Identify con trol ca ble fun ction before rigging outboard Identify each control cable Put the co ntrol ha...

Page 20: ...d section behind the straight section Cable Hose and Wire Routing Refer to Control Cable Identification on p 17 Apply soapy water to the inside surfaces of grom met and install cables and fuel line as...

Page 21: ...t o remove slack With outboard in NEUTRAL place the cable trun nion into the lower anchor pocket Adjust the trun nion nut so the casing fits onto the shift lever pin If there are not enough threads on...

Page 22: ...m SystemCheck Harness Connections Place th e wirin g harne ss through notch in lower motor cover a nd ro ute t o the recess in th e fly wheel cover Secure the cable with a tie strap as shown Before in...

Page 23: ...l tie straps as shown To prevent wire chafing harness must be routed below the flywheel cover Connect the I Command Engine Interface Cable to the EMM CANbus connector 2 CYLINDER MODELS To prevent inte...

Page 24: ...heck co nnector with 6 Pin Connector Seal P N 586076 If conne cting to an existing I Command Classic network connect the purple wires bet ween the I Command Ig nition and Trim Harn ess an d the I Comm...

Page 25: ...s Water Pressure Gauge To display engine water pre ssure install a water pressure hose fitting in th e cylind er block as shown Use Pipe Sealant with Teflon on the threads of the hose fitting Refer to...

Page 26: ...to the batte ry 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 27: ...the outside diameter of the hose when installed on the fitting Chose a clamp so that the outside diameter of the hose is approximately in the middle of the clamp ing range of the clamp A WARNING DO N...

Page 28: ...stepless clamps Oetiker p incers a re 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 29: ...s are equ ipped with a thro ttle friction adjustment knob lo cated on the st eering handle Tighten the knob to reduce the effort required to hold a throttle setting Turn the knob clockwise to increase...

Page 30: ...Check the adjustment by tilting the outboard fully Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it co n tacts the motor well To pre vent da mage to equi...

Page 31: ...Loosen cam scre w a nd rot ate eccen tric cam to adjust full down gauge position If the needle was above the lowest mark move the thick part of the cam T OWARD the contact point Tighten the screw and...

Page 32: ...the engine is trimmed to the full down position the bow of the boat goes deeper into the water If the trim limiter rod is left out the bow could plow into the wa ter cau sing the boa t to bow steer r...

Page 33: ...d to the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw as follows 40 90 HP 35 to 40 ft...

Page 34: ...ments Each app lica tion must be thoroughly tested until the idea l combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small a mo...

Page 35: ...rt In Gear Prevention Start outboard and shift to FORWARD Turn outboard OFF while control is in FORWARD Try to restart the o utboard Outboard should not start Shift back to NEUTRAL and restart outboar...

Page 36: ...d Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use COOLING SYST...

Page 37: ...ard in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Turn water supply on Run outboard at IDLE only until full operating tem perature is reached Leave the outb...

Page 38: ...ents 1 GPM Gallons per minute 2 LPM Liters per minute Install flushing adapter onto gearcase water inlet screens A steady stre am o f water should flo w f rom t he overboard indicator while the engine...

Page 39: ...it wit h gre ase Make sure wip er nu t is installed and not damaged Tiller Handle Lubricate the tiller ha ndle grease fitting s with Tri ple Guard grease A WARNING Failure to regrease as recommended c...

Page 40: ...from throttle and shift lever pins Carefully remove casing g uides from pins IMPORTANT DO NOT disturb cab le trunnion adjustments Shift remote cont rol into FULL THROTTLE REVERSE position to fully ex...

Page 41: ...stall propeller hardware and propeller Gearcase Lubricant Draining IMPORTANT Always check the fill le vel of the gearcase lub ricant at the u pper plug befo re removing the lower drain fill plug A tie...

Page 42: ...nspect ion is re commended when lubricant is contaminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 16 for service freque ncy and recommended lubricants S...

Page 43: ...eads 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 un it at lea st five complet e cycles to purge all air from the system When cycling t...

Page 44: ...e sp ark plug opposite the fuel injector nozzle Put an ink mark on the cera mic of the spark plug in line with the OPEN sid e of the ground ele c trode This mark will be used to orient the spark plug...

Page 45: ...system leaks Make certain the oil t ank is filled a nd oil supply is not contaminated Air Silencer The air silencer maximizes air flow while minimiz ing noise Routine cleaning of the air silence r is...

Page 46: ...based antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no re sistance If resistanc...

Page 47: ...nds the System Check lights will go off Move thro ttle to IDLE position SystemCheck lights will light again Wait ano ther 15 seconds SystemCheck lights will go of f At this poin t advance thrott le t...

Page 48: ...storage make sure it is reinstalled with fa ctory specified hardware Refer to the Predelivery and Installation Guide Outboard Mounting Bolts Check and re tig hten outb oard moun ting bolts to a torque...

Page 49: ...supp ly h ose and oil ret urn hose from outboard Drain and clean a ll oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil system an...

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

Page 51: ...3 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 50 LATCH HOOK INSTALLATION 50 LOWER COVER SERVICE 50 LOWER COVER REMOVAL 50 LOWER COVER INSTALLATION 51 LATCH HANDLE INSTALLATION 52 TRIM...

Page 52: ...sition with opening toward the front Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m LOWER COVER SERVICE Lower Cover Removal Remove lower engine cover screws Loosen port side cover slightly...

Page 53: ...t side cover Connect trim tilt switch connector Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enoug h to hold the gro mmet in plac...

Page 54: ...Pl ace spring washer and ho ok into position and tig hten 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...

Page 55: ...SWITCH 58 THROTTLE POSITION SENSOR 59 CRANKSHAFT POSITION SENSOR 59 NEUTRAL SWITCH 59 INTERNAL EMM FUNCTIONS 60 ENGINE MONITOR SYSTEM 61 S A F E WARNING SYSTEM 62 SHUTDOWN MODE 62 DIAGNOSTIC SOFTWARE...

Page 56: ...ust water valve activation 60 65 HP EMM Connections IMPORTANT EMM connections an d wiring must be clean and tigh t Improper electrical con nections can damage the EMM DO NOT r un the outboard with loo...

Page 57: ...e Sensor AT 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fuel Injector 14 Tachometer SystemCheck Gauge 15 I Command CANbus Display 16 D...

Page 58: ...or read s less than 71 F 57 4 C or greater than 313 F 156 C a senso r circuit fault is detected and the EMM 55 V Circuit Sensor Monitors the EMM s 55 V alternator circuit If system voltage exceeds 57...

Page 59: ...or sensor cir cuits It monitors all sen sor volt age inpu ts and compares them to prede termined accept able ranges Inputs that fa ll outside of the acceptable range create service codes Air Temperatu...

Page 60: ...e quarter t he EMM b egins counting oil pump pulse cycles When it reaches 40 65 HP 4800 pulses 75 90 HP 6000 pulses the EMM To recover from S A F E mode the oil pump must cycle for a minimum of th ree...

Page 61: ...a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 occurrences the EMM Approximate air g ap b etween CPS a nd flywhee l encoder ribs i...

Page 62: ...resumes when engine RPM returns to the specified range Neutral RPM Limiter This featu re prevents engine damage due to excessive RPM if accelerated in NEUTRAL Neu tral engine speed is limited to 1800...

Page 63: ...EMM Service Code Chart at the back of th is manual for a co mplete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position The horn se lf tests by...

Page 64: ...est on p 137 Check for external fuel leakage that could allow fuel and o r vapo r to enter th e engine throug h the air intake Check for internal fuel leakage from a le aking injector or vapor separat...

Page 65: ...ple of the EMM J1 B connec tor The EMM is also turn ed ON when it begins to receive AC volt age from the stator while the out board is being cranked ROPE START MODELS Diagnostic co mmunications on non...

Page 66: ...infor mation The outboard model and serial numbers displayed on the Identity screen must ma tch the identifica tion label on the outboard swivel bracket The serial number and cylinder location display...

Page 67: ...ours of the last occurrence Historical faults cannot be erased Static Tests Static Tests allow dia gnostic testing o f system components while the outboard is NOT running Ignition Test Use the diagnos...

