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Evinrude E-tec 75 HP, Service Manual

The Evinrude E-tec 75 HP is a high-performance outboard engine known for its efficiency and reliability. For comprehensive maintenance and repair guidance, our Service Manual is available for free download from manualshive.com. Ensure the longevity of your engine by accessing this essential manual today.

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51

INSTALLATION AND PREDELIVERY

OUTBOARD INSTALLATION

2

Lifting the Outboard

Lifting Fixtures

Remove shipping carton.

Remove any banding material used to secure out-
board to shipping palette. The mounting hardware
used to attach the outboard to the shipping frame
is reused to fasten outboard to boat transom.

Use correct Lifting Fixture to lift outboard:

Position lifting tool on flywheel and seat the three
screws completely.

IMPORTANT:

Use only the 1 1/8 in. (short)

screws, P/N 398067, included with the tool to
avoid damage to electronic components under the
flywheel.

Fasten appropriate chain hook to eye of tool.
Carefully hoist outboard with chain and unbolt out-
board mounting brackets from frame.

Before Mounting Outboard to Transom

Some rigging components that attach directly to
the outboard should be assembled before the out-
board is mounted to the boat's transom. Steering
system components and gearcase speedometer
pickup hoses are the most common. Determine
what equipment will be installed prior to mounting
the outboard to the transom or bracket.

Steering Systems

Mechanical Cables

All 

Evinrude/Johnson

 outboards equipped with tilt

tubes are designed to be compatible with
mechanical steering systems that meet ABYC
Standard P-17. Single-cable mechanical steering
systems can be used on single or dual-outboard
installations if an ABYC-approved steering link is
used.

Dual-cable mechanical steering helps provide firm
steering control at high speeds.

Extend the output end of the steering cable and
lubricate the inner core of cable prior to installa-
tion.

WARNING

To avoid personal injury, make sure the lift-
ing capacity of the hoist is at least twice
the weight of the outboard.

DO NOT allow the lift hook or chain from
the hoist to come in contact with any part
of the engine during lifting.

Model

Lifting Fixture

2 and 3-Cylinder 

Evinrude

 

E-TEC

P/N 396748

1.

Lifting fixture

2.

1 1/8 in. screws

002098

2

1

CAUTION

If chain hooks or snap hooks are too large,
the integrated lifting eye could break. The
outboard could drop suddenly and cause
serious damage.

ABYC-approved mechanical steering cable.

5873

Summary of Contents for E-tec 75 HP

Page 1: ......

Page 2: ...ul and never rush or guess a service pro cedure Human error is caused by many factors carelessness fatigue overload preoccupation unfamiliarity with the product and drugs and alco hol use to name a few Damage to a boat and outboard can be fixed in a short period of time but injury or death has a lasting effect When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equ...

Page 3: ...edly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery cables at the battery Twist and remove all spark plug leads The electrical system presents a serious shock hazard DO NOT handle primary or secondary ignition components while outboard is running or fly...

Page 4: ...VERY 31 3 MAINTENANCE 71 4 ENGINE MANAGEMENT MODULE EMM 85 5 SYSTEM ANALYSIS 103 6 ELECTRICAL AND IGNITION 123 7 FUEL SYSTEM 155 8 OILING SYSTEM 177 9 COOLING SYSTEM 191 10 POWERHEAD 201 11 MIDSECTION 239 12 GEARCASE 255 13 TRIM AND TILT 285 SAFETY S 1 INDEX Index 1 TROUBLE CHECK CHART T 1 DIAGRAMS EMM SERVICE CODE CHART ...

Page 5: ...GE B 9 TYPICAL PAGE C 10 TYPICAL PAGE D 11 ABBREVIATIONS USED IN THIS MANUAL 12 UNITS OF MEASUREMENT 12 LIST OF ABBREVIATIONS 12 ENGINE EMISSIONS INFORMATION 13 MANUFACTURER S RESPONSIBILITY 13 DEALER S RESPONSIBILITY 13 OWNER S RESPONSIBILITY 13 EPA EMISSION REGULATIONS 13 PRODUCT REFERENCE AND ILLUSTRATIONS 14 SYMBOLS 14 ELECTRICAL 14 VALUES 15 NOTES 16 ...

Page 6: ...luable aid to disas sembly and reassembly This manual presents the U S values and dimensions first and the metric values and dimensions second inside parenthe ses Identifying Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead Model Number Start Shaft Steer E75DPLSUM Electric 20 Remote E90DPLSUM Electric 20 Remote E90DPXSUM Electric 25 ...

Page 7: ... R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex SU 2007 MODEL RUN or SUFFIX DESIGN FEATURES AP Advanced Propulsion B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injection G Graphite Paint H High Output J Jet Drive M Military P Power Trim and Tilt R Rope Start w Tiller Steering S Saltwater Edition T Tiller Steering TE Tiller Electric V White Paint W Commercial Model ...

Page 8: ...me units appear as in lbs Use appropriate torque Tightening torque for a fastener Subsection title indicates beginning of the subsection Italic subheading above Service Chart indicates pertaining models Indicates list corresponding to applicable letter in exploded view of the Service Chart Exploded view of Service Chart assists in identifying parts and positions ...

Page 9: ...ressure hose through cover grommet with oil tank sending unit harness Route hose along battery cables toward the back of the powerhead Use tie straps to fasten in place If temperature gauge is to be used route sending unit wire through grommet with hose for water pressure gauge Follow the path of battery cables Provide adequate length to reach cylinder head Refer to installation instructions suppl...

Page 10: ...rmatex No 2 gasket sealant to inner exhaust housing flange Coat both sides of a new base gasket with Gasket Sealing Compound ALL MODELS Install a new base gasket on adapter To ensure proper sealing mating surfaces must be clean and free of oil grease and foreign matter Coat the driveshaft splines with Moly Lube Do not apply lubricant to end of driveshaft 39820 49557 1 Mount retainer screw 49556 1 ...

Page 11: ...e 38 A faulty electrical circuit or an inoperative pres sure switch activates service code 38 no oil sen sor feedback or lack of oil pressure and the EMM Service Code 39 If no oil pressure is detected during startup the EMM initiates an oil injector recovery mode to pressurize the system If inadequate oil pressure is still detected after the recovery mode is com pleted the EMM TYPICAL 1 Lower puls...

Page 12: ...op dead center AT air temperature sensor BPS barometric pressure sensor BTDC before top dead center CCA cold cranking amps CPS crankshaft position sensor DI Direct Injection ECU electronic control unit EMM engine management module ICOMIA International Council of Marine Industry Associations MCA marine cranking amps MWS modular wiring system NMEA National Marine Electronics Assoc NTC negative tempe...

Page 13: ...standards The owner operator is not to and should not allow anyone to modify the outboard in any manner that would alter the horsepower or allow emis sions levels to exceed their predetermined factory specifications Tampering with the fuel system to change horse power or modify emission levels beyond factory settings or specifications will void the product war ranty EPA Emission Regulations All ne...

Page 14: ... as representative views for refer ence only Certain features or systems discussed in this manual might not be found on all models in all marketing areas All service technicians must be familiar with nauti cal orientation This manual often identifies parts and procedures using these terms SYMBOLS Throughout this service manual symbols are used to interpret electrical troubleshooting results or to ...

Page 15: ...stance Ω is the sym bol for ohm the unit of measurement for resis tance Values When precedes a value on the meter face the reading must be less than or equal to the value shown When precedes a value on the meter face the reading must be greater than or equal to the value shown DR4205 DR4206 DR4207 ...

Page 16: ...16 INTRODUCTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 17: ...CIAL TOOLS 17 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA 18 STANDARD TORQUE SPECIFICATIONS 20 SPECIAL TOOLS 21 ELECTRICAL IGNITION 21 FUEL SYSTEM 22 GEARCASE 22 POWERHEAD 24 UNIVERSAL 25 SHOP AIDS 27 ...

Page 18: ...tandard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bottom Crankshaft Journal 1 5747 to 1 5752 in 40 0 to 40 01 mm Rod Crankpin 1 3757 to 1 3762 in 34 94 to 34 96 mm Piston Ring End Gap Both 0 011 to 0 023 in 0 ...

Page 19: ... Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC12PEPB 0 030 003 in 0 76 mm GEARCASE Gear Ratio 20 in L Models 13 26 500 25 in X Models 12 27 444 2 1 2 25 1 Lubricant HPF XR Gearcase Lube Capacity 20 in L Models 31 6 fl oz 935 ml 25 in X Models 32 8 fl oz 970 ml Shift Rod Height 20 in L Models 21 25 539 75 mm one half turn 25...

Page 20: ...These values apply only when a specific torque for a specific fastener is not listed in the appropri ate section When tightening two or more screws on the same part DO NOT tighten screws completely one at a time WARNING Torque wrench tightening specifications must be strictly adhered to Replace any locking fastener locknut or patch screw if its locking feature becomes weak Defi nite resistance to ...

Page 21: ... 005444 Interface cable P N 437955 45583 Stator Test Adapter P N 5005799 002273 Peak reading voltmeter P N 507972 49799 Bootstrap tool P N 586551 002276 Crimping pliers P N 322696 30387 Tachometer timing light P N 507980 49789 Analog multimeter P N 501873 49793 Connector Tool P N 342667 42004 AMP connector tools Primary Lock Tool P N 777077 Secondary Lock Tool P N 777078 Release Tool P N 351413 Lo...

Page 22: ...Fuel pressure gauge 60 PSI P N 5007100 90 fitting P N 353322 005135 Fuel pressure gauge 100 PSI P N 5000902 002275 Nipple Kit P N 5005844 002465 Gearcase filler P N 501882 49790 Gearcase pressure tester P N 507977 Stevens P N S 34 Gearcase vacuum tester P N 507982 Stevens P N V 34 49794 Prop shaft housing seal installer P N 336311 P N 326551 32973 ...

Page 23: ...r P N 328367 41553 Driveshaft puller P N 390706 32884 1 2 1 2 Seal installer P N 330268 32924 Driveshaft seal protector P N 318674 23692 Driveshaft socket P N 311875 23261 Lower driveshaft puller P N 342681 47257 Pinion bearing installer P N 350958 000818 Pinion bearing spacer P N 341437 38348 Pinion nut starting tool P N 342216 40372 Prop shaft front bearing installer P N 339750 32880 ...

Page 24: ... bearing remover and installer kit P N 391257 33974 Gauging Head S Type Gearcases P N 352879 005072 Shift rod height gauge P N 389997 32872 Crankshaft bearing and sleeve installer 1 P N 338647 2 P N 338649 21953B Cylinder bore gauge P N 771310 45303 1 2 Ring compressor standard P N 336314 Ring compressor oversize P N 336313 CO3768 Lifting ring assembly P N 396748 000669 Piston stop tool P N 342679...

Page 25: ... 336660 41029 Wrist pin pressing pin P N 326356 23668 1 Wrist pin retaining ring driver P N 318599 2 Wrist pin cone P N 318600 DR1641 1 2 Flywheel holder P N 771311 42938 Fresh water flusher P N 500542 50110 Large puller jaws P N 432129 23148 Small puller jaws P N 432131 23150 Bearing puller jaws P N 432130 23149 Puller Bridge P N 432127 23146 ...

Page 26: ...O1577 Slide hammer P N 432128 15345 Slide hammer adapter P N 390898 15356 Slide hammer adapter P N 340624 39435 Syringe P N 346936 50243 Temperature Gun P N 772018 45240 Tilt tube nut wrench P N 342680 46879 Tilt tube service kit P N 434523 33249 Universal Puller Set P N 378103 32885 ...

Page 27: ... Multi Purpose Lubricant P N 777192 Oil XD100 P N 777118 Ultra 4 Stroke Outboard Oil P N 775594 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 777225 4 Stroke Outboard Oil P N 775597 Anti Corrosion Spray P N 777193 Silicone spray P N 775630 Oil XD30 P N 777219 HPF XR Gear Lube P N 778747 ...

Page 28: ...ing Oil P N 777186 Lubriplate 777 P N 317619 Triple Guard Grease P N 508298 Needle Bearing Grease P N 378642 Power Trim Tilt and Power Steering Fluid P N 775612 Black Neoprene Dip P N 909570 Extreme Pressure Grease P N 508303 Starter Bendix Lube P N 337016 Biodegradeable TNT Fluid P N 763439 Electrical Grease P N 504824 ...

Page 29: ... System Cleaner P N 777184 Gel Seal II P N 327361 ThreeBond 1104 P N 351052 ThreeBond 1207B P N 351053 Gasoila Thread Sealant P N 200763 Carbon Guard P N 775629 Gasket Sealing Compound P N 317201 Pipe Sealant with Teflon P N 910048 1 Screw Lock P N 500417 Loctite Purple 222 equivalent 2 Nut Lock P N 500421 Loctite Blue 242 Equivalent 3 Ultra Lock P N 500423 Loctite Red 271 Equivalent 1 2 3 ...

Page 30: ... SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Locquic Primer P N 772032 GM Gear Mark Compound P N 772666 Adhesive 847 P N 776964 Thermal Joint Compound P N 322170 Instant Bonding Adhesive P N 509955 ...

Page 31: ...ONTROL CABLE ADJUSTMENTS 54 WIRING HARNESS CONNECTIONS 56 WATER PRESSURE CONNECTION 56 FUEL AND OIL PRIMING 57 FUEL REQUIREMENTS 57 FUEL SYSTEM PRIMING 58 OIL REQUIREMENTS 59 OIL INJECTION RATE 59 SYSTEMCHECK LOW OIL WARNING TEST 59 OIL SUPPLY PRIMING 60 BREAK IN OILING 60 BEFORE START UP 61 GEARCASE LUBRICANT 61 OIL LEVEL 61 TRIM AND TILT FLUID 61 RUNNING CHECKS 62 SYSTEMCHECK OPERATION 62 EMERGE...

Page 32: ...ional remote control information Power trim tilt switch s can be integral to the remote control for outboards with power tilt and trim Side mount controls require a neutral lock fea ture Single outboard binnacle remote controls are offered with or without an integrated key switch Dual outboard binnacle remote controls require separate key switches and a single emergency stop switch WARNING The rem...

Page 33: ...board when the cables are routed from the side of the splash well IMPORTANT Cables of the proper length style and quality that are correctly installed and adjusted will eliminate most control related opera tional problems SystemCheck Monitor The SystemCheck engine monitor alerts the oper ator of certain engine problems Refer to the Operator s Guide for detailed information related to the various w...

