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Evinrude E-TEC E115DBXSCR, Service Manual, Page: 1 / 445

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Evinrude E-TEC E115DBXSCR Service Manual Download Page 1

Summary of Contents for E-TEC E115DBXSCR

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Page 3: ...trademark of The General Motors Corporation Locquic and Loctite are registered trademarks of The Henkel Group Lubriplate is a registered trademark of Fiske Brothers Refining Company NMEA is a registered trademark of the National Marine Electronics Association Oetiker is a registered trademark of Hans Oetiker AG Maschinen Packard is a registered trademark of Delphi Automotive Systems Permatex is a ...

Page 4: ... 89 5 ENGINE MANAGEMENT MODULE EMM 93 6 SYSTEM ANALYSIS 111 7 ELECTRICAL AND IGNITION 127 8 FUEL SYSTEM 169 9 OILING SYSTEM 193 10 COOLING SYSTEM 215 11 POWERHEAD 225 12 MIDSECTION 269 13 GEARCASE 287 STANDARD ROTATION 307 COUNTER ROTATION 338 14 TRIM AND TILT 357 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1 DIAGRAMS EMM SERVICE CODE CHART ...

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

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

Page 7: ...edly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery cables at the battery Twist and remove all spark plug leads The electrical system presents a serious shock hazard DO NOT handle primary or secondary ignition components while outboard is running or fly...

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

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

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

Page 11: ...5 WH O E115DCXSCS 25 WH O CR E150DPLSCR 20 BL O E150DHLSCR 20 BL L E150DHLSCF 20 BL L2 E150HSLSCS 20 WH L E150HSLSCF 20 WH L2 E150DSLSCR 20 WH O E150DBXSCR 25 BL M E150DBXSCF 25 BL M2 E150DPXSCR 25 WH M E150DPXSCF 25 WH M2 E150DCXSCR 25 WH M CR E150DCXSCF 25 WH M2 CR E175DPLSCR 20 BL O E175DSLSCR 20 WH O E175DPXSCR 25 WH M E175DPXSCF 25 WH M2 E175DCXSCR 25 WH M CR E175DCXSCF 25 WH M2 CR Model Numb...

Page 12: ...cm3 158 2 cu in 2592 cm3 Bore 3 601 in 91 47 mm Stroke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm 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...

Page 13: ...ation Label GEARCASE Gear Ratio V4 S Type Gearcase 13 26 500 2 1 V4 O Type Gearcase 12 27 444 2 25 1 V6 M Type Gearcase 13 24 542 1 85 1 V6 O Type Gearcase 14 26 538 1 86 1 V6 L Type Gearcase 14 26 538 1 86 1 Refer to GEARCASE TYPES on p 305 Lubricant HPF XR Gearcase Lubricant Capacity S Type Gearcase 31 6 fl oz 935 ml V4 M Type Gearcase 43 0 fl oz 1270 ml V6 M Type Gearcase 44 0 fl oz 1300 ml M T...

Page 14: ... in all marketing areas All service technicians must be familiar with nauti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No 12 36 48 3 4 4 0 5 4 1 4 in 60 84 5 7 7 9 5 5 16 in 120 144 10 12 13 5 16 5 3 8 in 216 240 18 20 24 5 27 7 16 in 336 384 28 32 38 43 ...

Page 15: ...S 13 1 SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS 14 UNIVERSAL TOOLS 14 ELECTRICAL IGNITION TOOLS 16 FUEL OIL SYSTEM TOOLS 17 POWERHEAD TOOLS 17 GEARCASE TOOLS 18 TRIM AND TILT TOOLS 22 SHOP AIDS 23 NOTES 26 ...

Page 16: ...N 437955 45583 Universal Puller Set P N 378103 32885 Lifting tool P N 342672 44686 Slide hammer P N 391008 CO1577 Lifting eye P N 321537 23701 Flywheel service kit P N 434649 Includes P N 5007181 adapter 46215 Slide hammer P N 432128 15345 Flywheel holder P N 771311 42938 Flywheel puller adapter kit P N 5007181 005314 Slide hammer adapter P N 390898 15356 ...

Page 17: ...ench P N 342680 46879 Temperature gun P N 772018 45240 Large puller jaws P N 432129 23148 Tilt tube service kit P N 434523 33249 Fresh water flusher P N 500542 50110 Bearing puller jaws P N 432130 23149 Puller Bridge 432127 23146 Oetiker pincers P N 787145 001081 Syringe P N 346936 50243 ...