Page 68: ...lity chang es can b e observed Refe r to DYNAMIC TESTS on p 76 Prime Oil This test is used to cycle the oil injection pump for priming the o iling syst em Per form th is test with outboard running to...

Page 69: ...h an installed tiller conversion kit MUST be set to TILLER Ignition Timing Use the Ignition Timing scre en to check an d adjust EMM timing EMM timing must be synchro nized to crankshaft position Refer...

Page 70: ...set an absolute fixed speed Af ter the offset is changed th e EMM continues to control engine operation normally Engine idle speed is not fixed Fuel Injector Servicing All E TEC fuel inje ctors use so...

Page 71: ...available to enhance the opera tion of an outboard Select Engine Software Update from the Utilities menu and refer to the instructions pro vided with the program IMPORTANT If using Diagnostic Power S...

Page 72: ...y and follow the instructions provided with the program IMPORTANT Whenever th e EMM is rep laced EMM timing must be synchronized to crankshaft position Refe r to TIMING ADJUSTMENTS on p 113 EMM SERVIC...

Page 73: ...performing the following tasks Make sure isolator mounts are placed in slots in of EMM case Slide EMM into position Apply Nut Lock t o t hreads o f EMM ret aining screws Tighten to a torque of 30 to...

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

Page 75: ...77 RUNNING 78 IGNITION OUTPUT TESTS 79 REQUIRED IGNITION SYSTEMS 79 WIRING INSPECTION 79 CRANKSHAFT POSITION SENSOR CPS TEST 80 SYSTEM VOLTAGE TEST 80 STATIC IGNITION TEST 81 RUNNING IGNITION TESTS 82...

Page 76: ...spark plugs Check the fuse an d the emergency st op switch lanyard Operational Inspections Run the ou tboard to confirm actual symp toms before perfo rming any unne cessary procedures Inspection shou...

Page 77: ...D Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 77 Use the Evinrude Diagnostics software Monitor screen to check syste m 55 V and TPS vo lt ages System volt age should b...

Page 78: ...MPORTANT 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 fun ction to tem porarily disable...

Page 79: ...el begins to turn until the outboard is running for 2 seconds During st arting a ll four LEDs should light and then go off in sequence LED 1 CHARGING OKAY Stator signal 30 V or higher LED 2 CRANK POSI...

Page 80: ...ircuit shorted Code 102 No 2 ignition timing circuit shorted Code 103 No 3 ignition timing circuit shorted LED 3 Sensor circuits 5 V SENSOR FAULT For LIGHT ON check for possible fault codes Code 12 TP...

Page 81: ...rom EMM white red provides 55 VDC to the high pressure fu el pump the oil injection pump the fuel injectors and the igni tion coils Capacitor Connected to 55 V circuit white red to stabilize current o...

Page 82: ...esults EMM ON not running approximately 1 V less than battery voltage system voltage is GOOD EMM ON not running no voltage check 12 V power to EMM Repair connection or wiring RUNNING 55 V 2 system vol...

Page 83: ...gency stop switch lanyard must be installed Connect timing ligh t pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test an d observe timing light strobe for cons...

Page 84: ...oltage and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 84 Check for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace...

Page 85: ...d ig nition coil connector Refer to engine wiring diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil test s available Before replacing an ignition coil be...

Page 86: ...ntinuity between pin 2 of f uel pump co nnector a nd ground Use the fuel pump static test to activate the control function of the EMM Resi stance should drop as EMM connects the control circuit to gro...

Page 87: ...che d by the EMM The Dynamic Tests screen allows the contr ol signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always check t...

Page 88: ...the voltage at pin 2 blue red wire of the the water valve connector V oltage shou ld d rop while the static test is active Exhaust Water Valve Dynamic Test Use the diagnostics program t o pe rform a...

Page 89: ...ST 97 CHARGING SYSTEM TESTS 98 ELECTRIC START CIRCUIT 100 ELECTRIC START TESTS 102 REMOTE CONTROL SWITCH TESTS 104 TILT TRIM RELAY TEST 106 EXHAUST WATER VALVE TEST 106 SYSTEMCHECK CIRCUIT TESTS 107 T...

Page 90: ...o 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m N A T IMPORTANT DO NOT lubri...

Page 91: ...s 2 7 to 4 N m 60 to 84 in lbs 7 to 9 5 N m F 30 to 42 in lbs 3 4 to 4 8 N m 24 to 36 in lbs 2 7 to 4 N m B 15 to 30 ft lbs 20 to 41 N m X J 002249 A Triple Guard Grease B Gasket Sealing Compound C Ad...

Page 92: ...sition sensor Capacitor 7 8 Ignition coil Main harness ground 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34...

Page 93: ...1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34 33 32 31 30 29 28 27 26 24 25 23 22 21 20 19 18 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B J1 A J2 4 1 2 3 1 2 3 1 2 3 4 5 6 2 3 4 5 6 1 2...

Page 94: ...875 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 Boo...

Page 95: ...tor ground Black 15 vacant 16 vacant 17 vacant 18 vacant 19 Ignition cylinder 2 75 90 HP Orange Purple 19 Ignition cylinder 2 40 65 HP Orange Green 20 Injector ground Black 21 Injector ground Black 22...

Page 96: ...f the EMM J1 B conne ctor a nd the main h arness ground Sensor circuit g rounds Check continuity between terminal pin s 26 and 27 of the EMM J1 A co nnector and the appropriate sensor ground connectio...

Page 97: ...sure sensor resis tance betwee n the yellow a nd white wires The complete circuit can b e tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mount ed to the throttle body ho...

Page 98: ...ly as the sensor lever is moved Engine Temperature Sensor Test Remove the ele ctrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperatur...

Page 99: ...ed winding conne ct on e meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no contin uity If meter rea ds continuity replace stator Stator Voltage...

Page 100: ...be able to run the outboard continuously at approximately 5000 RPM such as in a test tank or on a marine dynamometer The test consist s of mo nitoring the system s response to a partially discharged b...

Page 101: ...ON che ck battery voltage at battery 12 V Then use Ele ctrical Test Probe Kit P N 342677 and a dig ital multimeter set to read 55 VDC to check voltage on white red wires a t J2 connector of EMM Volta...

Page 102: ...9 18 FUSE J1 B J1 A J2 4 B A NEG A B 2 1 6 5 4 15 10 2 3 M A S C M B 1 2 3 4 5 6 2 1 7 8 9 9 11 12 13 14 1 1 Marine battery 9 PURPLE wire switched B 2 RED wire POS 10 Engine Management Module EMM 3 BL...

Page 103: ...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 1...

Page 104: ...terminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to terminal A of solenoid and ground NEG to terminal B of solenoid Measure resi...

Page 105: ...arter cable of solenoid terminal Connect negative lead to starter motor terminal Activate st arter motor a nd observe volt age reading No Load Current Draw Test Securely fasten starter in a vise or su...

Page 106: ...nal S Meter should indicate continuity IMPORTANT The cho ke function or terminal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or con tinuity light to test the continuity...

Page 107: ...are incorrect Emergency Stop Switch Test This switc h can be part of the ke y switc h or installed as a separate swit ch Either st yle con nects the M terminals of the key switch The emergency stop s...

Page 108: ...ivated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure r ed and black wire s are connected to 12 V battery power supply Set voltmeter to...

Page 109: ...on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the ke y switch ON T est for b attery volt age be tween instrument harne ss termi nal 1 purple wir...

Page 110: ...f the Sys temCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and the MW...

Page 111: ...llow 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...

Page 112: ...lternat or o utput can he lp determine the flywh eel s co ndition Refer to CHARGING SYSTEM TESTS on p 98 Flywheel Removal Remove the recoil st arter asse mbly rope st art models Refer to RECOIL STARTE...

Page 113: ...nd washers Hold puller body with han dle and tighten pressing scre w u ntil flywheel releases T urn the center scre w a nd lif t the fly wheel off of the crankshaft Stator Service Disconnect stator ha...

Page 114: ...to TIMING ADJUSTMENTS on p 113 IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis connect ignition coil electrical connector Remove two ignition coil reta...