Page 34: ...NT Connect the battery positive cable to the battery positive post FIRST Con nect the battery negative cable 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 IMPORTANT Do not use wing nuts to fasten ANY battery cables Wing nuts can loosen and cause electrical system ...

Page 35: ...ction can be used for emergency starting if a primary battery becomes discharged The OFF position of the battery selector switch can be used to minimize battery discharge during periods of non use Typical battery functions Primary Used as starting battery under normal operating conditions Red cable connected to battery selector switch Primary battery is charged by connection to main red outboard b...

Page 36: ... to the installation of switch Fasten all battery switches to solid surfaces Route wiring as directly as possible Support the battery switch as needed to prevent abrasion Use appropriate wiring and connectors Seal all connections and terminals with liquid neoprene or electrical sealer to prevent corro sion IMPORTANT Insulate all battery positive terminals to prevent shorting Battery Switch Operati...

Page 37: ...for each outboard 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 One outboard Battery disconnect One outboard One primary starting battery one secondary battery OFF ON PRIMARY 1 S 000135rev1 SECONDARY PRIMARY S 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 1 1 1 2 2 000134rev2 1 2 OFF BOTH 2 Positive Battery cables Negative Battery cables ...

Page 38: ...LLATION AND PREDELIVERY BOAT RIGGING Two outboards One primary starting battery for each outboard PRIMARY 1 PRIMARY 2 S S 000086rev2 1 2 OFF BOTH 1 2 OFF BOTH 1 2 Positive Battery cables Negative Battery cables ...

Page 39: ...should be as short and horizontal as possible Use corrosion resistant metal clamps on perma nently installed fuel hoses Multi outboard applications require separate fuel tank pickups and hoses A fuel selector switch may be used for kicker motors as long as it has enough flow capacity for the larger out board Fuel System Primer Outboards require a priming system capable of refilling the fuel system...

Page 40: ... Supply Configuration 1 Primer bulb 2 Water separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC6797 1 2 3 Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5 16 in 7 9 mm min I D 3 8 in 9 5 mm min I D Fuel fittings 1 4 in 6 4 mm min I D 9 32 in 7 1 mm min I D Fuel supply hoses 5 16 in 7 9 mm min I D 3 8 in 9 5 mm min I D ALL MODELS Fuel tank pickup screen ...

Page 41: ...nd Wire Harness Routing Remote control cables wiring and hoses must follow a similar path into the lower motor covers Select the best routing possible for the specific application Proper remote control cable lengths are essential Installations must provide adequate slack for all cables wiring and hoses Check clearances of routings at all trim angles at all steering positions and at all possible co...

Page 42: ...es be sure to Route cables through the protective sleeve and to the appropriate location and Use the most direct path to route the battery cables to the battery or battery switch Fuel Hose Route the fuel supply hose with adequate slack to allow for the primer bulb to be held with the arrow pointing up during use The fuel hose routing could be the only hose routed outside of the protective sleeve o...

Page 43: ...he clamping range of the clamp Oetiker Stainless Steel Stepless Clamps WARNING DO NOT re use Oetiker clamps Fuel leak age could contribute to a fire or explosion 1 Clamp identification numbers 000093 1 CLAMP NO NOMINAL O D INCHES MILLIMETERS Replacement Clamp I D Inches MM Open Closed Open Closed 346930 95 3 8 9 5 0 374 0 307 9 5 7 8 348838 105 13 32 10 5 0 413 0 346 10 5 8 8 349516 113 7 16 11 3 ...

Page 44: ...epless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accessories Catalog P N 787145 Position correct size clamp over hose Install hose on fitting Close clamp ear fully with Oetiker pincers pli ers Clamp Removal Method 1 Position Oetiker pincers across clamp ear and cut clamp Method 2 Lift end of stepless clamp with screw driver Method 3 Use Oetiker pincers pliers t...

Page 45: ...ch control cable Put the control handle into NEUTRAL position The throttle cable casing guide will retract com pletely and the shift cable casing guide will go to the midpoint of its travel Extend the control cables and lubricate them with Triple Guard grease 1 Shift cable casing guide extended to midpoint 2 Throttle cable casing guide retracted DP0811 1 2 30501 ...

Page 46: ...kets Transom Clearances Make sure the transom and splash well area pro vide adequate clearances The top edge of the transom should be wide enough to allow full steering travel The ABYC standard for most single outboard installations is 33 in 84 cm Check cable and hose routing clearances Make sure there is clearance for mounting bolts and washers Check the inside area of the tran som for obstructio...

Page 47: ...enterline of the boat transom as it relates to the hull bottom of the boat Use a straightedge to draw a line connecting the port and starboard chines The chines should be used as reference points for determining the cen terline of the hull Use a framing square to accurately place a line on the transom The centerline of the hull should be in line with the keel of the hull and perpendicular to the m...

Page 48: ...ard spacing would result in two outboard centerlines each 13 in 330 mm from the hull centerline Transom Heights Make sure the transom height is consistent with the height of the outboard to be installed A 19 to 21 in 48 3 to 53 3 cm transom height uses a 20 in 50 8 cm shaft outboard The shaft length of the outboard being installed should come close to matching the transom height of the boat Determ...

Page 49: ...s top surface to make both indicators align the transom must be modified IMPORTANT DO NOT assume that the top edge of the transom is straight Position the drill fixture based on measurements aligning it to the bottom of the hull IMPORTANT Maintain at least 1 75 in 45 mm of transom surface above the top mounting bolts Make sure that the proposed mounting hole loca tions will provide adequate cleara...

Page 50: ...2 327053 3 in 76 mm 3 1 2 Bolt Hole Locations 7 318273 Retainer 2 318573 3 1 2 in 89 mm 4 Outside of Transom 8 319886 Screw 4 313327 4 in 102 mm 9 307238 Washer 2 336676 4 1 2 in 114 mm 10 320248 Washer 4 331578 5 in 127 mm 11 313623 Nut 4 321577 6 in 152 mm 12 318572 Cap 4 000133m 2 2 50 8mm 2 50 8mm 8 203 2mm 8 203 2mm 4 15 16 125 4mm 4 15 16 125 4mm 6 7 16 136 5mm 6 7 16 136 5mm 2 3 1 3 3 3 1 5...

Page 51: ...n Determine what equipment will be installed prior to mounting the outboard to the transom or bracket Steering Systems Mechanical Cables All Evinrude Johnson outboards equipped with tilt tubes are designed to be compatible with mechanical steering systems that meet ABYC Standard P 17 Single cable mechanical steering systems can be used on single or dual outboard installations if an ABYC approved s...

Page 52: ... in dual out board installations Refer to steering system man ufacturer s recommendations and to Dual Outboard Centerlines on p 47 Drag Links Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm For single motor single cable applications the drag link should be installed in the rear hole Use the correct drag link to allow full steering travel WARNI...

Page 53: ... for below waterline use Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces when removed Apply marine sealer under hex heads of bolts on the mounting plates and to the bolt shanks Assemble transom mounting plates on mounting bolts Apply sealant around the mounting bolt holes on the outer surface of the transom Install the mounting bolts through the trans...

Page 54: ...m a watertight seal around the cables Control Cable Adjustments IMPORTANT DO NOT complete final attach ment of cables to throttle and shift levers until all cables wires and hoses have been routed and grommet has been placed into the lower engine cover Pull firmly on shift cable casing to remove back lash With outboard in NEUTRAL place the cable trunnion into the lower anchor pocket and adjust the...

Page 55: ...roper installation review the following steps Place washer on pin Position retainer clip with straight section on the bottom and angled section on the top Use long noses pliers to insert straight section of clip into linkage pin hole Push the clip towards the hole while lifting on the curved end with the pliers Be sure retainer clip fully engages the pin Lock the retainer by moving the angled sect...

Page 56: ...ors check that the seal is in place Clean off any dirt from connectors Apply a light coat of Electrical Grease to the seal Push connectors together until latched Arrange connectors in flywheel cover Install electrical cover and secure with screws IMPORTANT Check to make sure wires are not pinched and cannot contact flywheel Water Pressure Gauge Fitting and hose for accessory water pressure gauge i...

Page 57: ...eposits which can damage the out board Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other fuel additives can result in poor performance or engine damage Evinrude Johnson 2 4 Fuel Conditioner will help prevent gum and varnish deposits from form ing in fuel system components and will remov...

Page 58: ...tting on outboard Secure hose with Oetiker clamp Route fuel supply hose through flexweave sleeve if necessary The fuel primer bulb must be acces sible Use the primer to fill the outboard s fuel system Once the fuel system has filled pressurize the fuel supply hoses by squeezing the fuel primer bulb or momentarily activating the boat mounted electric fuel primer Observe all fuel lines both in the b...

Page 59: ...al XD100 OIL CONTROL setting requires the use of Evinrude XD100 out board lubricant Running the outboard in XD100 OIL mode can reduce oil consumption by approxi mately one third Refer to Oil Control on p 98 Powerhead oil programming labels are provided to identify EMM oil programming Install the cor rect label to alert user to specific oil requirements SystemCheck Low Oil Warning Test IMPORTANT Le...

Page 60: ... the oil to fuel hose Observe oil flow through the oil distribution hoses The oiling system can also be primed using the Self Winterizing feature if diagnostic software is not available Refer to STORAGE on p 81 Break In Oiling IMPORTANT DO NOT add oil in the fuel tank on Evinrude E TEC models The Engine Management Module EMM will auto matically supply extra oil to the engine during the first two h...

Page 61: ...ate supply of the correct lubricant for the outboard and that the SystemCheck Low Oil Warning Test test has been performed When starting the outboard for the first time refer to Oil Supply Priming on p 60 Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run ning outboard Tilt the motor up and engage the tilt support Remove filler cap and check fluid level If necessary add enoug...

Page 62: ...outboard OFF while remote control is in FORWARD Attempt restarting the outboard Outboard should not start Pull remote control lever back to NEUTRAL and restart outboard Shift remote control lever to REVERSE Turn out board OFF while remote control is in REVERSE Attempt restarting the outboard Outboard should not start WARNING DO NOT run outboard without a water sup ply to the outboard s cooling sys...

Page 63: ... idle speed is essential for proper out board control and shift function Make certain the outboard idles within the specified idle RPM range If the outboard is run on a flushing device the idle speed and quality may not be representa tive of actual in water use Break In When the outboard is delivered the customer should be referred to the correct break in proce dure in the Operator s Guide The Eng...

Page 64: ...boat applications water skiing to high speed performance boating In such cases it might be necessary to have a propeller for each situation Refer to the Evinrude Johnson Genuine Parts and Accessories Catalog for propeller styles and sizes Right hand propellers are considered standard rotation propellers When propelling a boat for ward the propeller rotates in a right hand clockwise direction as vi...

Page 65: ...bs 95 to 109 N m Without Keeper 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the propeller nut Without Keeper and propeller shaft are not aligned tighten the nut until they are in line Do not loosen Insert a new cotter pin through the propeller nut and shaft or propeller nut keeper and shaft Bend its ends over the nut to secure the assembly IMPORTANT After fastening propeller nut make...

Page 66: ...um tilt position Confirm the adjustment by tilting the outboard fully using the trim tilt switch Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it con tacts the motor well To prevent damage to equipment provide addi tional motor well clearance when it is needed Consider either changing the outboard mounting position or modifying the boat if the possibil...

Page 67: ...just the sending unit by pivoting it up or down Lower the outboard against the thrust rod to check adjustment Repeat adjustment if necessary After adjustment is correct tilt the outboard up tighten the two sending unit screws and remove the thrust rod 29072 1 Screws 27339 1 1 Needle at center position 000662 WARNING When the outboard is returned to the cus tomer the trim limiter rod must be instal...

Page 68: ...im tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m Test the boat and if needed repeat the procedure until steering effort is as equal as possible Outboards with High Transom Heights The trim tab may be above the surface of the water when the outboard is trimmed out Steerin...

Page 69: ... be thoroughly tested until the ideal combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small amount of toe out and adjust inward until best results are achieved A typical set up with 2 stroke outboards mounted directly on the transom often runs best with a slight amount of toe in Outboards mounted behind the transom on motor ...

Page 70: ...70 INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 71: ...LLER SHAFT 77 GEARCASE LUBRICANT 77 TRIM AND TILT 78 BATTERY AND BATTERY CONNECTIONS 78 FUEL AND OIL SYSTEMS 79 FUEL FILTER 79 OIL RESERVOIR 79 AIR SILENCER 79 HOSES AND CONNECTIONS 79 SPARK PLUGS 80 INDEXING 80 STORAGE 81 FUEL SYSTEM TREATMENT 81 INTERNAL ENGINE TREATMENT 81 ADDITIONAL RECOMMENDATIONS 82 PRE SEASON SERVICE 82 OUTBOARD MOUNTING BOLTS 82 GEARCASE LUBRICANT 82 BATTERY S 82 POWER TRI...

Page 72: ...Controls steering and tilting check operation lubricate 3 Engine to transom mounting hardware re torque 40 ft lbs 3 Fasteners tighten any loosened components 3 Water intake screens check condition 3 Cooling system check water pump indicator water pressure 3 Anticorrosion anodes check condition 3 Gearcase check condition 3 Propeller check condition 3 Fuel and oil system components inspect and repai...

Page 73: ...hould indicate little or no resis tance If resistance is high check the following Remove the anode and clean the area where the anode is installed Clean the mounting screws Install the anode and do the test again Metallic Component Protection Protect metal components on outboards from cor rosion Use the following products to minimize corrosion Anti Corrosion Spray provides a heavy waxy coating to ...

Page 74: ... water inlet pressure between 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 65 Place outboard in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Shift the outboard to NEUTRAL with the propeller removed Turn water supply on START outboard Run it at IDLE only Shut OFF the outboard Turn off water supply and r...

Page 75: ...e vapor separator flow water freely Replace water pump LUBRICATION Steering System Grease the stainless steel output end of the steer ing cable with Triple Guard grease Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease Make sure wiper nut is installed and not damaged TYPICAL 1 Water intake screen 2 Overboard water pressure dsc...

Page 76: ... cable casing guides from pins IMPORTANT DO NOT disturb cable trunnion adjustments Shift remote control into FULL THROTTLE REVERSE position to fully extend the plastic cas ing guides Apply Triple Guard grease to Cable attachment pins of both the throttle and shift levers Brass inner casings of both the throttle and shift cables Shift the remote control to the NEUTRAL IDLE position Install control ...

Page 77: ...is black in color with a burnt odor indicates worn overheated oil Pressure and vacuum check gear cases with apparent leaks Repair all leaks Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 72 for service frequency and recommended lubricants Refer to LUBRICANT on p 258 for complete gearcase lubricant filling procedures Refill the gearcase with HPF XR Gearcase Lubri cant If HPF XR Gearcase Lubr...

Page 78: ...le last Clean all terminals battery posts and connectors with a solution of baking soda and water Use a wire brush or battery terminal tool to remove cor rosion buildup Rinse and clean all surfaces Reinstall battery and tighten connections securely Refer to Battery Installation on p 34 IMPORTANT DO NOT secure battery cables with wing nuts Coat all connections with Triple Guard grease and insulate ...

Page 79: ...filled and oil supply is not contaminated Air Silencer The air silencer on Evinrude outboards minimizes audible noise related to air flow into the engine Routine cleaning of the air silencer is recom mended to remove any accumulation of debris Hoses and Connections Check condition of all hoses and connections related to both the fuel and oil systems Visually inspect all components Observe all clam...

Page 80: ... the spark plug that is in line with the OPEN side of the ground electrode This mark will be used to orient the spark plug with the OPEN side of the ground elec trode facing the fuel injector Apply Triple Guard grease to the gasket surface of the spark plugs Install all spark plugs and tighten them to a torque of 15 ft lbs 20 N m If the mark is in unshaded area do not tighten any more If the mark ...

Page 81: ...e After approximately 15 seconds SystemCheck lights will go off move throttle control to IDLE position SystemCheck lights will illuminate again Run the outboard with throttle control in IDLE position for another 15 seconds System Check lights will go off Next with outboard still in NEUTRAL advance throttle control to FULL 100 throttle position SystemCheck lights will flash The outboard will automa...

Page 82: ...rtain it has been reinstalled with factory specified hardware Refer to INSTALLATION AND PREDELIVERY section for proper set up procedures Outboard Mounting Bolts Check and re torque outboard mounting bolts and nuts to 40 ft lbs 54 N m Gearcase Lubricant Check the lubricant level Inspect gearcase for leaks If leak is apparent pressure and vacuum test gearcase Repair gearcase as needed Battery s Repl...

Page 83: ...l fuel hoses filters and fuel tanks Drain and clean oil tank and oil injection hoses Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime fuel and oil systems Refer to FUEL AND OIL PRIMING on p 57 Make sure all oil injection hoses are clean and filled with oil Make sure high pressure fuel system does not contain water Flush as needed Inject a small amount of outboard lubricant...

Page 84: ...84 MAINTENANCE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 85: ...ERY 92 SHUTDOWN MODE 92 EMM DIAGNOSTICS 93 LED INDICATORS 93 DIAGNOSTIC SOFTWARE PROGRAMS 94 COMMUNICATION 94 PROGRAM INFORMATION 95 SERVICE CODES FAULTS 95 STATIC TESTS 96 DYNAMIC TESTS 97 OIL CONTROL 98 STARTER MODE TILLER REMOTE PROGRAMMING 98 TIMING VERIFICATION 98 TPS CALIBRATION 99 IDLE SPEED 99 FUEL INJECTOR SERVICING 99 FUEL CONTROL ADJUSTMENT 100 REPORTS 100 SOFTWARE REPLACEMENT 101 EMM T...

Page 86: ...and functions Fuel and ignition timing and duration Ignition system primary voltage output Fuel injector activation Oil injector pump activation Electric fuel pump control Alternator output 55 V and 12 V Idle speed control RPM limiter Electrical circuit monitoring Service codes and warning system activation ROM verification self test Choke less cold starting Output of real time diagnostic data Tac...

Page 87: ...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 below 45 volts with outboard running 500 to 1000 RPM or is below 52 volts with outboard running above 1000 RPM the EMM 12 V Circuit Sensor Monitors the EMM s 12 V alternator circuit If battery voltage exceeds 15 5 volts the EMM If battery voltage is below 12 volts ...

Page 88: ...ylinder head The sensor is a negative temperature coefficient thermistor NTC It provides engine temperature information to the EMM The EMM uses this infor mation to control engine operation and to activate the overheat warning system If engine temperature exceeds 212 F 100 C the EMM If engine temperature exceeds 248 F 120 C the EMM The outboard will not restart after a temperature related SHUTDOWN...

Page 89: ...utboard is started the code is stored If code 11 is present as both a Hard Fault and a Stored Fault refer to Control Cable Adjust ments on p 54 Crankshaft Position Sensor The CPS is a magnetic device It is mounted in the throttle body adjacent to the flywheel Encoder rib spacing on the flywheel coincides with crankshaft position As the encoder ribs of the fly wheel pass the magnetic field of the C...

Page 90: ...gnition timings 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 damage due to excessive RPM At 6250 RPM fuel and ignition to the cylinders is shut off Normal engine operation resumes when engine RPM returns to the specified range Neutral RPM Limiter This...

Page 91: ...43 1 Engine Management Module EMM 2 Battery 12 volt 3 Stator 4 Crankshaft Position Sensor CPS 5 Throttle Position Sensor TPS 6 Neutral Switch 7 Air Temperature Sensor AT 8 Oil Pressure Switch component of 11 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fuel Injector 14 Tachometer SystemCheck Gauge 15 Diagnostic Connector 16 LED Indic...

Page 92: ... MODE Outboard shutdown will occur if specific faults are detected by the EMM Conditions that initiate shutdown To recover from shutdown mode the EMM must not detect the related fault at start up IMPORTANT Shutdown related to code 57 requires the removal of the stored service code Use the diagnostic software program to erase a code 57 Code 57 occurs when the EMM detects abnor mally high RPM relati...

Page 93: ...de 18 system voltage 55 V above range Code 26 low battery 12 V voltage Code 27 high battery 12 V voltage LED 2 Damaged injector circuit ignition primary circuit or fuel pump circuit INJECTOR IGNITION FAULT For LIGHT ON investigate possible fault codes Code 51 cylinder no 1 injector circuit open Code 52 cylinder no 2 injector circuit open Code 53 cylinder no 3 injector circuit open Code 61 cylinder...

Page 94: ...n is accessed through Diagnostic Software running on a laptop computer or a PDA connected to the outboard IMPORTANT For software help refer to Help Info in the Evinrude Diagnostics software or to the PDA software User s Guide Communication Locate the diagnostic connector on the engine Remove the cover and install the Diagnostic Inter face Cable P N 437955 Connect the 9 pin connector of the interfa...

Page 95: ...e outboard is running Dynamic information updates quickly and allows the viewer to monitor voltage changes The displayed information can be used for troubleshooting and checking outboard infor mation Service Codes Faults Service codes are fault conditions the EMM has identified A service code may be stored as a result of some unidentified problem or condition If no codes are displayed the engine h...

Page 96: ...nition Test Use the diagnostic software to test each ignition circuit Refer to Static Spark Test on p 116 Check each circuit for continuity between the EMM and individual coil Check the resistance of the ignition coil windings Refer to Ignition Coil Tests on p 128 Fuel Test Use the diagnostic software to test each fuel injec tor The injector should make an audible click Make sure the injector bein...

Page 97: ...erheat This test is used to simulate an overheat situation and is used to check the ENG TEMP or HOT circuit of the SystemCheck gauge Check Engine This test is used to check the CHECK ENGINE circuit of the SystemCheck gauge Tachometer This test is used to check operation of the tachom eter circuit Dynamic Tests Dynamic tests are performed with the outboard running Fuel Test The Fuel Test is perform...

Page 98: ...r Mode Tiller Remote Programming This feature provides specific programming related to neutral switch operation Tiller conver sion kit installation requires programming of the EMM Tiller operated models must be set to TILLER Timing Verification Use the Ignition Timing screen of the diagnostic software to check and adjust EMM timing EMM timing must be synchronized to crankshaft posi tion Refer to T...

Page 99: ...parts Idle Speed Use Idle Adjust of the diagnostic software to increase or decrease the IN GEAR IDLE speed This Idle Offset can be set for approximately 600 to 1000 RPM The usable scale of this function is is 250 to 100 Once Idle Offset is changed the EMM will continue to control engine operation nor mally Engine idle speed is not fixed This idle speed adjustment offsets increases or decreases the...

Page 100: ...rd is started or while it is running Fac tory fuel flow settings are restored when the key switch is returned to the OFF position Reports Engine reports provide service records and can be used to document the running history of an out board Reviewing this information can help iden tify or resolve some service issues Clicking the print button in several windows of the diagnostic software allows the...

Page 101: ...and follow the help info instructions pro vided in the program IMPORTANT Whenever the EMM is replaced timing verification must be performed Refer to Timing Verification on p 143 SystemCheck ENGINE MONITOR The SystemCheck engine monitor warns the operator of conditions that could damage the engine The monitoring system consists of a dash mounted gauge with four light emitting diodes LED a warning h...

Page 102: ...turning the indicator lights on simultaneously then off in sequence This self test routine might occur more than once during start up if battery voltage drops to 7 V Self test repeats if the key switch is turned OFF and ON Service Mode SystemCheck goes into a service mode if the key is left ON after self test engine NOT running All light circuits and sensors are active but the horn is not Groundin...

Page 103: ...111 VOLTAGE TESTING 112 START CIRCUIT 112 ELECTRIC STARTER OPERATION 112 STARTER SOLENOID ACTIVATION 113 IGNITION AND ELECTRICAL CIRCUITS 114 IGNITION OUTPUT 115 WIRING INSPECTION 115 IGNITION VOLTAGE 115 SYSTEM VOLTAGE 116 STATIC SPARK TEST 116 RUNNING IGNITION TESTS 117 IGNITION PRIMARY CIRCUIT RESISTANCE TEST 118 CRANKSHAFT POSITION SENSOR CPS TEST 118 FUEL DELIVERY 119 MANIFOLD PRESSURE TEST 1...

Page 104: ...ire Color 1 Stator winding yellow Yellow White 2 Stator winding yellow Yellow 3 Stator winding orange Orange White 4 Stator winding orange Orange 5 Stator winding brown Brown White 6 Stator winding brown Brown 001875 Pin No Description of Circuit Wire Color 1 Oil Pressure switch Tan White 2 Diagnostic connector Red 3 Diagnostic connector White 4 vacant 5 vacant 6 Crankshaft position sensor CPS Yel...

Page 105: ... ground Black 17 Ignition ground Black 18 vacant 19 Ignition cylinder 2 Orange Purple 20 Injector ground Black 21 Injector ground Black 22 vacant 23 Oil solenoid Blue 24 Ignition ground Black 25 vacant 26 Ignition cylinder 1 Orange Blue 001877 Pin No Description of Circuit Wire Color 1 Stator winding 1S Yellow 2 Stator winding 2S Brown 3 Stator winding 3S Orange 4 Fuel pump control Brown 5 Ground ...

Page 106: ...enoid ground terminal screw to Injector circuits check continuity to terminal pins 14 20 and 21 of the EMM J1 B connector Ignition circuit check continuity to terminal pin 16 of the EMM J1 B connector Power supply check continuity to terminal pins 6 7 and 8 of EMM J2 connector Starter solenoid check continuity at terminal B Trim and Tilt module check connection at main ground terminal solenoid mou...

Page 107: ...D 3 Light ON Sensor 5 V circuits SEN SORS OKAY LED 4 Light ON Lanyard Stop circuit not grounded LANYARD STOP OKAY Refer to EMM DIAGNOSTICS on p 93 for addi tional diagnostic information Running Mode Light ON indicates system is MALFUNCTIONING LED 1 Light ON Low charging output less than 30 V CHARGING FAULT LED 2 Light ON Injector or ignition circuit malfunction INJECTOR IGNITION FAULT LED 3 Light ...

Page 108: ...ng Observe the outboard and confirm the actual symptoms Refer to TROUBLE CHECK CHART at the end of this manual Inspect spark plugs for indication of wear oil fowling or damage A rich or lean running con dition or evidence of internal engine damage could be identified by the appearance of the spark plugs Make sure the outboard can be turned over easily There should not be any mechanical binding Che...

Page 109: ...S on p 164 for fuel system pressure tests No spark on one or more cylinders Note cylinder with no ignition output Refer to IGNITION OUTPUT on p 115 Monitor cranking RPM using the diagnostic pro gram 300 RPM minimum Check CPS operation verify RPM reading Perform ignition coil resistance test s Refer to Ignition Coil Tests on p 128 Use the Evinrude Diagnostics Software pro gram to check ignition vol...

Page 110: ...ircuit has been identified as malfunctioning a thorough inspection of all related wiring and connections must be per formed Check all voltage inputs and grounds and perform resistance tests for all circuits prior to replacing any suspect components Testing with Timing Light An inductive timing light can be used to monitor ignition system output and the activation of fuel injectors and the oil inje...

Page 111: ...ircuit voltages prior to replacing EMM for faulty injector or pump control function Inductive Amp Meter Test Use an inductive amp meter to monitor battery charging and current flow Identifying erratic amperage in a circuit can be used to isolate a problem component Engine Monitoring Information Use the Evinrude Diagnostics Software program to access the engine Monitor screen This screen display pr...

Page 112: ...ngs Determine if the voltage source or the wiring and connections of the circuit are the prob lem START CIRCUIT The start circuit provides the required current to the starter motor and associated electrical circuits Electric Starter Operation The starter must engage and turn the flywheel A minimum cranking speed of 300 RPM must be achieved for the outboard to start Optimum starter performance is a...

Page 113: ...y switch and 12 V is applied to neutral safety switch Neutral Safety Switch Remote Control Terminal S of the key switch provides 12 V yel low red to the neutral safety switch key switch in START position A depressed or activated neutral safety switch in remote control provides 12 V to the engine wire harness yellow red wire key switch in START position and terminal A of starter solenoid 1 Starter ...

Page 114: ...pply EMM digital ground ignition grounds and injector grounds must be functional Crankshaft Position Sensor Provides EMM with input Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated Alternator Output Voltage Alternator output from EMM white red pro vides 55 V to the high pressure fuel pump the oil injector pump the fuel injectors and the igni tion module of EMM Capacitor...

Page 115: ...ion voltage is GOOD check voltage with outboard run ning Refer to Static Spark Test on p 116 KEY ON no voltage check system voltage to EMM Refer to System Voltage on p 116 RUNNING 200 V 10 Ignition voltage is GOOD Refer to Static Spark Test on p 116 RUNNING less than 200 V 10 check stator output to EMM Refer to System Voltage on p 116 and Stator Tests on p 129 Low or no voltage on EMM ignition cir...