Page 115: ...ol Mark the flywheel directly across from the pointer Label this mark A Rotate th e flywheel clockwise until the p iston contacts the tool Mark the flywheel directly across from the pointer Label this...

Page 116: ...gramming IMPORTANT Make sur e the timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS Calibration Use Evinrude Diagnostics sof tware to te ll...

Page 117: ...tarter positive cable from post on starter Remove the bat tery neg ative cable from the double ended stud Remove two starter mounting screws and double ended stud Remove the starter Starter Installati...

Page 118: ...and gently pull on wire Terminal Installation Push terminal through seal until it locks into place Fill conn ector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push we dge in u...

Page 119: ...ck Tool P N 77 7077 to release locking tab of connector housing Release locking tab a nd pull on wire to remove fro m connector housing Terminal Installation Align terminal with co nnector housing Pus...

Page 120: ...eated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 conne ctor of the EMM is an AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull co nnector from...

Page 121: ...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 o...

Page 122: ...120 ELECTRICAL AND IGNITION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 123: ...PRIMING 136 VENT LINE CLAMP 136 PRIMING THE FUEL SYSTEM 136 FUEL SYSTEM TESTS 137 FUEL SYSTEM PRESSURE TEST 137 PRESSURE REGULATOR TEST 138 VAPOR SEPARATOR VENT CHECK 138 FUEL INJECTOR PRESSURE TEST 1...

Page 124: ...lbs 2 7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F 002154a Tighten in 3 stages A Triple Guar...

Page 125: ...n lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Ad...

Page 126: ...7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F A Triple Guard Grease B Gasket Sealing Compound...

Page 127: ...20 in lbs 7 14 n m 10 14 in lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m F F IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease...

Page 128: ...system Fuel lift pump 2 to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel in...

Page 129: ...to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel injector s Fuel return mani...

Page 130: ...EMM Fuel injector Fuel circulation pump 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 GREEN BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15...

Page 131: ...mp 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 11 PURPLE GREEN 2 BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B...

Page 132: ...rage 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...

Page 133: ...damage the out board Additives IMPORTANT The only fuel additives ap proved for use in Evinrude outboards are 2 4 fuel condi tioner a nd Evinrude Johnson Fue l System Cleaner Use of other fuel additiv...

Page 134: ...aches the pump interna l pump pressure force s 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 pressur...

Page 135: ...he fuel level in the fu el chamb er Hot fuel causes an increase in vapor pressure This results in a lower fuel level in th e vapor separator The float valve drops and the vent opens This allows fuel v...

Page 136: ...manifo lds route fue l through the high pressure side of the fuel system Fuel Supply Manifold The fuel supply manifold supplies pressurized fuel to the inlet port of each fuel injector Fuel Return Ma...

Page 137: ...or s unique fuel flow characteristics Fuel injectors MUST NOT be moved from one cylinder to another EMM program ming is associated with the cylinder location of each injector Installing an injector on...

Page 138: ...hose Once fue l flow is observed co nnect fuel supply hose from fuel tank to hose fitting on outboa rd Secure hose with Oetiker clamp TILLER MODELS Connect the fuel hose connector to the quick con nec...

Page 139: ...t on p 140 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supp lying enou gh fuel to vap or s...

Page 140: ...us Fuel Injector Pressure Test This te st re quires Inj ector T est Fi tting ki t P N 5005844 Disconnect the battery cables at the battery Loosen oil tank assembly to provide access to fuel manifolds...

Page 141: ...urple or green Resistance should be the same as o r slightly higher than the injector alone Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter with...

Page 142: ...lift pump Temporarily install a vacuum gauge T fitting and 8 in 20 3 cm of clear vinyl hose between the fuel supply hose and fuel lift pump inlet Secure con nections with tie straps to prevent fuel o...

Page 143: ...ti siphon valve fro m f uel tank Install adapter fitt ings and a 36 in 91 4 cm leng th of clear hose to the inlet side tank end of valve Fill clear hose with water to a height of 20 in 500 mm W ater m...

Page 144: ...into a suit able con tainer Slowly open gauge s venting valve Clean up any spilled fuel with shop towels A WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use ca...

Page 145: ...ld pressure on bulb and check for fuel leaks Connect battery cables Run outboard and check for fuel leaks Fuel Lift Pump Service The fuel lif t pump is serviceab le as a comple te assembly or can be...

Page 146: ...lation pump Remo ve clamp and va por vent hose from separator cover Remove clamp s and vap or separator cooling water hoses Remove clamps and fuel return manifold and fuel supply hose from bottom of v...

Page 147: ...remove the manifold assemblies Installation Check condition of sealing O rings on fuel man i fold fittings Lubricate O rings with outboard lubri cant and insert fuel manifo ld fittings into injector B...

Page 148: ...ry Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 142 Remove fuel manifold s Refer to Fuel Manifold Service on p 145 Remove the ignition coil assemblies Disconnect the fuel...

Page 149: ...r coefficient dat a ca n be downloade d from th e Evinrude Johnson dealer website Ref er to th e instructions provided with the injector kit Upload Coefficient Files to EMM IMPORTANT If using Diagnost...

Page 150: ...eaned prior to reassembly Injector Cylinder head Adapter Screws Threaded areas Place injector and insulator in the proper cylinder location IMPORTANT Be careful not to pinch any wiring or hoses during...

Page 151: ...N m Install fuel manifolds Refer to Fuel Manifold Ser vice on p 145 Intake Manifold Service Removal Disconnect vapor separator vent hose main bear ing vent hose air temperature sensor crankshaft posi...

Page 152: ...an assembly Inspection Inspect the leaf plate a ssemblies for da mage or contamination Leaf plates must not be distorted Leaf valve must not be cracked or chipped Leaf plate stops must not be distorte...

Page 153: ...rottle body on reed plate and install new screws IMPORTANT If old screws mu st be re used make sure all previous thread locking mate rial is removed and apply Nut Lock to threads Tighten the center sc...

Page 154: ...152 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 155: ...V 161 LOW OIL WARNING 162 NO OIL WARNING 162 CYLINDER AND CRANKCASE 162 OIL RECIRCULATION SYSTEM 163 OIL CONTROL SETTINGS 164 OIL INJECTION RATE 164 BREAK IN OILING 165 OIL SUPPLY PRIMING 165 OILING S...

Page 156: ...P F F 30 to 42 in lbs 3 5 to 5 N m X 30 tp 42 in lbs 3 5 5 N m 30 to 42 in lbs 3 5 5 N m 008058 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboa...

Page 157: ...n lbs 3 5 to 5 N m X 30 to 42 in lbs 3 5 to 5 N m 30 to 42 in lbs 3 5 to 5 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubrica...

Page 158: ...M OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 40 65 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1...

Page 159: ...OILING SYSTEM 157 8 75 90 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1 5 4 6 6 5 6 5 008061...

Page 160: ...158 OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 40 65 HP 75 90 HP 002483a Starboard view Port view 002223 Starboard view Port view...

Page 161: ...RED Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK No oil signal to SystemCheck gauge TAN YELLOW 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 1...

Page 162: ...itor warn ing display should show LOW OIL Add enough oil to raise level to at least one quar ter capacity The LOW OIL warning should not display Failure to follow these recommen dations could void th...

Page 163: ...ls activation of the pump The oil manifold distributes the oil supplied by the pump Electrical Circuit 55 V The oil injector is powered by t he 55 V electrical circuit The EMM controls pump operation...

Page 164: ...ing re sets after thre e oil p ump pulse cycles when th e out board has been stopped and restarted If outboard has be en run fo r more th an 3 hou rs with NO OIL faults codes 34 117 the EMM Cylinder a...

Page 165: ...e upper cylin der port Crankcase Main Bearing Recirculation The movement of oil through the main bearings is controlled by int ernal p assages e xternal fittings and hoses and check valves Lower to up...

Page 166: ...XD100 out board lub ricant and is not re commended for all applications IMPORTANT The XD100 setting is not avail able on all models Use the XD100 setting for Conventional use runabouts cruisers Moder...