Page 116: ...cluding the ignition module of the EMM Power is normally supplied to the EMM when the key switch is ON Switched B 12 V is supplied to the engine wire harness Voltage enters the EMM at pin 10 purple of the EMM J1 B connector Static Spark Test Perform the static spark test using the Evinrude Diagnostics Software program and a timing light IMPORTANT DO NOT use a spark checker tool with E TEC models R...

Page 117: ... the spark signal through each of the high tension spark plug wires Start outboard and observe the timing light s strobe Look for a consistent flash and only one flash per revolution The strobe of the timing light should be consistent or the same for each cylin der s ignition output IMPORTANT Test on primary circuit if strobe from secondary circuit appears faulty Results Steady voltage and strobe ...

Page 118: ... is 130 V or higher Refer to Secondary Winding Resistance Test on p 128 Repair high tension spark plug lead or replace ignition coil and or high tension spark plug lead assembly Crankshaft Position Sensor CPS Test Use the Evinrude Diagnostics Software program to check RPM reading An RPM display higher than zero indicates a CPS signal to the EMM Cranking RPM is typically 200 RPM or higher Observe E...

Page 119: ...03 kPa after outboard pump is OFF for five min utes Leakdown indicates a fuel system leak or leaking injector Low or no pressure pump runs Suspect damaged fuel pressure regulator in vapor separator or faulty circulation pump Per form Pressure Regulator Test on p 165 Pump does not run Check voltage at pin 1 of fuel pump connector Voltage should be 12 V key ON 55 V cranking or running Check voltage ...

Page 120: ...el supply hose or boat fuel system FUEL INJECTOR OPERATION Neutral Switch The powerhead mounted neutral switch provides a ground signal for the EMM to indicate shift link age position The engine Monitor screen of the diagnostic program provides a display which indi cates switch position NEUTRAL or IN GEAR Make sure switch is operating properly Refer to Neutral Switch on p 90 Static Tests Perform t...

Page 121: ...rientation of the timing light pickup and the oper ation of the timing light to avoid needless part s replacement Results Steady light activation on all injector wires and consistent voltage readings EMM injector control function is good Irregular or no light activation on some injector wires Check the voltage on each circuit Test the resistance of each injector circuit Measure resistance between ...

Page 122: ...122 SYSTEM ANALYSIS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 123: ... WATER TEMP HOT CIRCUIT TEST 133 LOW OIL CIRCUIT TEST 134 NO OIL CIRCUIT 134 REMOTE CONTROL SWITCH TESTS 134 ELECTRIC STARTER TESTS 136 STARTER SOLENOID TEST 136 NO LOAD CURRENT DRAW TEST 137 TILT TRIM RELAY TEST 138 OPERATION 138 TEST PROCEDURE 138 TACHOMETER CIRCUIT TESTS 139 FLYWHEEL SERVICING 140 REMOVAL 140 INSTALLATION 141 TIMING ADJUSTMENTS 142 TIMING POINTER 142 TIMING VERIFICATION 143 TPS...

Page 124: ...8 N m 60 to 84 in lbs 6 8 to 9 5 N m 60 to 84 in lbs 6 8 to 9 5 N m 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m N A T IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock N Starter Bendix Lube T Liquid Neoprene 002...

Page 125: ...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 3 to 40 7 N m X J F T A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock J Thermal Grease T Liquid Neoprene X Refer to Spark Plug Indexing on p 144 002249 ...

Page 126: ...nnector Connect to a pre wired remote control or to a dash mounted key switch Black purple white tan wires Connect to the trim gauge 8 pin connector Connect to a 2 in System Check gauge or to a 3 1 2 in SystemCheck tachometer 2 pin connector Must connect to the warning horn in all installations Black purple gray wires Connect to a con ventional tachometer when a SystemCheck tachometer is not used ...

Page 127: ...ect the battery cables at the battery Remove the electrical connector from the TPS Use an ohmmeter to measure sensor resistance IMPORTANT DO NOT lubricate TPS to throttle shaft surface STEP 1 Connect red meter lead to terminal A and black meter lead to terminal B STEP 2 Connect red meter lead to terminal A and black meter lead to terminal C Rotate the sensor lever through its range of travel Resis...

Page 128: ...nd IMPORTANT A reading of less than 2 ohms is acceptable Make sure meter is calibrated to read 1 ohm or less Secondary Winding Resistance Test Connect ohmmeter between coil secondary termi nal and coil primary terminal Engine Temperature Sensor Resistance 9000 to 11000 Ω 77 F 25 C 1 Engine temperature sensor 002288 AT Sensor Resistance 9000 to 11 000 Ω 77 F 25 C 1 AT sensor 002287 1 1 Ignition Coi...

Page 129: ...ated to read 1 ohm or less STEP 2 To check for a grounded condition connect one meter lead to ground wire and alternately connect the other meter lead to each stator wire Meter should read no continuity If meter reads continu ity replace stator due to grounded winding Stator Voltage Output Test Use a voltmeter to check the stator output voltage Set meter to read 55 VAC output Disconnect CPS Discon...

Page 130: ...ng Circuit To test the operation of the regulator in the EMM you must be able to run the outboard continuously at approximately 5000 RPM such as in a test tank or on a marine dynamometer The test consists of monitoring the system s response to a partially discharged battery Use a variable load tester to discharge the battery IMPORTANT The regulator requires battery voltage on the red wire to opera...

Page 131: ...With the key switch ON check battery voltage at battery then check voltage on white red wires at J2 connector of EMM Voltage at EMM connector should be 0 5 to 1 V less than battery STEP 3 With outboard running at 1000 RPM voltage on white red wires should increase to 55 V Voltage readings at a specific speed RPM should be steady If there is any other reading perform Stator Resistance Tests on p 12...

Page 132: ...turn on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the key switch ON Test for battery voltage between instrument harness terminal 1 purple wire and terminal 2 black wire If battery voltage is present replace the gauge If there is no battery voltage check that 12 V is present at terminal B of the key switch Check condition of the instrument har...

Page 133: ...wire of 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 MWS har ness receives a signal from the EMM The EMM receives information from the temperature sensor on the cylinder head Using a jumper wire connect tan wire pin 6 of the engine harness connector...

Page 134: ... connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits REMOTE CONTROL SWITCH TESTS Key Switch Test Refer to Wiring Diagrams at back of manual Use an ohmmeter or a continuity light to test key switch operation Replace switch if results are incorrect with any of the following tests IMPORTANT Disconnect battery and key switch wiring before pro...

Page 135: ...urn the key switch to START Meter must NOT indicate continuity Move the remote control handle to REVERSE and turn the key switch to START Meter must NOT indicate continuity IMPORTANT Reconnect shift cable and MWS instrument harness connector to key switch har ness connector Neutral Start Switch Test Use an ohmmeter or a continuity light to test neu tral start switch operation IMPORTANT All wiring ...

Page 136: ... running ELECTRIC STARTER TESTS Starter Solenoid Test Disconnect the B POS battery cable at the bat tery IMPORTANT Disconnect all wiring from sole noid terminals before proceeding with this test Use an ohmmeter to measure resistance STEP 1 Put one ohmmeter lead on the starter positive cable terminal and the other ohmmeter lead on the battery positive cable terminal Ohmmeter must not show continuit...

Page 137: ...r suitable fixture before proceeding with this check Use a battery rated at 500 CCA 60 amp hr or higher that is in good condition and fully charged Use an inductive ammeter or connect a 0 to 100 amp ammeter in series with a heavy jumper between the battery positive terminal and the starter positive terminal Fluke model 334 or 336 Snap On model MT110 or EETA501 and various other ammeters should be ...

Page 138: ...onnec tion to TNT motor Terminals 87 and 30 are considered normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure red and black wires are connected to 12 V battery power supply Set voltmeter to 12 VDC scale Connect test leads to terminals A and B of TNT motor connector Use a wir...

Page 139: ...voltage check the purple red purple and black wiring circuits fuse key switch and battery connections STEP 2 Disconnect instrument harness gray wire and black wire at tachometer Set Fluke 29 Series II meter or equivalent to Hz scale Connect meter between gray wire and black wire With outboard running at 1000 RPM meter should indicate 90 to 105 Hz If meter reads 90 to 105 Hz replace tachome ter If ...

Page 140: ... ponents An accurate test of alternator output can help determine the flywheel s condition Refer to CHARGING SYSTEM TESTS on p 130 Removal Remove the electrical cover from flywheel cover Disconnect wiring for MWS harness and remove wiring from cover Remove fuse holder from flywheel cover Lift flywheel cover to remove WARNING To prevent accidental starting while ser vicing disconnect the battery ca...

Page 141: ...l with body flat side up Attach the puller body with the three shoulder screws and washers Hold puller body with han dle and tighten pressing screw until flywheel releases Turn the center screw and lift the fly wheel off of the crankshaft Installation Install the outer edge of flywheel key parallel with centerline of crankshaft Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solv...

Page 142: ...n the piston firmly against the tool Mark the flywheel directly across from the pointer Label this mark A Rotate the flywheel in a clockwise direction until the piston contacts the tool Mark the flywheel directly across from the pointer Label this mark B Rotate flywheel counterclockwise slightly to release tool and remove it from spark plug hole Use a flexible measuring device to measure the dista...

Page 143: ...eplacement EMM replacement EMM software replacement reprogramming IMPORTANT Make sure the timing pointer is set and the outboard reaches operating tempera ture before timing verification is performed TPS Calibration Use the Evinrude Diagnostics Software program to tell the EMM what the throttle position sensor voltage level is when the throttle plates begin to open Remove the air silencer On the S...

Page 144: ...e ceramic of the spark plug that is in line with the OPEN side of the ground electrode This mark will be used to orient the spark plug with the OPEN side of the ground elec trode facing the fuel injector Apply Triple Guard grease to the gasket surface of the spark plugs Install all spark plugs and tighten them to a torque of 15 ft lbs 20 N m If the mark is in unshaded area do not tighten any more ...

Page 145: ...nd commutator Disconnect the battery cables at the battery Remove port side lower motor cover Refer to Powerhead REMOVAL on p 205 Disconnect battery positive cable from post on starter Remove the three screws from the starter Remove the starter from engine Disassembly Remove the retaining ring spacers spring and starter pinion from pinion shaft Mark the end cap and brush holder cap orienta tion Re...

Page 146: ...y trace of oil or metal dust from commutator Check the armature on a growler for shorted turns using a test light or meter Inspect armature insu lation for indications of overheating or damaged windings Clean off any carbon deposits or foreign matter which could contribute to failure of wind ings Check permanent magnets and make sure they strongly attract any steel or iron object held inside frame...

Page 147: ... the brush card screws before installing Place armature in frame Apply Extreme Pressure Grease to the armature bushing Route the brush leads and install the springs and brushes IMPORTANT Incorrect orientation of the brushes could damage the starter or cause reverse rotation Compress the brushes and springs with a modi fied putty knife Align and place brush holder cap firmly on arma ture and slide ...

Page 148: ...ration of the starter refer to No Load Current Draw Test on p 137 Installation Apply Triple Guard grease to the threads of the two starter screws the double ended stud and also to the washers Position the starter and install the screws and washers Torque to 168 to 192 in lbs 19 to 21 N m Attach starter positive cable to post with lock washer and nut tighten securely Coat connec tions with Black Ne...

Page 149: ...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 latched Wedge in 2 pin receptacle is not symmetrical position latch shoul ders next to terminals Crimping Terminals Strip insulation back 3 16 in 5 mm Place termi nal in 18 gauge notch of Crimping Pliers...

Page 150: ...ctor housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push con nector and seal into housing until seated Align anti backout device with connector housing and terminals Use Secondary Lock Installer P N 777079 to seat device in connector Crimping Terminals Crimping Superseal 1 5 terminals requires the PRO CRIMPE...

Page 151: ...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 plug Connect Push connector until seated in plug Close latch completely Terminal Removal Use Terminal Release Tool P N 351413 to release BOTH locking mechanisms of connector Pull terminal from housing 1 J1 A con...

Page 152: ... into connector housing until seated Packard Connectors IMPORTANT Always use the appropriate meter test probes and adapters when testing compo nents fitted with these terminals Disconnect Lift latch s Remove connector Connect Confirm the seal is in place Push connector onto housing until latched 1 Latch 2 Terminal with seal 002456 1 2 ...

Page 153: ...stall wire gasket on wires and feed wires through the correct terminal position of the con nector housing Terminal is crimped onto wire and then pulled back into connector housing until lock ing tab engages and terminal is seated Crimping Terminals Strip insulation back 3 16 in 5 mm Position end of wire strands in terminal past the wire crimp area and the end of insulation in the insulation crimp ...

Page 154: ...154 ELECTRICAL AND IGNITION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 155: ...M HOSE ROUTING 162 DIRECT INJECTION ELECTRICAL CIRCUITS 163 INJECTOR CIRCULATION PUMP CIRCUITS DIAGRAM 163 FUEL COMPONENT TESTS 164 INJECTORS 164 FUEL SUPPLY 165 FUEL COMPONENT SERVICING 168 RELIEVING FUEL SYSTEM PRESSURE 168 FUEL FILTER 169 FUEL LIFT PUMP 169 VAPOR SEPARATOR 170 FUEL INJECTORS 170 FUEL MANIFOLDS 174 INTAKE MANIFOLD 174 REMOVAL 174 DISASSEMBLY 174 INSPECTION 175 ASSEMBLY 175 INSTA...

Page 156: ...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 60 84 in lbs 6 8 9 5 N m 24 26 Ft lbs 33 35 N m 120 in lbs 14 N m 1 2 3 F A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant S STP Oil Treatment Torque in 3 stages 002154b ...

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

Page 158: ...ator IMPORTANT The oil injector supplies oil to the outboard s incoming fuel supply A limited amount of oil is injected into the fuel supply to clean injec tors and reduce internal fuel system deposits Refer to Oil Supply and Distribution Diagram on p 182 Fuel Filter The in line filter protects the vapor separator and the high pressure components of the fuel system from water and contaminants Refe...

Page 159: ...ER FLOW DIAGRAM on p 192 Venting The fuel vapor vent regulates fuel vapor pressure in the fuel system The vapor separator vent is opened and closed by a float valve The float valve moves relative to the fuel level in the fuel chamber Hot fuel causes an increase in vapor pressure This results in a lower fuel level in the vapor separator The float valve drops and the vent opens This allows fuel vapo...