Page 167: ...up Use Evinrude Diagnostics sof tware to m ake sure the break in program has been started on a new outboard Use the diag nostics sof tware to st art break in oiling after a powerhead rebuild The oper...

Page 168: ...ly This will p roduce false results Refer to Communication on p 63 The EMM controls the pump by providin g ground through pin 23 blue wire of th e J1 B co nnector and pin B blue wire of the oil pump c...

Page 169: ...eter lead to pin A white red wire of oil injection pu mp electrical connector Observe voltage at pin A Voltage at pin A should be approximately 12 V Set digital multimeter to a scale that re ads 55 V...

Page 170: ...in serted int o ma nifold Refer to Oil Distribution Hoses on p 169 Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remo...

Page 171: ...a cement 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 full...

Page 172: ...a torq ue of 30 to 42 in lbs 3 5 to 5 N m Install protective sleeves and route oil distribution hoses from the oil distribu tion ma nifold to the crankcase oil delivery fittings Refer to OIL SUP PLY...

Page 173: ...s from oil pump assembly Twist and pull up on oil pump to remove from tank DO NOT pull up on oil manifold Installation Apply a dro p of out board lubricant to a new oil pump o ring Install o ring on...

Page 174: ...n front of oil t ank ba ffle to prevent interference with the LOW OIL switch ALL MODELS Install oil pump ret ainer screw s T ighten securely IMPORTANT Turn self tapping screws cou nter clock wise to s...

Page 175: ...7 THERMOSTAT 177 BLOCK VENTING 178 WATER PRESSURE CONNECTION 178 OPERATION 179 CYLINDER BLOCK CYLINDER HEAD COOLING 179 EMM AND VAPOR SEPARATOR COOLING 179 ENGINE TEMPERATURE CHECK 180 SOFTWARE METHOD...

Page 176: ...5 6 8 7 10 60 65 HP 004971 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Exhaust housing Cylinder block Pressure relief valve Thermostat Water suppl...

Page 177: ...01818 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply EMM to vapor separator Overboard...

Page 178: ...IMPORTANT The water pump hou sing on 2 cylinder models includes a small hole to the rear of the wa ter outlet This hole provides cooling water for the tip of the exhaust passage Be sure to use the co...

Page 179: ...incre ases Spring tension sets the opening pressure Overheating A restricted or fa ulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing complet...

Page 180: ...ck Circulated water flows t hrough the EMM and vapo r separator before exiting through the overboard indicator Water Pressure Connection A fitting and hose for an accessory water pressure gauge can be...

Page 181: ...down through the cylinder head to a passage in the cyl inder block W ater flows through the block to the exhaust housing and then out of the outboard At higher speeds wate r pressure op ens th e pres...

Page 182: ...mon itor d isplay ind icates a W ATER TEMP warning refer to WATER TEMP HOT Cir cuit Test on p 108 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperatur e...

Page 183: ...ief Valve Inspection The pressu re re lief va lve should b e closed at IDLE speed W ater should no t flo w past th e plunger and seal Start the outboard and check IDLE operating tem perature If IDLE t...

Page 184: ...gasket sealing com pound SLOWLY tighten temperature sensor to a torque of 50 to 70 in lbs 5 6 to 8 0 N m Wait 10 minutes for trapped air to bleed from cav ity Th ermal compo und may seep past threads...

Page 185: ...y close attent ion when pe rforming the following additional tasks Coat t hreads of thermost at cover with Gasket Sealing Compound and install new O ring Install and tighten cover to a torque of 120...

Page 186: ...sassemb ly Pa y close attent ion when pe rforming 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 ri...

Page 187: ...K CLEANING 200 POWERHEAD INSPECTION 201 POWERHEAD ASSEMBLY 203 CRANKSHAFT ASSEMBLY 203 PISTONS AND CONNECTING RODS 205 CYLINDER HEAD INSTALLATION 207 CRANKSHAFT AND CONNECTING ROD INSTALLATION 208 CRA...

Page 188: ...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 F 60 84 In lbs 7 9 5 N m B J 18 20 ft lbs 24 5 27 N m B 002283 A Triple Guard Grea...

Page 189: ...iple 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 H 30 32 Ft...

Page 190: ...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 002281 A Triple Guard Grease B Gas...

Page 191: ...gnment tool 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 Grea...

Page 192: ...ed pistons broken or stuck piston rings scored cylinder walls Return throttle to idle position and reconnect CPS connector Replace sp ark plugs Refer t o S park Plug Indexing on p 42 POWERHEAD REMOVAL...

Page 193: ...ectronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool an d support weight of powerhead with hoist Loosen the screws holding the exhaust wa ter valve to the exhaust housi...

Page 194: ...o use only the 1 1 8 in short screws P N 398067 included with the tool to avoid damage to electronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool a nd support weight of...

Page 195: ...sembly Label connectors for reassembly locations Re fer to EMM SERVICING on p 70 Remove flywheel and stator Refer to FLYWHEEL AND STATOR SERVICING on p 110 Remove ignition coils and fuel injectors Ref...

Page 196: ...ld ing t he shift shaft 2 cylinder models Slide ent ire shif t linkag e assembly from crank case Remove t he ball g uide and spring of the shif t detent assembly from the crankcase 2 Cylinder Models 1...

Page 197: ...ANT Do not use a t apered pun ch or any othe r tool th at co uld jam in or damage th e taper bore when removing the pin Remove crankcase flange screws Loosen in stages and remove the main bearin g nut...

Page 198: ...N 331638 t o loo sen in stages the ro d cap ret aining screws DO NOT remove the screws Use one hand to sup port the piston an d remove the rod cap screws with your other hand Remove each piston and r...

Page 199: ...sin g Tool P N 326356 to remove the wrist pin bearing Be careful not to lose any of the 28 needle bear ings or the two wrist pin washers Do not mix bear ings with those from another cylinder If any of...

Page 200: ...using O ring Discard O ring Use a punch to remove the housing seal Discard seal Inspect housing and replace if necessary Remove the O ring from cr ankshaft sleeve a nd inspect it Repla ce the O ring i...

Page 201: ...be replaced Use e xternal retaining ring pliers to remove the lower bearing retaining ring IMPORTANT If the lower main bearing is removed fro m the cranksha ft it must be dis carded DO NOT reuse it U...

Page 202: ...al and Gasket Remover to remove all traces o f g askets adhesives and Gel Seal II sealant from th e cylinder block crankcase cylin der head and water cover Carefully rem ove an y carbon ac cumulation...

Page 203: ...ge must not exceed 0 006 in 0 15 mm per inch of me asurement Re place head if warpage exceeds this dimension Check fuel deflector pins for damage Crankshaft Measure the diameter of each crankp in and...

Page 204: ...uge to measu re the ring end gap Ring end gap should be 0 011 to 0 023 in 0 28 to 0 58 mm IMPORTANT Ring end g ap increases ap proxi mately 0 003 in 0 076 mm for e ach 0 001 in 0 025 mm incre ase in c...

Page 205: ...e lower main bearing If the inst aller sticks on the sleeve after installa tion thread Slide Hamme r P N 391008 in to installer and pull it off IMPORTANT Inspect sleeve af ter inst allation Sleeve mus...

Page 206: ...et Sealing Compound to outer edge of O ring Place lower seal housing on crankshaft Lubricate upper main bearing with outboard lubri cant and install on crankshaft Pack lip of upper oil seal with Moly...

Page 207: ...the flywheel Apply Needle Bearing Grease to the wrist pin bearings Install the bearings in the small end of the connecting rod Align be arings with Wrist Pin Bearing Tool P N 336660 Place the two wri...

Page 208: ...all Gel Seal II has been removed from the cyl inder block and crankcase mating flanges If traces of hardened Gel Seal II are left main bearings could be misaligned Refer to CYLIN DER BLOCK CLEANING on...

Page 209: ...nd install in cylinder head Apply soa py water to water dam and insert into block Apply a 1 16 in 2 mm be ad of RTV Adhesive around each water passage on the block and cyl inder head as shown Install...

Page 210: ...cylin ders Remove numbered connecting rod caps Gently lower crankshaft into place Align t ab o n lower bearing seal housing with hole in crankcase Align upper oil seal in groove Locate each main bear...

Page 211: ...dot on rod and that both dot s face fly wheel Tightening rod cap screws without Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent damage to the connecting rod and cra...

Page 212: ...forcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 N m IMPORTANT Make sure that frame is squ arely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Tor...

Page 213: ...mating fla nge Th e sea ler must no t come within 1 4 in 6 4 mm of bearings IMPORTANT Gel Seal II ha s a shelf life o f at least one year when stored at room temperatu re Test the Gel Seal II or repla...

Page 214: ...ing Compound to both sides of a new water cover gasket Place gasket and cover on cylinder block Apply Nut Lock to cover screws Position J clamps as shown Tighten all screws to a torque of 60 to 84 in...

Page 215: ...k 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 sprin...

Page 216: ...nition coils Ref er to Fuel Injector Installation on p 147 and IGNITION COIL SERVICING on p 112 IMPORTANT All inj ectors mu st be installed i n their original location Improper injector installation c...

Page 217: ...assemblies and remove Inspect mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position...

Page 218: ...st housing If necessary rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines Apply Triple Guard g rease to th e t hreads a nd Gasket Sealing Compound to the shan k of th...

Page 219: ...Nut Lock to threads of exhaust water valve screws and tighten to a torque of 60 to 84 in lb s 7 to 9 5 N m Connect cooling water hoses to exhaust housing Connect the power trim connectors and exhaust...

Page 220: ...slowly lower powerhead ont o exhaust hou sing Guide into positio n over alignment pin at rear of exhaust housing If necessary rotate flywheel in a clockwise direction to align crankshaft and drive sh...

Page 221: ...s to a to rque of 60 to 84 in lbs 7 to 9 5 N m Place the shift rod in the shift rod lever Install the retaining pin and washer Tighten pin to a torque of 60 to 84 in lbs 7 to 9 5 N m Check shif t lin...

Page 222: ...NT on p 323 Tighten adjustment screws to 60 to 84 in lbs 7 to 9 5 N m Final Adjustments After installing a new or rebuilt powerhead perform the following procedures before returning outboard to servic...

Page 223: ...221 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS 2 Cylinder Port Hose Routings 2 Cylinder Starboard Hose Routings 006490 006491...

Page 224: ...222 POWERHEAD POWERHEAD VIEWS 2 Cylinder Port Dressed Powerhead 2 Cylinder Starboard Dressed Powerhead 008428 008159...

Page 225: ...223 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Port Rope Start Models 2 Cylinder Starboard Rope Start Models 008370 008185...

Page 226: ...224 POWERHEAD POWERHEAD VIEWS 2 Cylinder Front 008160...

Page 227: ...225 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Rear 008161...

Page 228: ...226 POWERHEAD POWERHEAD VIEWS 2 Cylinder Top 008162...

Page 229: ...POWERHEAD POWERHEAD VIEWS 227 10 2 Cylinder Top Rope Start Models 008186...

Page 230: ...228 POWERHEAD POWERHEAD VIEWS 3 Cylinder Port Hose Routings 3 Cylinder Starboard Hose Routings 006760 006761...

Page 231: ...229 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Port Dressed Powerhead 3 Cylinder Starboard Dressed Powerhead 008163 008164...

Page 232: ...230 POWERHEAD POWERHEAD VIEWS 3 Cylinder Front 008166...

Page 233: ...231 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Rear 008167...

Page 234: ...232 POWERHEAD POWERHEAD VIEWS 3 Cylinder Top 008165...

Page 235: ...251 STERN BRACKET DISASSEMBLY 251 STERN BRACKET ASSEMBLY 252 STERN BRACKET 75 90 HP POWER TILT 253 STERN BRACKET DISASSEMBLY 253 STERN BRACKET ASSEMBLY 256 STERN BRACKET 40 60 HP MANUAL TILT 258 CLAM...

Page 236: ...t Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex No 2 Q Gel Seal II 004304 60 84 in lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B F 16 18 ft...

Page 237: ...9 5 N m E 60 84 In lbs 7 9 5 N m C C A B B 60 84 In lbs 7 9 5 N m F 150 180 In lbs 17 20 N m A A C B 18 20 Ft lbs 24 5 27 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lub...

Page 238: ...BRACKET 40 60 HP POWER TILT 144 168 In lbs 16 19 N m F 10 16 In lbs 1 2 N m 45 50 Ft lbs 61 68 N m A A A 45 50 Ft lbs 61 68 N m A Triple Guard Grease B Gasket Sealing Compound 002220 IMPORTANT Use Tri...

Page 239: ...16 240 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 A A A...

Page 240: ...6 19 N m 144 168 In lbs 16 19 N m F 40 45 Ft lbs 54 61 N m See Text A 144 168 In lbs 16 19 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lo...

Page 241: ...60 84 In lbs 7 9 5 N m A F 60 84 In lbs 7 9 5 N m 40 Ft lbs 54 N m Marine Sealant 18 20 Ft lbs 24 27 N m 18 20 Ft lbs 24 27 N m 18 20 Ft lbs 24 27 N m 60 84 In lbs 7 9 5 N m A 110 130 Ft lbs 149 176 N...

Page 242: ...2 3 3 4 N m 36 48 In lbs 4 5 4 N m 36 40 Ft lbs 49 54 N m 18 20 Ft lbs 24 5 27 N m 24 36 In lbs 2 7 4 N m A F F F A A D D 18 20 Ft lbs 24 5 27 N m Switched 12V For CANbus To Engine Key Switch Connecto...

Page 243: ...ollar Remove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer f rom Tilt T ube Service Kit P N 434523 on to the st arboard end of th e tilt tube Remove st...

Page 244: ...se a wood or leather mallet to t ap 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 l...

Page 245: ...e Re fer to Ge arcase GEARCASE REMOVAL AND INSTALLATION on p 296 Remove th e powerhea d Refer to Powerhe ad POWERHEAD REMOVAL on p 190 Remove the three lower mount cover screws Separate lower mount co...

Page 246: ...valve and bracket in position Apply Nut Lock to screws install and tighten 60 to 84 in lbs 7 to 9 5 N m Exhaust Relief Muffler Remove exhaust relief muffler cover to inspect fil ter element Clean or r...

Page 247: ...Place lo wer thrust washer on th e stee ring shaf t and place the lower front mount into position Install lower side mount covers Install and tighten the screws in stages to a torque of 16 to 18 ft l...

Page 248: ...NSTALLATION on p 296 Remove the p owerhead Refer to POWER HEAD REMOVAL on p 190 Remove and discard four lower mount screws Remove the exhaust housing Lower Mount Service Remove lower mount covers and...

Page 249: ...crews and tighten to a torque of 150 to 180 in lbs 17 to 20 N m Exhaust Housing Installation Bring the exhaust housing into position with th e stern bracket Install four new lower mount screws with lo...

Page 250: ...r exhaust housing to the adapter housing Remove the wa ter tube from the inne r exhaust housing Discard water tube grommet Remove the se al from the bott om flan ge of the inner exhaust housing Remove...

Page 251: ...mum 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...

Page 252: ...Adhesive 847 to the bottom flange of the inner exhaust hou sing Install a new seal Apply Triple Guard grease to outer seal surface Clean an d d egrease t he a dapter hou sing a nd outer exhaust ho usi...

Page 253: ...0 to 84 in lbs 7 to 9 5 N m STERN BRACKET 40 60 HP Power Tilt Stern Bracket Disassembly Remove th e bumpers from th e uppe r mou nt retaining screws Remove the screws upp er mount and ground lead from...

Page 254: ...d to two thirds its origi nal size Stern Bracket Assembly Assemble the tie bar to the stern brackets Place the ground lead and starwasher between the port stern bracket and tie bar Lubricate the swive...

Page 255: ...dhesive 847 to head s of the upper mount screws Place the bumpers on the upper mount screws STERN BRACKET 75 90 HP Power Tilt Stern Bracket Disassembly Before servicing the stern bracket Remove gearca...

Page 256: ...scard Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to TILT TUBE 75 90 HP on p 241 Remove the two tilt tube washers Remove the anode Remove the swivel bracket Inspect a...