Page 160: ...the fuel chamber The fuel injec tors receive pressurized fuel from a fuel supply manifold connected directly to the circulation pump Electrical Circuit Activation of the circulation pump is controlled by the EMM The outboard must be cranking or run ning for the circulation pump to be activated Acti vation of the circulation pump requires CPS input to the EMM Fuel Manifolds The fuel supply and retu...

Page 161: ...njector includes these coefficients on a 3 5 in floppy disk The disk also includes the software necessary to install a replacement injector This software enables the EMM to control each injector based on unique fuel flow characteristics IMPORTANT The cylinder location of each injector must always be maintained EMM pro gramming is associated with the cylinder location of each injector Injector Fuel...

Page 162: ...y 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 injector s Fuel return manifold Vent hose to intake manifold Pressure regulator high pressure 6 3 4 Fuel Supply Fuel Return 1 2 8 11 7 9 12 Oil to Fuel 5 13 10 10 10 ...

Page 163: ...h the EMM to ground The injector s internal coil provides approximately 3 ohms of resistance in the injector circuit Requirements for injector or circulation pump acti vation 55 V output from the alternator to the EMM and through the individual circuits and Switched ground connection provided by the EMM IMPORTANT The 55 V alternator output is pro duced by stator input to EMM and rectifier circuits...

Page 164: ...psi 207 kPa Pressure must hold for at least five minutes Static Test Use the Evinrude Diagnostics Software program to test circulation pump and fuel injectors IMPORTANT Static tests are performed when outboard is not running Listen carefully for fuel pump and injector activation These tests are operating components on battery voltage 12 V Resistance Test Disconnect the battery cables at the batter...

Page 165: ...pressure Check fuel supply to fuel lift pump Refer to Lift Pump Vacuum Test on p 167 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Lift pump not supplying adequate fuel to vapor separator Refer to Lift Pump Pressure Test on p 166 If the above requirements are met and vapor separator remains full of fuel suspect damaged circulation pump Replace vapor se...

Page 166: ...e Lift Pump Vacuum Test on p 167 Make certain no air leaks or restrictions exist in the fuel supply hose or boat fuel system Low pressure Check pulse hoses and fittings for restrictions Perform the Lift Pump Vacuum Test on p 167 Make sure no air leaks or restrictions exist in the fuel supply hose or boat fuel system Check fuel flow through fuel lift pump Use fuel primer bulb to force fuel through ...

Page 167: ...s IDLE to WOT A higher vacuum indicates an excessive restric tion in the fuel supply Repair as needed Refer to Fuel System Requirements on p 39 for fuel sup ply component requirements Lift Pump Diaphragm Test Perform this test only if a damaged pump is sus pected This test does not confirm the perfor mance of internal fuel pump check valves Remove the pulse hose from the crankcase fitting Apply 15...

Page 168: ... up any spilled fuel with shop towels WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use caution when working on any part of the fuel system Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure Always disconnect the battery cables at the battery before servi...

Page 169: ...nnect battery cables Run outboard and check for fuel leaks Fuel Lift Pump The fuel lift pump is serviceable as a complete assembly or can be repaired with a fuel pump repair kit Refer to appropriate parts catalog for service parts Removal Disconnect the battery cables at the battery Remove air silencer and lower motor covers as needed Disconnect the fuel lift pump pulse hose at the crankcase fitti...

Page 170: ...on pump Remove clamp and vapor vent hose from separator cover Remove clamps and vapor separator cooling water hoses Remove clamps and fuel return manifold and fuel supply hose from bottom of vapor separator Remove the vapor separator housing retainer clip Remove vapor separator fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts Installation I...

Page 171: ...combustion chamber Removal Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 168 Remove oil tank assembly Remove the injector fuel fitting retainer and disen gage fuel manifold fittings Remove injector screws Disconnect the fuel injector coil electrical connec tor Disengage fuel manifold fittings from fuel injector and remove fue...

Page 172: ...g Installation IMPORTANT All injectors must be installed in the correct cylinder by serial number Improper injector installation can result in outboard failure Installation of replacement injectors requires the use of diagnostic software and coefficient data supplied with all replacement injectors on 3 5 in floppy disk IMPORTANT PDA software requires manually moving the coefficient data file to th...

Page 173: ...lubri cant and insert fuel manifold fittings into injector Both fittings must be fully seated into the injector fuel ports Install retainer and screw Retainer must engage the outer groove of the manifold fittings Reconnect fuel injector coil electrical connectors and high tension spark plug leads with retainers Reconnect battery cables Start outboard briefly to pressurize fuel system Turn outboard...

Page 174: ...al Pay close attention when performing the following additional tasks Connect battery cables Start outboard briefly to pressurize fuel system Turn outboard OFF and inspect all fuel system components for leaks Repair any fuel leaks Install lower engine covers and air silencer INTAKE MANIFOLD Removal Disconnect throttle linkage Remove throttle body screws and throttle body assembly Remove gasket fro...

Page 175: ...ect the intake manifold All gasket surfaces must be cleaned smooth and free of nicks Use a machinist s straight edge to check flatness in all directions Surface must be flat 0 004 in 0 10 mm Inspect the leaf plate assemblies for damage or contamination Leaf plates must not be distorted Leaf valve must not be cracked or chipped Leaf plate stops must not be distorted or loose Leaf plate assemblies m...

Page 176: ...ws Install all screws Tighten the center screws first and expand out ward Tighten in stages Final torque is 60 to 120 in lbs 7 to 14 N m Position gasket on throttle body Install throttle body on reed plate and install screws Tighten the center screws first and expand out ward Final torque is 60 to 120 in lbs 7 to 14 N m Install upper main bearing vent hose and secure with tie strap Connect throttl...

Page 177: ...ION DIAGRAM 182 OIL RECIRCULATION SYSTEM 183 RECIRCULATION HOSE DIAGRAM 183 PRIMING 184 OILING RATES 184 OIL INJECTION RATE 184 BREAK IN OILING 184 OILING SYSTEM TESTS 185 OIL INJECTION PUMP STATIC TEST 185 OIL INJECTION PUMP VOLTAGE TEST 185 OIL INJECTION PUMP CIRCUIT RESISTANCE TEST 186 OIL FLOW TESTS 186 OIL TO FUEL CHECK VALVE TEST 188 LOW OIL SENDING UNIT TEST 188 NO OIL WARNING TEST 188 OIL ...

Page 178: ...4 in lbs 6 8 9 5 N m F 30 42 in lbs 3 4 4 8 N m 30 42 in lbs 3 4 4 8 N m 30 42 in lbs 3 4 4 8 N m F F 002213 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant S STP Oil Treatment ...

Page 179: ... Assembly Components Oil injection pump and distribution manifold Pickup tube and filter Low oil sending unit Oil pressure switch Oil distribution hoses Check valve oil to fuel Oil Pressure Switch The oil pressure switch is located in the oil distri bution manifold and reacts to changes in oil mani fold pressure The EMM supplies and monitors electrical current to the switch The switch opens or clo...

Page 180: ...y monitors the oil level in the tank This sending unit is designed to activate the Sys temCheck LOW OIL light when the oil level falls below one quarter capacity Approximate oil reserve at Low Oil activation 75 90 HP models 0 61 qt 0 57 l IMPORTANT This warning circuit does NOT interact with the EMM If the oil tank is run out of oil the EMM will react to the oil pressure switch input initiate S A ...

Page 181: ...5 V Main harness ground BLACK 55 V to injection pump WHITE RED EMM oil injector pump control BLUE Oil injection pump EMM to switch TAN WHITE Oil pressure switch Low oil switch to SystemCheck gauge TAN BLACK Oil level sending unit 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 J2 4 1 2 3 4 5 6 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 1 4 2 1 3 4 ...

Page 182: ...e is routed to a check valve that is connected to the incoming fuel supply hose This provides a limited amount of oil to keep injec tor nozzles clean Oil Supply and Distribution Diagram 75 90 HP MODELS 1 Pressed in fitting 002359 1 1 2 3 4 5 Oil tank Oil inlet filter Oil pick up Oil injection pump Oil distribution manifold 6 7 8 9 Oil distribution hose cylinder 1 Oil distribution hose cylinder 2 O...

Page 183: ...Bearing Recirculation The movement of oil through the upper main bear ing center main bearing s and lower main bear ing is provided through internal powerhead oil drain passages external fittings and external in line check valve s and hoses Lower to upper main bearing oil flow Lower main bearing cavity to internal crankcase passage to external fitting external hoses with in line check valve to ext...

Page 184: ...C W3 OIL control setting allows the out board to be run on TC W3 outboard lubricant Changing to the optional XD100 OIL CONTROL setting requires the use of Evinrude XD100 out board lubricant Running the outboard in XD100 OIL mode can reduce oil consumption by approxi mately one third See Oil Control on p 98 Two oil programming labels are provided to iden tify EMM oil programming Install the correct...

Page 185: ...t pin 1 white red wire of oil tank electrical connector with key switch ON Results Slightly less than 12 V is acceptable with out board not running See Oil Injection Pump Cir cuit Resistance Test No voltage reading proceed to STEP 2 STEP 2 Check voltage on the 55 V alternator output wires of the EMM The alternator output wires white red are terminals 12 13 14 of the EMM J2 connector Results Proper...

Page 186: ...il injector control circuit of the EMM Check continuity of all wiring and connec tions Oil Flow Tests Running With outboard not running remove oil distribution hose from fitting at oil distribution manifold Do not lose the brass hose support Allow oil in hose to drain allowing air to enter the hose Reinstall hose into manifold IMPORTANT Make sure hose support is in hose and hose is fully inserted ...

Page 187: ... from fitting at oil dis tribution manifold Do not lose the brass hose sup port Temporarily install a 12 in 30 cm length of oil hose P N 776892 Use the Oil Injector static test of the Evinrude Diagnostics Software program to activate oil injec tion pump IMPORTANT Disconnect CPS electrical con nector to prevent engine from starting Crank outboard momentarily to boost voltage to oil injection pump M...

Page 188: ... gauge should activate Once the warning has been verified turn the key switch ON and refill the oil tank Confirm that the LOW OIL warning stops as the oil level exceeds one quarter of oil tank s capacity NO OIL Warning Test STEP 1 Monitor the voltage on the oil pressure switch cir cuit at pin 5 tan white wire of oil tank connector with outboard running at 1500 RPM Use Electrical Test Probe Kit P N...

Page 189: ...oil hose retainer mechanisms incorporated into the design Use a pen or marker to mark the position of the oil hose relative to the retaining mechanism Release the hose by depressing the outer ring of the hose retaining mechanism Once hose is removed from the manifold make sure hose support is in end of the hose Installation Installation is essentially the reverse of removal Pay close attention whe...

Page 190: ... apply Nut Lock to threads of screws Install screws and torque to 30 to 42 in lbs 3 4 to 4 8 N m Install nut and torque to 30 to 42 in lbs 3 4 to 4 8 N m Route oil distribution hoses from the oil distribu tion manifold to the crankcase oil delivery fittings Install protective sleeves and route hoses as they were prior to removal See Oil Supply and Distri bution Diagram on p 182 Connect oil hoses t...

Page 191: ...ENTS 195 GENERAL DESCRIPTION 195 WATER PUMP AND INTAKES 195 WATER SUPPLY TUBE 195 ADAPTER HOUSING 196 PRESSURE RELIEF VALVE 196 THERMOSTAT 197 BLOCK VENTING 197 WATER PRESSURE CONNECTION 197 OPERATION 198 CYLINDER BLOCK CYLINDER HEAD COOLING 198 EMM AND VAPOR SEPARATOR COOLING 198 THERMOSTAT SERVICING 199 DISASSEMBLY 199 INSPECTION 199 ASSEMBLY 199 PRESSURE RELIEF VALVE SERVICING 200 DISASSEMBLY 2...

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

Page 193: ...in range but the SystemCheck gauge indicates a WATER TEMP warning refer to WATER TEMP HOT Circuit Test on p 133 Software Method Use the Evinrude Diagnostics Software program to monitor engine temperature Typical temperature sensor readings at IDLE speed should be 155 F 5 F 68 3 C 3 C Typical temperature sensor readings at WOT speed should be 160 F 40 F 71 C 22 C At 5000 RPM operating temperature m...

Page 194: ...T SERVICING on p 199 Pressure Relief Valve Inspection The pressure relief valve should be closed at IDLE speed Water should not flow past the plunger and seal If IDLE temperature is too low check pressure relief valve plunger and seal for damage or debris that could prevent the valve from closing com pletely If IDLE temperature is still below operating range replace pressure relief valve assembly ...

Page 195: ...ump A nylon wedge impeller key is used to engage the impeller bushing and driveshaft The nylon impeller housing with stainless steel liner must seal against a separate stainless steel water pump plate The pump operates as a positive displacement pump at LOW speeds below 1500 RPM and as a centrifugal pump at HIGHER speeds The bottom plate MUST seal to gearcase hous ing Refer to WATER PUMP on p 262 ...

Page 196: ... speeds above approximately 2000 RPM Pressure relief valve activates or blows off the seat as water pressure increases Spring tension is used to set the blow off pressure Overheating A restricted or faulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing completely The pressure relief valve diaphragm allows the valve plunger to lift off the se...

Page 197: ... A fitting and hose connected to the top of the exhaust cover allows the constant movement of water and or air from the block Circulated water flows through the EMM and vapor separator before exiting through the overboard indicator Water Pressure Connection Fitting and hose for accessory water pressure gauge is connected at top of cylinder block adja cent to the pressure valve housing 1 Cover and ...

Page 198: ...ins on a seat in the cylinder head Water flows through the thermostat only when it is open The thermostat opens at approximately 143 F 60 C At higher speeds temperature is water pressure controlled The pressure relief valve spring ten sion provides the proper blow off pressure The valve lifts from the seat in the cylinder block at approximately 2000 RPM Cooling water flows around the valve to achi...

Page 199: ... Inspection Inspect all components for cracks heat damage or signs of corrosion Replace damaged compo nents Clean debris from all housings and thermo stat components Assembly Assembly is essentially the reverse of disassem bly Pay close attention when performing the fol lowing additional tasks Coat threads of cylinder head thermostat cover with Gasket Sealing Compound and install new O ring Instal...

Page 200: ...g screws Remove the pressure relief valve assembly Inspection Inspect all components for cracks heat damage or signs of corrosion Replace damaged compo nents Clean all debris from pressure relief valve components Assembly Assembly is essentially the reverse of disassem bly Assemble components as shown above Torque cover screws to 60 to 84 in lbs 7 to 9 5 N m 002443 002459 002458 Pressure relief va...

Page 201: ...ION 213 CYLINDER HEAD 213 CRANKSHAFT 214 CYLINDER BORE 214 PISTONS 214 PISTON RINGS 214 BEARINGS 215 ASSEMBLY 216 CRANKSHAFT 216 PISTONS AND CONNECTING RODS 218 CYLINDER HEAD 220 CRANKSHAFT AND CONNECTING RODS 221 CRANKCASE 224 SHIFT LINKAGE 226 THROTTLE LINKAGE 227 GENERAL 227 UPPER MOUNT SERVICING 228 REMOVAL 228 INSTALLATION 228 INSTALLATION 229 POWERHEAD VIEWS 233 PORT SHORT BLOCK 233 STARBOAR...

Page 202: ...cedure Q Apply to crankcase mating flange M Apply to water passages F 60 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m B 60 84 In lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B J A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant J Thermal Grease M RTV Sealant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease ...

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

Page 204: ...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 15 psi 100 kPa between cylinders check for damaged cylinder head damaged pistons broken or stuck piston rings scored cylinder walls Return throttle to idle position and reconnect CPS connector Replace spark plug...

Page 205: ... connector Then remove port and starboard covers Disconnect power trim connectors Remove screw and washer from shift rod lever to release the lower shift rod WARNING Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressure Refer to Relieving Fuel System Pressure To prevent accidental starting while ser vicing disconnect the battery cables ...

Page 206: ...e flywheel Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist Remove the small powerhead screw at rear Remove remaining four small powerhead screws six large powerhead screws and the upper mount screws Use a suitable tool to carefully separate the pow erhead from exhaust housing 002159 1 Lifting fixture 2 1 1 8 in screws 002098 2 1 1 Rear small powerhead screw ...

Page 207: ...moval All injectors must be rein stalled in their original location Improper injector installation can result in powerhead failure Shift Linkage The shift linkage can be removed as an assembly First remove the shift lever screw Next remove the set screw from the shift rod lever The shift rod lever will slide off the shaft Pull the shift linkage assembly out and away from the crankcase Remove the b...

Page 208: ... hoses Remove screws and one double ended stud and remove exhaust side water cover Using a 1 8 in diameter pin punch push crank case taper pin toward the front side of the engine Remove crankcase flange screws Loosen in stages and remove the main bearing nuts and washers 1 Crankcase recirculation hose port 2 Block to block recirculation hose starboard 3 Crossover hose 002128 005018 002124 WARNING ...

Page 209: ...the cylinder head Dis card thermostat seal and O rings Connecting Rods and Pistons Use a permanent marker to identify each connect ing rod cap connecting rod and piston by cylinder number Number 1 is closest to the flywheel Use Torquing Socket P N 331638 to loosen in stages the rod cap retaining screws DO NOT remove the screws Using one hand to support the piston remove the rod cap screws with you...

Page 210: ... Retaining Ring Pliers or equivalent to remove wrist pin retaining rings Discard retaining rings The wrist pin fit is loose on both sides Push the wrist pin through to free the piston from the con necting rod If necessary use Wrist Pin Pressing Tool P N 326356 to remove the wrist pin bearing Be careful not to lose any of the 28 needle bear ings or the two wrist pin washers If any of the bearings a...

Page 211: ...Discard seal Inspect housing and replace if necessary Remove O ring from crankshaft sleeve and inspect it Replace the O ring if it is not in good condition Inspect the crankshaft sleeve and replace if nec essary To remove the sleeve use Slide Hammer P N 432128 and Large Puller Jaws P N 432129 1 Upper oil seal 2 Upper main bearing 002034 002042 002044 1 2 1 Punch 002053 002040 002041 1 ...

Page 212: ...ents must be completely clean and free of contaminants Remove any carbon accumulation from exhaust port areas Remove any carbon accumulation from cylinder head combustion chambers If cylinder walls are glazed from extended use use a rigid medium grit cylinder hone to resurface walls Use slow RPM for best oil retention and ring sealing When finished a cross hatch pattern of 22 to 32 should be visib...

Page 213: ... to prevent corrosion INSPECTION For dimensions refer to TECHNICAL DATA on p 18 IMPORTANT Before any inspection process can begin all internal components must be com pletely clean and free of contaminants Visually inspect all parts Check for unusual wear patterns scuffing or deterioration of aluminum parts heat related discoloration of bearings and bearing surfaces and broken components Cylinder H...

Page 214: ...ylinder must not be out of round by more than 0 004 in 0 10 mm The dimensional difference between the two areas is cylinder taper The cylinder taper must not exceed 0 002 in 0 05 mm The difference between the measurements and standard bore is cylinder oversize For dimen sions refer to TECHNICAL DATA on p 18 The cylinder must not be oversized by more than 0 003 in 0 08 mm IMPORTANT If any cylinder ...

Page 215: ...e Position piston rings on piston Push rings into groove and hold straightedge against the side of the piston Rings must be even or just below the surface of piston Rings must move freely in piston ring groove Bearings Inspect center main bearings and split sleeves for excess wear nicks or scratches Replace if nec essary Inspect crankshaft rod bearings for excess wear nicks or scratches Replace if...

Page 216: ...nd drive the sleeve onto the crank shaft until the installer contacts the lower main bearing If the installer sticks on the sleeve after installa tion thread Slide Hammer P N 391008 into installer and pull it off IMPORTANT Inspect sleeve after installation Sleeve must not be used if surface is damaged Using retaining ring pliers install bearing retaining ring with sharp edge facing away from beari...

Page 217: ...aling Compound on the outer rim of a new lower housing seal Press seal into the lower seal housing so that lip of seal extends through the bottom of the housing Lubricate a new lower seal housing O ring with outboard lubricant and place the O ring on the housing Lubricate seal lip with Triple Guard grease and place lower seal housing on crankshaft 1 Upper main bearing 002033 1 Upper oil seal 00203...

Page 218: ... very important that the connecting rods are installed with the alignment dots and the diagonal oil hole facing up toward the flywheel Apply Needle Bearing Grease to the wrist pin bearings Install the bearings in the wrist pin bore Align bearings with Wrist Pin Bearing Tool P N 336660 Place the two wrist pin thrust washers on the tool with flat side of the washers facing out 1 Exhaust side of bloc...

Page 219: ...ough the piston Use Wrist Pin Cone P N 318600 and Driver P N 318599 to install new wrist pin retaining rings in each wrist pin hole Gap of retaining ring faces up away from notch in piston Repeat steps for each piston Installing Pistons When all pistons and connecting rods are assem bled install piston ring sets Be sure rings are installed in the cylinder used to test ring end gap IMPORTANT Be sur...

Page 220: ...ace appropriate ring com pressor on piston Slide piston and rod assembly into the correct cyl inder as marked during disassembly Guide con necting rod through cylinder block to avoid scratching cylinder wall Repeat steps for each piston Cylinder Head Install a new thermostat seal in cylinder head with side marked TO CYL HEAD facing toward ther mostat Refer to THERMOSTAT SERVICING on p 199 prior to...

Page 221: ... DO NOT put any sealer in upper seal groove Check that main bearing alignment dowel pins are seated in the block Push all pistons to the top of cylinders Remove numbered connecting rod caps Gently lower crankshaft into place Align tab on lower bearing seal housing with hole in crankcase Align upper oil seal in groove Locate each main bearing on its dowel pin A mark placed on the bearing race oppos...

Page 222: ...um IMPORTANT Be sure alignment dot on rod cap matches dot on rod and that both dots face fly wheel IMPORTANT Torquing the screws without Alignment Fixture P N 396749 or using an incor rect procedure could cause permanent damage to the connecting rod and crankshaft To maintain accurate torque values keep torque wrench extension length to a minimum Install Rod Cap Alignment Fixture P N 396749 before...

Page 223: ...s must be centered on the rod crankpin diameter Tighten the forcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 N m IMPORTANT Make sure that frame is squarely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Torquing Socket P N 331638 to tighten rod cap screws in three stages Apply an initial torque of 40 to 60 in lbs 5 to 7 N m to both rod cap screw...

Page 224: ...ase mating flange The application must not come within 1 4 in 6 4 mm of bearings IMPORTANT Gel Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the tube cannot be determined Using old Gel Seal II could cause crankcase air leaks IMPORTANT If Locquic Primer is used crank case halves must be assembled and tightened within t...

Page 225: ...gasket and cover on cylinder block Apply Nut Lock to screws and double ended stud and hand start in cover Place star washer under J clamp and position as shown Torque all screws to 60 to 84 in lbs 7 to 9 5 N m Install pressure valve assembly Refer to PRES SURE RELIEF VALVE SERVICING on p 200 Connect crankcase and block to block recirculat ing hoses Check valves must flow toward fly wheel end of po...

Page 226: ... detent of the shift lever assembly Guide shaft through bushings in crankcase Install shift rod lever on the shaft and start set screw Torque screw 60 to 84 in lbs 7 to 9 5 N m Apply Triple Guard grease to shoulder of shift lever screw and Nut Lock to threads Install lever screw and washer on cylinder block and torque screw to 120 to 144 in lbs 13 5 to 16 N m 1 Shift detent assembly 002135 1 1 Shi...

Page 227: ...hrottle levers or shoulder screws General Install fuel pump assemblies and fuel injector coil assemblies Refer to FUEL SYSTEM section IMPORTANT All injectors must be reinstalled in their original location Improper injector installation can result in powerhead failure Install the stator flywheel EMM and wiring har ness assembly Refer to ELECTRICAL AND IGNITION and ENGINE MANAGEMENT MOD ULE EMM sect...

Page 228: ...ct mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position with flats fac ing away from each other Apply Extreme Pressure Grease to all sides of retainer and install between mounts Apply Nut Lock to retainer screw install the screw and torque to 15 to 20 ft lbs 20 to 27 N m 002069 002...

Page 229: ... powerhead screws Apply Triple Guard grease to upper mount screw threads and reinstall Loosely install the powerhead screws and upper mount screws Torque the six large powerhead screws to 18 to 20 ft lbs 24 to 27 N m Torque the five small powerhead screws to 60 to 84 in lbs 7 to 9 5 N m Torque upper mount screws to 110 to 130 ft lbs 149 to 176 N m Confirm that screw heads are tight against steerin...

Page 230: ...and the distance between the shift lever pin and the center of the shift cable trunnion pocket should be approximately 7 in 17 8 cm IMPORTANT The shift rod height is the most critical of these adjustments and should not be moved during this procedure Refer to SHIFT ROD ADJUSTMENT on p 265 Tighten adjustment screws to 60 to 84 in lbs 7 to 9 5 N m Position the shift rod in the shift rod lever Instal...

Page 231: ... starter and in front of capacitor as shown Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enough to hold the grommet in place Start the top front screw next and draw cover halves together Install remaining cover screws and tighten all screws to 24 to 36 in lbs 3 to 4 N m 002152 1 Battery cable 2 Trim cable grommet 3 Trim connect...

Page 232: ... Plug Indexing on p 144 Use the Evinrude Diagnostics Software pro gram to initiate powerhead break in Refer to Powerhead Break In on p 98 Adjust timing pointer and check engine timing Refer to TIMING ADJUSTMENTS on p 142 Run outboard and check for water fuel or oil leaks Confirm that engine reaches correct operating temperature and does not overheat 1 Top rear cover screw 002150 1 ...

Page 233: ...233 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS Port Short Block Starboard Short Block ...

Page 234: ...234 POWERHEAD POWERHEAD VIEWS Port Dressed Powerhead Starboard Dressed Powerhead ...

Page 235: ...235 POWERHEAD POWERHEAD VIEWS 10 Front ...

Page 236: ...236 POWERHEAD POWERHEAD VIEWS Rear ...

Page 237: ...237 POWERHEAD POWERHEAD VIEWS 10 Top ...

Page 238: ...238 POWERHEAD NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 239: ...OF CONTENTS SERVICE CHART 240 TILT TUBE 242 REMOVAL 242 INSTALLATION 243 EXHAUST HOUSING 244 REMOVAL 244 DISASSEMBLY 244 CLEANING AND INSPECTION 246 ASSEMBLY 246 INSTALLATION 249 STERN BRACKET 249 REMOVAL 249 DISASSEMBLY 249 ASSEMBLY 252 ...

Page 240: ...s 68 73 N m See Text 216 240 In lbs 25 27 N m 40 50 In lbs 4 5 5 7 N m 40 50 In lbs 4 5 5 7 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 6 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m A A A A A B 120 144 In lbs 14 16 N m A 110 130 Ft lbs 149 176 N m 216 240 In lbs 25 27 N m U F A 004105a IMPORTANT Use Triple Guard grease on all pivot points A Triple Guard Grease B G...

Page 241: ... N m E 60 84 In lbs 7 9 5 N m C C A B B 60 84 In lbs 7 9 5 N m F 150 180 In lbs 17 20 N m A A C B 18 20 Ft lbs 24 5 27 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex Number 2 Q Gel Seal II 002210 ...

Page 242: ...ove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer from Tilt Tube Service Kit P N 434523 onto the starboard end of the tilt tube Remove steering cable wiper nut from tilt tube Thread the adapter from Tilt Tube Service Kit P N 434523 onto the port end of the tilt tube WARNING Support the outboard with a suitable hoist 1 Locking tabs 30749 30748 1 3074...

Page 243: ... or leather mallet to tap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Torque starboard tilt tube nut to 50 to 54 ft lbs 68 to 73 N m then loosen nut 1 8 to 1 4 turn Replace steering cable wiper nut on port end of tilt tube Apply one drop of instant bonding adhesive in receiving channels of tilt limit switch collar and install collar and t...

Page 244: ...rhead must be removed Refer to Powerhead REMOVAL on p 205 Remove and discard four lower mount screws Remove the exhaust housing Remove lower mount covers and inspect the lower mounts Disassembly Remove the front and rear screws retaining the adapter inner exhaust housing to the exhaust housing 20 Models 23036 25 Models 32590 001986 001970 1 Adapter retaining screws 001981 1 1 ...

Page 245: ... water tube grommet Remove the seal from the bottom flange of the inner exhaust housing Remove the four screws securing the exhaust megaphone to the adapter housing Remove the lower mount assemblies as neces sary Lubricate with soapy water and carefully pry at both ends 001980 1 Upper inner exhaust housing screws 001975 1 Lower inner exhaust housing screws 001974 1 1 1 1 1 Water tube grommet 00198...