Page 257: ...etainer Remove the trail lock arm and b ushings from the swivel bracket Remove the two trim rod rollers from the swivel bracket Remove the tilt support and bushing from the swivel bracket and inspect...

Page 258: ...ng in the swivel bracket T ighten bushing to a torque of 28 to 30 f t lbs 38 to 41 N m Install the two trim rod rollers on the swivel bracket Tighten to a torque of 216 to 240 in lbs 25 to 27 N m Inst...

Page 259: ...w seals in the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compound Coat the bushing s and sea l lip s with Triple Guard grease Coat tilt tu be bushin...

Page 260: ...d stern brackets through the two forward grease fit tings Install the e xhaust housing Refe r to Exhaust Housing Installation on p 247 STERN BRACKET 40 60 HP Manual Tilt Clamp Screw Service Inspect cl...

Page 261: ...teering friction pin When the pin is flush with the inside surface of the ca sting remove the steering friction thrust ring Tighten the ste ering friction screw until the ste er ing friction pin can b...

Page 262: ...p link screws and nuts from the stern brackets Remove the two stern bracket flange screws and separate the stern bracket s from the swive l bracket Place the tilt ru n lever in the RUN positio n Loose...

Page 263: ...e l bracket Insert the reverse lock pins in the swivel bracket and p art wa y throu gh the reverse lock springs Place the reverse lock assembly between the springs Push the pins through the springs an...

Page 264: ...tilt tube nuts loosely Starboard stern bracket Thrust washer Bushing Swivel bracket Bushing Thrust washer Port stern bracket Apply Nut Lock to threads of the two flange screws Inst all the two screws...

Page 265: ...rin g friction bu shing in the swivel bracket with groove in line with the setscrews Apply Triple Guard grease to the steering frictio n pin Install the pin in the swivel bracket flush with inside sur...

Page 266: ...rd side and the steering arm Install and tighten the mount retaining scr ews to a torque of 24 to 26 f t lb s 32 5 to 35 N m Place the mount screw bumpers on the up per mount screws Tilt Assist Cylind...

Page 267: ...isassembly Install new cotter p ins in upper pivot pin Install a new set screw in st arboard stern bra cket lower pivot pin access hole and tighten securely STERN BRACKET 90 HP Manual Tilt Stern Brack...

Page 268: ...Remove starboard reverse lock link Remove port reverse lock link Loosen bellcrank set screw remove bellcrank and handle link rod 1 Pins 2 Locking lever 006699 1 Starboard reverse lock link 006696 1 2...

Page 269: ...e trail lock 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 shaf t bush ings from swivel b...

Page 270: ...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 268 for correct orientation of re verse lock and trail lock components Assembl...

Page 271: ...shaft spacer on reverse lock pivot shaft then install retaining ring Install the handle link rod to reverse lock lever and bellcrank Install b ellcrank on reverse lock pivot shaft Tighten the setscre...

Page 272: ...and screw Tighten screw to a torqu e of 60 to 84 in lbs 7 to 9 5 N m Install reverse lock release collar a nd tighten set screw Install locking lever pins and new cotter pins Install reverse l ock sp...

Page 273: ...c trical harness Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove throttle cable and wires from grommet in lower engine cover Remove the scre w attach...

Page 274: ...to depress the grip de tents Tighten screw and remove the grip by pulling grip Remove the helix halves rollers and guides Pull the throttle pin out of the cable Remove stop switch cover screws and co...

Page 275: ...andle by driving the outer handle off with a mallet and a punch Inner handle is bonded to the outer handle After removing chip away remnants of inner handle Remove throttle cable seal from the inner h...

Page 276: ...retainer clip Install the throttle control plate on outer handle Push the throttle cable pin throug h the end of the throttle cable Lubricate e nd of t he pin guides rollers h elix grooves an d inner...

Page 277: ...he bushin gs into the steering bracket Attach the steering handle to the bracket Tighten screw to a torqu e of 36 t o 40 f t lbs 49 to 54 N m Route t hrottle cab le and electrical ha rness through gro...

Page 278: ...hrottle cam is against idle stop when anchor screw aligns with throttle bod y boss Th en rotate a nchor fo ur turns to ward the end of the cable Install washer cable a nchor and cable anchor screw on...

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

Page 280: ...Loosen th rottle frict ion control so the re is no restriction on grip IMPORTANT Do not back screw out com pletely Nut is under spring tension Remove seven screws and bottom cover of tiller handle Rem...

Page 281: ...d guides Pull the throttle pin out of the cable Remove the throttle friction control Remove the thro ttle cable ret aining clip Pry the cable trunnion ou t of th e st eering hand le an d remove cable...

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

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

Page 284: ...of tab must be flush with top of flange Apply Nut Lock on the screw threads install the washer and screw IMPORTANT Turn se lf tapping screw counter clock wise until th reads of screw en gage threads...

Page 285: ...er steering handle Wire guide sho uld slide easily into place If any binding is felt inspect trim switch wirin g for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Mak...

Page 286: ...Lube Place the guides over the roller p in and into t he slots of the inner handle Place the rollers on t he ends of the roller pin Assemble the helix halves on the handle and slide the grip over the...

Page 287: ...ioned straight or angled 15 port or starboard by moving the adjust ment plate Place tiller bracket on steering arm from the bot tom Thread steering arm screws with washers into steering arm and tighte...

Page 288: ...the lower anchor pocket Adjust the trunnion nut so the cas ing fits onto the shift lever pin Secure shift cable to the shift lever pin For proper installation review the following steps Place washer o...

Page 289: ...Adjust cable anchor so throttle cam is against idle stop when anchor screw aligns with throttle bod y boss Th en rotate a nchor fo ur turns to ward the end of the cable Install washer cable an chor a...

Page 290: ...288 MIDSECTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 291: ...SHAFT INSTALLATION 314 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION 316 FINAL ASSEMBLY AND ADJUSTMENT 317 GEARCASE SERVICE 75 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION 318 WATER PUMP SER...

Page 292: ...In lbs 13 5 16 5 N m A B C 60 84 In lbs 7 9 5 N m D B C B A B 96 120 In lbs 11 13 5 N m 60 84 In lbs 7 9 5 N m B A 18 20 Ft lbs 24 5 27 N m A 40 45 Ft lbs 54 60 N m 35 40 Ft lbs 47 54 N m B 48 80 In...

Page 293: ...0 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61...

Page 294: ...bs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m A A C A A J 14 18 In lbs...

Page 295: ...t full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blades have too much pitch the engine will operate below its normal range at full throttle Power will be lost and powerhead dam...

Page 296: ...r Propeller Hardware Installation IMPORTANT Depending on propeller style dif ferent thrust bushings sp acers and cotter pin keepers are used See the Evinrude Johnson Genuine Parts and Accessories Cata...

Page 297: ...source of leak If the gauge does not in dicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leaks Make necessary repairs and repeat test Install Gearca se V acuum T ester P N 50...

Page 298: ...in screw and washer and remove 7 16 14 x 3 5 in screw and washer Remove the four 3 8 16 x 1 5 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being car...

Page 299: ...rectly Shift rod does not turn and is positio ned prop erly in the shift rod lever below the crankcase Apply Triple Guard g rease to th reads o f th e gearcase retaining screws Tighten the screws to a...

Page 300: ...ing screws Slide the wate r pump of f the driveshaft Remove the impeller key impeller plate and gasket Dis card the gasket Remove all the parts from the housing Inspection Check impeller for o verheat...

Page 301: ...on install the impeller into the linerwith the slot for the impeller key facing out Apply a thin bead of Adhesive 847 in the seal groove and install the special shaped O ring seal Apply Gasket Sealing...

Page 302: ...oove of the impeller housing grommet Install the grommet on the impeller housing Before installing gearcase shift rod adjustment MUST be checked Refer to SHIFT ROD ADJUSTMENT on p 300 SHIFT ROD ADJUST...

Page 303: ...d amaged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss o f boat an d outboard control and gearcase damage Hydrostatic Seal...

Page 304: ...2 from Universal Puller Set P N 378103 Remove the two ret aining ring s using Ret aining Ring Pliers P N 331045 Remove the retainer plate from the gearcase COA3571 9437 A CAUTION Retaining rings are u...