Page 246: ...he maximum allowable run out is 0 009 in 0 228 mm If you do not have access to a dial indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a distorted housing replace it IMPORTANT A distorted exhaust housing will cause the upper driveshaft splines to wear exces sively and will damage the crankshaft splines Inspect the water tube for obstructions or kinks whi...

Page 247: ... 847 to the bottom flange of the adapter inner exhaust housing Install a new seal Apply Triple Guard grease to outer surface of seal Clean and degrease the adapter housing and outer exhaust housing mating surfaces with Cleaning Solvent Apply Gel Seal II sealant to the adapter flange of the exhaust housing Place the adapter inner exhaust housing into the exhaust housing Guide the water tube through...

Page 248: ...ing screws and torque to 60 to 84 in lbs 7 to 9 5 N m If removed coat the lower mounts with soapy water and press into the exhaust housing with the OUTSIDE mark facing outward Position the mount covers Apply Nut Lock to screws install washers and screws and torque to 150 to 180 in lbs 17 to 20 N m 1 Alignment pin 001980 1 Adapter retaining screws 001981 1 1 1 001972 ...

Page 249: ...Powerhead INSTAL LATION on p 229 STERN BRACKET Removal Before servicing the stern bracket The gearcase must be removed Refer to Gear case REMOVAL AND INSTALLATION on p 260 The powerhead must be removed Refer to Powerhead REMOVAL on p 205 The exhaust housing must be removed Refer to Exhaust Housing Removal on p 244 The power trim tilt unit must be removed Refer to TRIM AND TILT section Disassembly ...

Page 250: ...rd Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to TILT TUBE on p 242 Remove the two tilt tube washers Remove the anode Remove the swivel bracket Inspect and if neces sary replace the tilt tube bushings Remove the trim sender unit from the port stern bracket and pull its wires through the braided tube 30735 30765 30764 30763 1 Anode 30762 1 Tilt tube bushing 30761 ...

Page 251: ...Remove the trail lock arm and bushings 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 the detent roller and spring 1 Tilt limit switch 2 Retainer 30758 1 Trail lock spring 2 Trail arm retainer 30756 1 Trail lock bushing 30755 2 1 1 2 1 1 Trim rod roller 30754 1 Tilt support bushing 30753 1 1 ...

Page 252: ...the swivel bracket Torque bushing to 28 to 30 ft lbs 37 9 to 40 7 N m Install the two trim rod rollers on the swivel bracket Torque to 216 to 240 in lbs 24 4 to 27 1 N m Install the trail lock and bushings in the swivel bracket Torque to 216 to 240 in lbs 24 4 to 27 1 N m Install the trail lock spring in the swivel bracket and connect the spring to the trail lock 30752 1 Tilt support bushing 30753...

Page 253: ...the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compound Coat the bushings and seal lips with Triple Guard grease Coat tilt tube bushings with Triple Guard grease and if removed install them in the swivel bracket Place the swivel bracket between the stern brack ets and install the anode Install the tilt tube and tilt limit cam Refer to TILT TUBE on...

Page 254: ...unstaked side facing the mount bracket Align the bracket with the steering arm and torque the nut to 130 to 150 ft lbs 176 to 204 N m Fill the swivel bracket with Triple Guard grease through the grease fitting on the bracket s port side Lubricate the tilt tube swivel bracket and stern brackets through the two forward grease fit tings Install the exhaust housing Refer to Exhaust Housing Installatio...

Page 255: ...FT SERVICE 269 SHIFT HOUSING GEAR AND PROPELLER SHAFT REMOVAL 270 WATER INTAKE SCREENS 270 GEARCASE HOUSING INSPECTION 270 BEARING AND SEAL REMOVAL 271 SHIFT HOUSING 271 PINION GEAR BEARING 272 DRIVESHAFT BEARING HOUSING 273 PROPELLER SHAFT BEARING HOUSING 273 BEARING AND SEAL INSTALLATION 274 SHIFT HOUSING 274 PINION GEAR BEARING 276 DRIVESHAFT BEARING HOUSING 277 PROPELLER SHAFT BEARING HOUSING ...

Page 256: ...B G B 60 84 In lbs 7 9 5 N m 20 24 Ft lbs 27 33 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m 215 240 in lbs 24 27 N m B B B 26 28 Ft lbs 35 38 N m B F 60 84 In lbs 7 9 5 N m F A B 120 144 In lbs 13 6 16 3 N m B B A B 24 36 In lbs 2 7 4 1 N m D See Water Pump Assembly instructions C A A B A A 60 84 In lbs 7 9 5 N m F C A B F 60 84 In lbs 6 8 9 5 N m DSS133 A Triple Guard Grease B Gasket Sealin...

Page 257: ...54 N m 60 84 In lbs 7 9 5 N m G D 26 28 Ft lbs 35 38 N m B B B A 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 B A B 120 144 In lbs 13 6 16 3 N m A 60 84 In lbs 7 9 5 N m F See Water Pump Assembly instructions B C A A B C F 24 36 In lbs 2 7 4 1 N m A B B B B C A 60 84 In lbs 7 9 5 N m 45 50 Ft lbs 61 68 N m B DSS152 A Triple Guard Grease B Gasket Sealing Compound C Adhesive ...

Page 258: ...be from the gear case into a container Inspect the lube and the magnets on the plugs for metal chips The presence of metal fuzz can indicate normal wear of the gears bearings or shafts within the gearcase Metal chips can indicate extensive internal damage Outboard Model Gearcase Type General Comparison Service Procedure Comparison L Models with 20 in shaft S Unique housing shafts gears and bearing...

Page 259: ...t the oil level hole Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely Clean plug seal area and install the lubricant level plug and new seal then the lubri cant drain fill plug and new seal Tighten them to a torque of 60 to 84 in lbs 7 to 9 5 N m LEAK TEST Drain lubricant before testing STEP 1 Install lubricant drain fill plug and seal thread pressure...

Page 260: ...ase retaining screws Remove the gearcase assembly from the exhaust housing being careful not to bend the shift rod or damage the water tube The lower inner exhaust housing may come out with the gearcase WARNING To prevent accidental starting while ser vicing twist and remove all spark plug leads During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s w...

Page 261: ...eshaft engages the crankshaft Water tube enters the water pump Lower inner exhaust housing installs correctly Shift rod does not turn and is positioned prop erly in shift shaft connection area Apply Gasket Sealing Compound to threads of the gearcase retaining screws Torque the screws 3 8 in screws 26 to 28 ft lbs 35 to 38 N m 7 16 in screws 40 to 50 ft lbs 54 to 68 N m Apply Gasket Sealing Compoun...

Page 262: ...impeller hous ing screws Slide the water pump off the driveshaft Remove the impeller drive cam O ring impeller plate and gasket Discard the gasket Remove all the parts from the housing Inspection Check impeller for overheating hub separation and other wear or damage Check liner and wear plate for scoring distortion and impeller material transfer Inspect the housing for cracks or melting 1 Trim tab...

Page 263: ...ound Install the cup in the impeller housing Install the water tube grommet with the inside taper facing up Install the impeller housing cover and torque two screws to 24 to 36 in lbs 2 7 to 4 1 N m Apply Adhesive 847 to flat side of the impeller housing grommet Install the grommet flat side down Lightly coat the liner with Triple Guard grease With a counterclockwise rotation install the impel ler...

Page 264: ... engage the impeller cam with the impeller and slide water pump down over cam Be sure impeller cam does not fall out of position IMPORTANT Make sure the impeller engages the impeller cam properly Serious powerhead damage will result if impeller cam is displaced Align the impeller housing with the gearcase Apply Gasket Sealing Compound to threads of the four impeller housing screws Install the scre...

Page 265: ...lever in NEUTRAL rotate the shift rod up or down as necessary for correct adjustment Once correct height is achieved rotate rod one half turn or less to face offset forward IMPORTANT The NEUTRAL detent is a two step design Make sure the NEUTRAL detent ball is in the center step before checking shift rod height Shift Rod Heights COA6166 Model Type Height 20 in L S 21 25 in One Half Turn 25 in X O 2...

Page 266: ...d threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase damage Hydrostatic Seal Grooves Must be in good condition to help prevent propeller ventilation Gearcase Anodes If anodes have eroded to two thirds their original size they must be replaced Drive Shaft Check splines for visible dam a...

Page 267: ... obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing and reverse gear from gearcase Pinion Gear and Driveshaft Removal Position the shift rod to move the clutch dog as far forward as possible This will assist in the removal of the pinion nut Loosen the pinion nut from the bottom of the driveshaft using Driveshaft Holding Socket...

Page 268: ...Backing Plate P N 325867 to break the lock Install the tools as shown by clamping them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gearcase until the driveshaft pops loose from the pinion If upper driveshaft becomes separated from lower driveshaft use Lower Driveshaft Puller P N 342681 to remove Install puller into...

Page 269: ...eshaft install new driveshaft retainer into the groove of the upper driveshaft Install the upper driveshaft into the lower drive shaft aligning the holes in the driveshaft retainer and the lower driveshaft S Type Gearcases Install the roll pin flush O Type Gearcases Install the roll pin to the specified dimension 29337 29338 29330 1 Roll pin DR4596 1 Roll pin DR4610 1 1 0 125 in 3 2 mm ...

Page 270: ... water intake screens Replace if damaged GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection Inspect pinion bearing and forward thrust surface of gearcase housing Use Gearcase Alignment Gauge Kit P N 5006349 to check the condition of gearcase housing prior to reassembly Refer to instructions provided with kit Use Gauging Head P N 352879 f...

Page 271: ...e clutch dog Remove all components Remove the gear thrust bearing and thrust washer from the shift housing Remove the shift lever pin from the housing Remove shift shaft cradle and shift lever Move shifter detent accordingly to assist in removal of components WARNING Wear safety glasses to avoid injury 1 Clutch dog spring COA3560 1 Pin COA3561 1 1 1 Gear 2 Thrust bearing 3 Thrust washer COA3562 1 ...

Page 272: ...earcase as follows Use a mallet to drive the bearing from the hous ing O Type Gearcases Use a 7 8 in wrench to hold the remover in place Use a 3 4 in wrench to turn flange nut clockwise Draw the bearing up from the housing 1 Shifter detent 2 Ball and spring DSC02518 1 Pinion bearing retaining screw 2 Water screen pocket 3 Seal DSC02370 DRC7416 DSC02313 2 1 2 3 1 1 1 4 20 x 1 2 in Hex Head Screw 2 ...

Page 273: ...er from the seal bore and the O ring groove Propeller Shaft Bearing Housing Rear Seal Removal Remove seals using Puller Bridge P N 432127 and Small Puller Jaws P N 432131 Position the plate on top of the housing to support the bridge and tighten jaws securely behind the inner seal Bearing Removal Rear seals must be removed if bearing replace ment is needed See Rear Seal Removal IMPORTANT Inspect b...

Page 274: ... Check for and remove any nicks or burrs on front of bearing housing BEARING AND SEAL INSTALLATION Shift Housing IMPORTANT Clean and inspect all components before beginning assembly procedures Replace any damaged components Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at 90 angle into the housing as shown wh...

Page 275: ... arms into the recesses of the shift cradle Pull shifter detent back up to NEUTRAL position to hold the cradle and shaft in place Coat thrust bearing and thrust washer with Needle Bearing 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 IMPORTANT Bearing and washer must be installed in the corr...

Page 276: ...n three coils over each end of the pin MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE Pinion Gear Bearing Assemble the following components of Pinion Bearing Remover and Installer P N 391257 as shown S Type Gearcases O Type Gearcases 1 PROP END COB7581 1 Retaining spring COB3101 1 1 1 1 4 20 X 1 2 in Hex head screw 2 1 in O D Flat washer 3 Spacer P N 341437 4 Plate P N 391260 5 Rod P N 326582 ...

Page 277: ...ase until the washer on the tool contacts the spacer Remove the tool Position new O ring on the pinion bearing retain ing screw Apply Nut Lock to screw threads Install the screw and torque to 60 to 84 in lbs 7 to 9 5 N m Driveshaft Bearing Housing 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 IMPOR...

Page 278: ...tion Install new seals back to back in bearing housing using Seal Installer Apply Gasket Sealing Com pound to metal casings of the seals before install ing Install inner seal with lip facing toward the bearing housing then outer seal with lip facing away from the bearing housing Seal installation tool P N 326551 S Type gearcases P N 336311 O Type gearcases Apply Triple Guard grease to seal lips In...

Page 279: ...er installing or removing the bearing hous ing Lightly coat the threads of the pinion nut with outboard lubricant and torque to 100 to 110 ft lbs 136 to 149 N m IMPORTANT The original pinion nut may be used for shimming but must NOT be used in final assembly Select Collar P N 341440 and Shim Gauge Bar P N 328367 Slide the collar onto the driveshaft with large end in contact with the bearing housin...

Page 280: ...sing from the driveshaft and add the required amount of shims IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 318674 Check shimming by reassembling the driveshaft with shims and placing it back into the tool base The measurement between the gauge bar and the pinion should be 0 020 in 0 508 mm Remove the nut and pinion from the ...

Page 281: ...n the shift rod while pushing it through the cover to avoid damaging the O ring Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket Position the gasket on the gearcase Thread the shift rod into the shifter detent about four turns Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the locat...

Page 282: ...n the tapers with Cleaning Solvent Use a shop towel free of grease and lint Lightly coat the threads of a new pinion nut with outboard lubricant and install on the driveshaft using Pinion Nut Starting Tool P N 342216 Turn the driveshaft by hand to engage the nut Hand tighten pinion nut and remove the pinion nut start ing tool Proceed to next step and then torque pro cedure Install washers on the d...

Page 283: ...ly apply Gasket Sealing Compound to a new bearing housing O ring Install O ring in groove in the housing Install housing into gearcase aligning screw holes with retainer slots in gearcase Housing must be completely seated to install retainer tabs Install two retainers washers and screws Apply Ultra Lock to threads and torque screws 18 to 20 ft lbs 24 to 27 N m 1 Holding socket 2 Pinion holder 3 Re...

Page 284: ... m Confirm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m To complete gearcase assembly refer to LEAK TEST on p 259 WATER PUMP on p 262 SHIFT ROD ADJUSTMENT on p 265 REMOVAL AND INSTALLATION on p 260 LUBRICANT on p 258 Propeller Hardware Installation on p 65 Trim Tab Adjustment on p 68 During break in period of a reassembled gear case change the gearcase lubricant between 10 to 2...