Page 305: ...e pinion nu t from the bottom of the driveshaft Pad han dle of the wrench to prevent damage to gearcase Remove th e four driveshaf t bearing ho using screws Remove th e drivesha ft fro m the gearcase...

Page 306: ...inserte d be tween the puller and the gearcase unt il the driveshaf t pops loose from the pinion Shift Housing Gear and Propeller Shaft Removal Push d own o n t he shift rod This will move t he detent...

Page 307: ...g Water Intake Screen Inspect the water int ake screen for blockage an d remove it by depressing the tabs on either side of the screen and pushing upward Pinion Bearing Installation Install the water...

Page 308: ...the screw and tighten to a torque of 48 to 80 in lbs 5 5 to 9 0 N m Shift Housing Disassembly IMPORTANT The shif t h ousing and forward gear bea ring are serviced as an asse mbly If either are worn o...

Page 309: ...re beginning assemb ly pro cedures Replace any damaged parts Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at...

Page 310: ...ng grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the ge ar bearing and washer into t he bearing housing Bearing and washer must be installed in t...

Page 311: ...ller Bridge P N 432127 and Large Puller Jaws P N 432129 Discard the seal Remove and discard the O ring from the bearing housing Clean the bearing ho using in solven t to re move sealer from the seal b...

Page 312: ...dge and tighten jaws secu rely behind the bearing Remove fro nt bearing using Puller Brid ge P N 432127 and Bearing Puller P N 432130 Place the puller plate on top of the housing to sup port the b rid...

Page 313: ...d of the bearing should be visible Bearing Installation Tool P N 326562 Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool...

Page 314: ...aring housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 40 to 45 ft lbs 54 to 60 N m IMPORTANT The origina l pinion nut may be used for shimming bu...

Page 315: ...required shims between the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 312403 Check cl...

Page 316: ...cator pin into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Place the cover se...

Page 317: ...aft into the gearcase and thro ugh the pin ion gear Using Drivesha ft Sea l Protector P N 312403 slide the driveshaf t b earing ho using o nto the driveshaft and into position in the gearcase Align th...

Page 318: ...g a nd la rger thru st washer on hu b of reverse gear Slide the gear assembly onto the propeller shaft until it engages the pinion gear Slide the bearing housing ret ainer plate into posi tion over th...

Page 319: ...e top Place the housing into gearcase and tap the housing with a soft face mallet to seat the O ring Apply Gasket Sealing Compound t o th e threads and seals of the four prope ller housing retaining...

Page 320: ...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 rod A WARNING To prevent accide...

Page 321: ...g installs correctly Shift rod does not turn and is positio ned prop erly in the shift rod lever below the crankcase IMPORTANT New gearcase screws are treated with a thread locking material Apply Trip...

Page 322: ...n WATER PUMP SERVICE Disassembly Rotate the driveshaf t counterclockwise to unlock the impeller key Remove th e four impeller hous ing screws Slide the wate r pump of f the driveshaft Remove the impel...

Page 323: ...g with a square index tab Make sure vent hole in impeller cup is open Install th e water tub e grommet wit h the insid e taper facing up Apply Triple Guard grease to screw threads and install the imp...

Page 324: ...eller and slide water pump down over key Be sure impeller key does not fall out of position Make sure the impeller engages the impeller key Serious powerhead damage will result if impeller key is not...

Page 325: ...ase in NEUTRAL rot ate the shif t rod up or d own as necessary fo r correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTANT The NEUTRAL...

Page 326: ...d amaged threads Shift Rod Check fo r misad justed bent or binding rod A misadju sted shift rod height can cause shift difficulty loss o f boat an d outboard control and gearcase damage Hydrostatic S...

Page 327: ...wo 5 16 18 nuts obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing and reverse gear from gearcase Pinion Gear and Driveshaft Rem...

Page 328: ...867 to break the lock Install the too ls as shown by clamp ing them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between th e p uller an d th e...

Page 329: ...emble the driveshaft install new driveshaft retainer into the groove of the upper driveshaft Install the upp er driveshaf t into the lower drive shaft aligning the holes in the d riveshaft retainer an...

Page 330: ...ter intake screens Replace if damaged GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and deb ris prior to inspe ction Inspect pinion bearing an d forward thrust surfa...

Page 331: ...stallation Assemble the following componen ts of Pinio n Bearing Remover and Installer P N 5005927 as shown S Type Gearcases 1 Pinion bearing retaining screw 2 Water screen pocket 3 Seal DSC02370 DRC7...

Page 332: ...be aring into the gearcase Drive the bearing into the gearcase until the washer on the tool contacts the spacer Remove the tool Place a new O ring on the pinion bearing retaining screw Appl y G asket...

Page 333: ...h a shop cloth to cat ch 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...

Page 334: ...ing t he ba ll and spring with a suitable tool Once the shifter detent is past the ball remove th e too l an d po sition detent to engage NEUTRAL position Thoroughly grease 25 needle bearings wit h Ne...

Page 335: ...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 336: ...al bore and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage Do no...

Page 337: ...432127 and Large Puller Jaws P N 432129 Place the puller plate on top of the housing to sup port the bridge and tighten jaws secu rely behind the bearing Inspect th e b earing h ousing anode Replace a...

Page 338: ...N 339750 O Type gearcases Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to install new seals back to back in bearing...

Page 339: ...g the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 100 to 110 ft lbs 136 to 149 N m IMPORTANT The origina l pinion nut may be used for...

Page 340: ...he drivesha ft from the tool and add the required shims b etween the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driv...

Page 341: ...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 t he shifter d...

Page 342: ...aring IMPORTANT The inside t aper of the p inion gear and the driveshaft taper MUST be com pletely free of grease Clean the t apers with Cleaning Solvent Use a shop towel free of grease and lint Place...

Page 343: ...he gear assembly onto the propeller shaft until it engages the pinion gear Lightly apply Gasket Sealing Compound to a new bearing housing O ring Install O ring in groove in the housing Install hou sin...

Page 344: ...firm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 295 WATER PUMP SERVICE on p 320 SHIFT...

Page 345: ...GENERAL 348 RESERVOIR FLUID 348 MANUAL RELEASE VALVE 348 STERN BRACKETS 348 TROUBLESHOOTING 348 ELECTRICAL CIRCUIT TESTS 349 RELAY TESTING 349 TRIM AND TILT MOTOR CURRENT DRAW TESTS 349 TRIM AND TILT...

Page 346: ...TRIM AND TILT SERVICE CHART SERVICE CHART 40 60 HP MODELS 007632 W W 45 to 55 in lbs 5 to 6 N m 45 to 55 in lbs 5 to 6 N m 30 to 50 in lbs 4 to 5 6 N m A A A Triple Guard Grease W Biodegradable TNT Fl...

Page 347: ...TRIM AND TILT SERVICE CHART 345 13 75 90 HP MODELS 005002 A Triple Guard Grease W Biodegradable TNT Fluid 30 to 50 In lbs 4 to 5 6 N m A A W 45 to 55 In lbs 5 to 6 N m 45 to 55 In lbs 5 to 6 N m...

Page 348: ...outboard through the tilt range IMPORTANT When in tilt range ma ke sure water is available to gearcase water pickups Manual Adjustment The outboard can be ma nually raised or lo wered through its enti...

Page 349: ...c system from damage Tilt the outboard up fully engage the bracket then tilt the outboard down until the bracket is firmly in position For mooring or storing the boat with the outboard tilted a tilt s...

Page 350: ...k the manual release valve with a torq ue wrench IMPORTANT Tighten valve to a torque of 45 to 55 in lbs 5 to 6 N m Stern Brackets Inspect the stern brackets for binding Tighten starboard tilt tube nut...

Page 351: ...ric motor s cu rrent draw and trim tilt unit operating speed aids evalu ation of the electric motor a nd certain mechanical components Use a battery rated at 360 CCA 50 Ah or higher that is in good co...

Page 352: ...Ah or higher that is in good condition and fully charged to per form this test Connect a 0 to 25 A ammeter in series with the battery positive terminal ammete r red le ad toward terminal Attach or ho...

Page 353: ...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 immedia te me ter dam age never apply an ohmmeter to an e...

Page 354: ...hile the tab is depressed pull on the wire from the rear of the connector to release it from the connector Separate the trim tilt unit wires in the braided tube to p ermit remo val t hrough the hole i...

Page 355: ...ugh to remove the ground lead from the pump motor mounting screw 75 90 HP MODELS Remove the externa l snap rings from the up per pin Use a punch to remove the upper pin Retract the tilt cylinder rod R...

Page 356: ...the bushings Install the ground lead Place trim tilt unit into position Lubricate th e an gle adjustment ro d with Triple Guard grease Install the rod Tighten the locknuts to a torque of 20 to 25 ft...

Page 357: ...ilt cylinder rod to match with ho les in swivel bracket Apply Triple Guard grease to upper pin and install the pin Install e xternal snap rings o nto upp er pin with sharp edge facing out ALL MODELS P...

Page 358: ...vidual com ponents may cause fla kes of paint to e nter the hydraulic p assages du ring a ssembly T ape the trim tilt piston rods before painting IMPORTANT Before re moving manual r elease valve relie...

Page 359: ...pect the manual release valve Discard the O rings on the housing Remove t he fou r larg e mo tor flange retaining screws Remove the motor and discard O rin g screws and washers Remove drive coupler fr...

Page 360: ...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 inst all th e ma nual release...

Page 361: ...T Fluid Install the fill plug Run the motor then recheck oil level Cycle the unit several times and check the oil level when the cylinder is fully e xtended Oil should be level with bottom of fill por...

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

Page 363: ...1 14 MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 362 RECOIL STARTER REMOVAL 363 RECOIL STARTER DISASSEMBLY 363 RECOIL STARTER CLEANING AND INSPECTION 365 RECOIL STARTER ASSEMBLY 365 RECOIL STARTER...

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

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

Page 366: ...g and remove ring from the starter Remove the friction plates and friction plate spring washer Hold the pulley in the starter housing while turning the starter over legs do wn Hold fingers clear of th...

Page 367: ...length of 1 2 in 12 mm Examine the pulley and the starter housing Look for shar p edge s an d rough surf aces that cou ld fray the starter rope File and polish to remove Examine the st arter and star...

Page 368: ...e starter winder base Remove the crank retainer screw and the cran k and pin asse mbly from the st arter win der base Remove the starter winder base from the vise Install the rewind spring into the st...

Page 369: ...oss of t he st arter pawl Pla ce spring washer on the boss of the starter pawl Place the starter pawl in the pulley Place th e st arter hou sing sp ring in t he st arter housing Install the starter pa...

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

Page 371: ...LLATION Apply Nut Lock to the thre ads of st arter ratch et screws Install washers and ratchet on flywheel Tighten screws to a torque of 120 to 14 4 in lbs 13 5 to 16 N m Place t he st arter a ssembly...

Page 372: ...370 MANUAL STARTER NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 373: ...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 374: ...S 2...

Page 375: ...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 recommendati...

Page 376: ...RWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of...

Page 377: ...OP propeller What could happen If Operat or ca nnot slow do wn the ou tboard o r shift into NEUTRAL gea r stop prope ller Ope rator could panic and lose control of boat How can loss of speed control b...

Page 378: ...l 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 operato...

Page 379: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom ca n change a set up which was OK earlier If moved up or down eve...

Page 380: ...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...

Page 381: ...tion as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked...

Page 382: ...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 383: ...t s transom Outboard may S L I D E on transom Boat may turnand be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Page 384: ...d may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken Check for a high speed...

Page 385: ...suddenly Boat may SINK At high speeds suddentrimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test y...

Page 386: ...and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key...

Page 387: ...un into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemb...

Page 388: ...Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Repla...

Page 389: ...t hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly P N 396748 use only the spec...

Page 390: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils c...

Page 391: ...haust fumes from the engine o r 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 hig h...

Page 392: ...t Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people i...

Page 393: ...r 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 Bat...

Page 394: ...tches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters...

Page 395: ...re to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little childre...

Page 396: ...al 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 co...

Page 397: ...cting Rod 209 Crankshaft 198 199 203 204 Driveshaft 309 334 Pinion Gear 305 329 Propeller Shaft 310 335 336 Wrist Pin 197 205 Break In EMM Programming 165 220 Gearcase 298 317 320 342 Oiling 165 Proce...

Page 398: ...ming 68 146 Fuel Injector Tests 84 Fuel Pump Test 84 I Command settings 23 Idle Speed Control 68 Oil Injector Test 167 Oil Priming 170 Oiling Rate 66 164 Reports 69 Sensor Monitoring 95 Service Codes...

Page 399: ...l Lift Pump 132 139 141 143 Fuel Manifolds 145 Fuel Requirements 131 Hose Routing 126 Injector Servicing 68 Intake Manifold 149 Minimum Octane 10 12 131 Pressure Tests 137 Priming 136 Relieving Pressu...

Page 400: ...cing 215 243 245 251 253 258 Muffler Installation 219 Removal 192 Servicing 244 N New Engines Outboard Rigging Procedure 17 O Oetiker Clamp Servicing 25 Oil Injector Electrical Circuit 55 V 161 Electr...

Page 401: ...le Adjustment 19 Rigging Outboard 17 Rope Replacement 368 RPM Limit 11 13 59 60 S S A F E Description 62 Low Oil 58 No Oil 162 Temperature 56 57 Safety 1 Sensor Tests 95 Sensors Air Temperature Sensor...

Page 402: ...Tilt 265 Removal 254 SystemCheck Circuits 107 LOW OIL Warning Signal 162 NO OIL Warning Signal 162 Outboard connections 20 Tests 107 108 109 Winterization Procedure 45 T Tachometer Pulse Setting 33 Te...

Page 403: ...ting Kit P N 5005844 138 Key Switch Assembly P N 176408 64 Large Puller Jaws P N 432129 199 309 310 334 335 Lifting Fixture P N 396748 191 192 216 218 Lower Driveshaft Puller P N 342681 326 Oetiker Pi...

Page 404: ...ion 354 Lubrication 41 Removal 352 Reservoir Fluid 11 348 Troubleshooting 348 349 Trim Gauge Test 351 Trim Sender Adjustment 29 30 Test 351 Trim Tab Adjustment 31 Installation 297 Removal 296 318 Trou...

Page 405: ...A Check wiring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendi...

Page 406: ...king Check voltage at injectors Excessive fuel or oil engine flooded Check for leaking injectors leaking fuel or oil lift pump or leaking vapor separator vent refer to FUEL SYSTEM Low or no 55 V alter...

Page 407: ...eck 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 C...

Page 408: ...t 55 V Check voltage on 55 V circuits refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND...

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

Page 410: ...up check for fuel system air leaks Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring...

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

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

Page 413: ...A B C 5 1 2 3 6 4 5 1 2 3 6 4 5 1 2 3 6 4 DRC6165R MWS Instrument Wiring Harness 1 2 5 1 2 3 6 7 4 8 A B C...

Page 414: ...1 I Command Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 5 wa...

Page 415: ...Dual Outboards B M M C A S 3 4 2 5 1 6 5 2 3 4 6 1 Lanyard Switch Emergency Stop Circuits B M M C A S 5 2 3 4 6 1 Single Outboard 000705 B M M C A S...

Page 416: ......

Page 417: ...ND 12V PUL REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASH...

Page 418: ...tion Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will...

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

Page 420: ......

Page 421: ...5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Connector 12 Temperature Sensor 13 Igniti...

Page 422: ......

Page 423: ...ure ABOVE range 3 3 LED 4 ON Running WATER TEMP HOT 8 seconds EMM Temperature 176 F 80 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running LOW BATTERY 5 minutes Bat...

Page 424: ...ltage 4 75 V Check sensors and related wiring Check for pinched or chafed wiring 81 Ignition timing circuit 1 OPEN LED 2 ON Running 10 instances EMM counts failed ignition events Check wiring Test wit...

Page 425: ......

Page 426: ......

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