Page 285: ...287 RESERVOIR FLUID 287 MANUAL RELEASE VALVE 287 STERN BRACKETS 287 TROUBLESHOOTING 288 ELECTRICAL CIRCUIT TESTS 288 RELAY TESTING 288 TRIM AND TILT MOTOR CURRENT DRAW TESTS 288 TRIM AND TILT MOTOR NO LOAD TEST 289 TRIM GAUGE TEST 290 TRIM SENDER TEST 291 REMOVAL AND INSTALLATION 291 REMOVAL 291 INSTALLATION 293 SERVICING 294 DISASSEMBLY 294 ASSEMBLY 295 ADJUSTMENTS 296 ...

Page 286: ...t down to the top of the trim range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be manually raised or lowered through the entire trim and tilt range by opening the manual release valve a minimum of three turns The manual release valve must be closed and torqued 45 to 55 in lbs 5 to 6 N m to hold the outboard in position and...

Page 287: ... plug and torque 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the unit at least five complete cycles to purge all air from the system When cycling the unit hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the oppo site direction Manual Release Valve Check the manual release valve with a torque wrench IMPOR...

Page 288: ... trim motor wire remains grounded When the button is released the blue trim motor wire returns to a grounded position When the trim DOWN button is pressed the DOWN relay is energized and connects the green trim motor wire to the battery positive terminal The blue motor wire remains grounded When the button is released the green trim motor wire returns to a grounded position Refer to TILT TRIM RELA...

Page 289: ...ck for Pump binding Motor binding Cylinder binding Valves sticking C Normal current draw slow operating speed Check for Impact valves damaged Check valve or shuttle valve malfunctioning Manual release valve damaged Trim and Tilt Motor No Load Test IMPORTANT Securely fasten motor in a suit able fixture before proceeding with this test Use a battery rated at 360 CCA 50 Ah or higher that is in good c...

Page 290: ...or Trim Gauge Test STEP 1 Turn key switch ON Using a voltmeter check for voltage between the trim gauge I and G termi nals If no voltage check condition of instrument har ness key switch and engine 20 A fuse If voltage go to STEP 2 STEP 2 Remove the white tan lead from the trim gauge S terminal With key switch ON gauge should indicate full trim DOWN position Now connect a jumper wire between termi...

Page 291: ... must show a reading above 80 Ω With the outboard fully UP meter must show a reading below 10 Ω If results agree refer to Trim Gauge Test on p 290 If results are different replace trim sender REMOVAL AND INSTALLATION Removal Remove port lower engine cover and disconnect the trim tilt connectors Refer to Powerhead REMOVAL on p 205 Remove the rubber grommet from the blue green trim tilt cable connec...

Page 292: ...nual release valve raise the unit and lock it in place with the tilt support Remove the external snap rings from the upper pin Use a punch to remove the upper pin Retract the tilt cylinder rod Remove the external snap rings from the lower pin Use a punch to remove the lower pin and remove the trim tilt unit from the stern brackets 25078 27381 25064 25065 25077 25076 ...

Page 293: ...ngs on lower pin with sharp edge of ring facing out Extend tilt cylinder rod to match with holes in swivel bracket Apply Triple Guard grease to upper pin and install the pin Install external snap rings onto upper pin with sharp edge facing out Place trim tilt wires in braided tube and install through hole in the stern bracket Release the tilt support and lower the outboard Torque the manual releas...

Page 294: ...ing IMPORTANT Before removing manual release valve relieve pressure by fully extending cylinder Screw the manual release valve in Remove the retaining ring using a small pick or screwdriver Discard the retaining ring Slowly remove the manual release valve There may be pressure behind the valve wear safety glasses Inspect the manual release valve Discard the O rings on the housing Remove the four l...

Page 295: ...in pump assembly Install a new motor O ring Position the motor on the manifold and install four new screws and lock washers Tighten the screws 35 to 50 in lbs 4 to 6 N m Oil O rings and install them on the manual release valve Oil and install the manual release valve Tighten the valve to a torque of 45 to 55 in lbs 5 to 6 N m Install new retaining ring in groove 004281 004280 004282 004285 1 Retai...

Page 296: ...is time Run the motor then recheck oil level Cycle the unit several times and check the oil level when the cylinder is fully extended Oil should be level with bottom of fill port Install and tighten the fill plug to a torque of 45 to 55 in lbs 5 to 6 N m ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p 67 Refer to Tilt Limit Switch Adjustment on p 66 1 Reservoir cap 004278 1 ...

Page 297: ...S 6 OUTBOARD FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY S 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY S 14 SUMMING UP S 16 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM S 17 HANDLING OUTBOARDS S 17 HANDLING LEAD ACID BATTERIES S 21 GASOLINE HANDLE WITH CARE S 22 HAZARDOUS PRODUCTS S 23 SAFE...

Page 298: ...S 2 ...

Page 299: ...self but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommendations contained in this manual and use of good judgment when servicing outboards will help promote safety Always be alert and careful a good foundation for safety First A word about parts Plain par...

Page 300: ...FORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of shift control be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemble parts carefully Make adjustments carefully T...

Page 301: ...to STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How can loss of speed control be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemble parts carefully Make adjustments carefully Test your work Do not...

Page 302: ...heel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams operator may not be able to avoid obstacles Operator could panic If steering is loose boat may weave while operator tries to steer a straight course With some rigs at high speed loose steering could lead ...

Page 303: ... weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK earlier If moved up or down even one half inch run test again to make sure steering parts are free and clear During this procedure steering parts Must not bind and Must not touch other boat outboard or accessory parts in transom ar...

Page 304: ...akage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is stored base ment or cottage could be ignited by any open flame or spark furnace pilot light etc When boating fuel leaking under the engine cover could be ignited by a damaged or deteriorated electrical part or loose wire connection makin...

Page 305: ...ition as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked Fully pushed onto spark plug Spark Plugs Avoid rough handling that could crack ceramic part of plug Sparks may jump across outside of plug All Connections Clean Tight Prevents sparks Electric Cable ...

Page 306: ...der engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is trapped in tank and not in the hose where it might leak onto the floor if the hose deteriorates If gasoline tank is stored indoors do not put it in a room having an appliance with a pilot light or where electrical ap...

Page 307: ...t s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on the transom boat occupants may be injured from the outboard or its parts entering the boat Boat s transom could break away Outboard may be lost overboard Boat may SINK The mounting system includes o...

Page 308: ...rd may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken Check for a high speed blow to the lower unit OR I was backing up and I think the outboard may have hit a tree or something Check for a slow heavy squash to the outboard Look for damaged parts and loosened nuts and bolts ...

Page 309: ... suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test your work whenever possible If oil leaks are seen in service areas determine source Keep reservoir filled If outboard is hydraulic tilt trim model always return rod to hole position determined by boa...

Page 310: ... and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key switch If switch fails If lanyard is caught engine will keep running engine will keep running when clip is pulled from the switch ...

Page 311: ...run into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemble parts carefully Inspect lanyard for cuts or fraying clip for wear Replace with original parts Do not substitute Locate control box and other items in area to keep lanyard from being caught ALWAYS ...

Page 312: ... Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Replaced parts are like originals in every way Customer is told of things which need attention But do you really want the alternative ...

Page 313: ...ht hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly P N 396748 use only the special hardened screws and washers from the set Outboard can drop suddenly if hoist or engine stand are in poor shape or too small for the job Make sure shop aids have extra capacity and keep them in go...

Page 314: ... remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils can shock you and may cause you to recoil into the rotating flywheel When you do things that turn the flywheel like Off season storage fogging oiling of outboard Removing propeller with a powered tool ...

Page 315: ...aust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In high concentrations CO can be fatal within minutes Lower concentrations are just as lethal over long periods of time DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fum...

Page 316: ...t Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water Eyes need protection when Grinding Spraying cleaners and paints Chiseling Tip When steel on steel use plastic or brass type hammers They don t chip off as easily as steel hammers Protect e...

Page 317: ...ger leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Battery may EXPLODE While charging or discharging remember No smoking No flames No sparks DO NOT check battery charge by placing metal objects across posts You will make sparks and serious burns are po...

Page 318: ...atches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters Loose wires on running outboards Other variables which may ignite fumes How many of these are in your repair area 20 Parts Air By Volume 1 Part Gasoline Gas Fumes If the air around you is calm the p...

Page 319: ...ere to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little children are very curious and will try to taste everything so keep containers away from children ...

Page 320: ...nual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to common shop safety practices to protect your self and others around you 7 When replacement parts are required will you use Evinrude Johnson Genuine Parts or parts with equivalent characteristics inclu...

Page 321: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Barometric Pressure Sensor 88 Batteries Battery Switches 35 Cable Routing 42 Cables 35 Charging System Tests 130 Connections 34 78 Installation 34 Maintenance 78 Multiple Batteries 35 Requirements 19 34 Storage 82 Wiring Diagrams 37 Bearing...

Page 322: ...ogramming 99 161 171 173 Fuel Injector Tests 120 121 164 Fuel Pump Test 119 164 Idle Speed 99 Oil Injector Test 185 Oil Priming 60 184 190 Oiling Rate 60 98 Reports 100 Sensor Monitoring 127 Service Codes 95 Shutdown Mode 92 Static Spark Test 116 Tiller Remote Programming 98 Timing Verification 98 143 TPS Calibration 99 143 Voltage Monitoring 117 Driveshaft Installation 282 Removal 267 Service 269...

Page 323: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Gauges SystemCheck 33 101 Trim Gauge Test 290 Gearcase Assembly 280 Bearing and Seal Installation 274 Bearing and Seal Removal 271 Disassembly 266 Inspection 266 Installation 261 Leak...

Page 324: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 325: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Page 326: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Tachometer Pulse Setting 63 Test 139 Technical Data 18 Temperature Operating 63 197 Operation below freezing 59 Temperature Sensor Description 87 Resistance Test 128 Thermostat Assembly 199 Description 195 Disassembly 198 Inspection 199 Temperature 19 196 Throttle Linkage Ins...

Page 327: ...Diagnostic Procedures 108 Engine Temperature Sensor 128 Fuel Injectors 120 Fuel System 119 164 165 Ignition 114 115 117 Inductive Amp Meter Test 111 Specialized Test Procedures 110 Timing Light Test 110 Trim and Tilt 288 Voltage Testing 112 Un n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n ...

Page 328: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Water Intake Screens 72 74 ...

Page 329: ... A Check wiring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendix drive gears Check starter inspect bendix drive gears Seized powerhead or gearcase Check and repair as needed Outboard turns slowly Discharged battery Check battery recharge or replace Battery cable...

Page 330: ...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 on p 103 Low or no 55 V alternator output Check voltage on 55 V circuit refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 Capacitor or 55 V circuit wiring Check capacitor and 55 V circuits refer to SYSTEM ANALYSIS on p 103 and ...

Page 331: ... 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 on p 103 and ELECTRICAL AND IGNITION on p 123 Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit white red refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM on ...

Page 332: ...ts refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 Contaminated or poor fuel quality Check or replace fuel supply Low fuel pressure Check pressure refer to FUEL SYSTEM on p 155 Air in fuel system Check for air in fuel supply manifold refer ...

Page 333: ... refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS on p 103 Restricted or leaking fuel injectors Check injectors refer to FUEL SYSTEM on p 155 Low fuel pressure Check circulation pump operation refer to FUEL SYSTEM on p 155 EMM programming timing or operation Check EMM prog...

Page 334: ...tem air leaks Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM on p 155 Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring Check CPS air gap Low alternator output 55 V Check voltage on 55 V circuit refer to SYSTEM ANALYSIS on p 103 and ELECTRICAL AND IGNITION on p 123 EMM program timing or operation Check EMM program and timing check...

Page 335: ...rm hot Incoming water cool 6 4 8 9 10 1 Intake water screens 2 Water pump 3 Water tube 4 Adaptor housing 5 Cylinder block 6 Pressure valve 7 Thermostat 8 Water supply to EMM 9 Water supply EMM to vapor separator 10 Overboard indicator outgoing water from vapor separator 5 001818 ...

Page 336: ...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 337: ...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 338: ...B M M C A S OFF M B S A C M ON M B S A C M START M B S A C M 4 5 6 1 2 3 MWS Key Switch and Neutral Safety Switch 000691 ...

Page 339: ...V PUL REV 5 6 4 3 2 S I G S I G S I G S I G 5 1 2 3 7 4 8 6 TO OUTBOARD WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM TILT FUEL WATER PRES LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASHBOARD ...

Page 340: ...tion ALL LED s ON indicates outboard running in Winterization Mode Stop circuit not grounded FLASHING LED Use Diagnostic Software and see Service Code Chart Indicates URGENT engine overheat or no oil condition Sensor circuits TPS CPS and 5V circuits FLASHING LED Use Diagnostic Software and see Service Code Chart Indicates URGENT conditon Code 57 Indicates 30V or higher on 55V circuit Indicates CPS...

Page 341: ... 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 FUSE B AC A B A B 1 2 3 1 2 3 1 2 3 1 2 3 2 1 2 1 J1 B J1 A J2 A B C 4 A B C 1 2 1 2 3 1 2 3 1 2 A B POS NEG 1 2 3 4 5 6 2 3 4 5 6 1 2 1 2 3 4 5 1 2 3 4 5 1 2 3 1 2 3 1 2 3 1 A B B 2 1 1 2 2 1 1 2 3 4 5 6 1 2 3 4 5 6 001683N 1 2 E TEC 75 90HP ...

Page 342: ... 3 WATER TEMP HOT FLASHING Flash NO OIL OVERHEAT LED4 4 seconds Outboard will crank but will NOT RESTART until EMM temperature falls below 212 F 100 C Verify EMM cooling and outboard cooling system operation 31 Engine temperature OVER range 3 3 3 WATER TEMP HOT FLASHING Flash NO OIL OVERHEAT LED 4 4 seconds Check engine temperature and cooling system operation Check temperature sensor resistance C...

Page 343: ...73 Oil pressure ABOVE expected range 3 SENSOR FAULT LED 3 8 seconds 4 5 V 74 Water pressure sensor circuit fault detected 3 CANBus Option SENSOR FAULT LED 3 8 seconds Use Evinrude Diagnostic Software to activate option 0 12 V 4 88 V 75 Water pressure BELOW expected range 3 SENSOR FAULT LED 3 8 seconds 0 5 V 76 Water pressure ABOVE expected range 3 SENSOR FAULT LED 3 8 seconds 4 5 V 77 S A C overcu...

Page 344: ......

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