Page 18: ...tator Test Adapter P N 5006211 004222 Peak reading voltmeter P N 507972 49799 Crimping pliers P N 322696 30387 Connector tool P N 342667 42004 Test probe kit P N 342677 45241 Tachometer timing light P N 507980 49789 AMP connector tools Primary Lock Tool P N 777077 Secondary Lock Tool P N 777078 Release Tool P N 351413 Lock Installer P N 777079 002277 ...

Page 19: ...ge 15 PSI P N 5006397 90 fitting P N 353322 004560 Injector test fitting kit P N 5005844 002465 Alignment pin kit P N 5007167 005279 Cylinder bore gauge P N 771310 45303 Piston stop tool P N 342679 Replacement tip P N 5006098 46543 Rod cap alignment fixture P N 396749 21596 Torquing socket P N 331638 000797 Crankshaft bearing and sleeve installer P N 338647 21953B ...

Page 20: ...rist pin retaining ring driver P N 318599 2 Wrist pin cone P N 318600 DR1641 1 2 Ring compressor standard P N 336314 CO3768 Universal Driveshaft Shimming Tool P N 5005925 1 Lower Driveshaft Shimming Bolt S2 gearcase P N352878 002601 1 Universal Pinion Bearing Remover and installer kit P N 5005927 002805 Gearcase filler P N 501882 49790 ...

Page 21: ...P N 311875 23261 Gearcase Alignment Gauge Kit P N 5006349 004315 Gauging Head M2 Type Gearcases P N 5007749 006822 Piinion Driveshaft Wrench P N 352877 005073 Backing plate P N 325867 23621 Gauging Head S Type Gearcases P N 352879 005072 Gauging Head L2 Type Gearcases P N 5007750 006823 Lower DriveshaftSpline Tool P N 5007052 005074 Lower Driveshaft Puller P N 342681 47257 ...

Page 22: ...N 432400 15358 1 Pinion nut holder P N 334455 2 Wrench retainer P N 341438 40371 Bearing Installation Tool P N 339778 32519 Prop shaft bearing installer P N 339750 32880 Prop shaft bearing installer P N 432401 15355 1 2 Pinion nut starting tool P N 342216 40372 Seal installation tool P N 330268 32924 Seal installation tool P N 354056 006824 Driveshaft seal protector P N 318674 23692 ...

Page 23: ...ng housing installers P N 354058 L2 P N 354057 M2 006783 Prop shaft bearing housing remover puller P N 354060 006784 Prop shaft bearing housing alignment pins P N 354140 006788 Gearcase pressure tester P N 507977 Stevens P N S 34 Gearcase vacuum tester P N 507982 Stevens P N V 34 49794 ...

Page 24: ... tilt systems 33741 Trim tilt service kit P N 390010 33013 1 Trim tilt service kit P N 434524 2 Replacement o ring kit for adapter tips P N 434729 27340 Tilt cylinder end cap remover P N 352932 for single piston tilt systems 005340 2 1 Tilt cylinder seal protector P N 326005 23694 1 Trim cylinder end cap remover installer P N 436710 2 Replacement tip for 436710 33742A Spanner wrench P N 912084 322...

Page 25: ...ti Purpose Lubricant P N 777192 Oil XD100 P N 777118 Engine Tuner P N 777185 D P L Spray P N 777183 Oil XD50 P N 777225 Anti Corrosion Spray P N 777193 Silicone spray P N 775630 Oil XD30 P N 777219 HPF XR Gear Lube P N 778755 HPF PRO Gearcase Lube P N 778755 Moly Lube P N 175356 ...

Page 26: ...8298 Needle Bearing Grease P N 378642 Power Trim Tilt and Power Steering Fluid P N 775612 Black Neoprene Dip P N 909570 Starter Bendix Lube P N 337016 Biodegradeable TNT Fluid P N 763439 Electrical Grease P N 503243 2 4 Fuel conditioner P N 775613 Gel Seal and Gasket Remover P N 771050 Permatex No 2 P N 910032 ...

Page 27: ...t Sealing Compound P N 317201 Pipe Sealant with Teflon P N 910048 Locquic Primer P N 772032 Adhesive 847 P N 776964 Thermal Joint Compound P N 322170 Instant Bonding Adhesive P N 509955 1 Screw Lock P N 500417 Loctite Purple 222 equivalent 2 Nut Lock P N 500421 Loctite Blue 242 Equivalent 3 Ultra Lock P N 500423 Loctite Red 271 Equivalent 1 2 3 ...

Page 28: ...26 SPECIAL TOOLS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 29: ...BLE INSTALLATION 53 ELECTRICAL HARNESS CONNECTIONS 55 WATER PRESSURE GAUGE 56 CANBUS CONNECTIONS 56 FUEL AND OIL PRIMING 58 FUEL REQUIREMENTS 58 FUEL SYSTEM PRIMING 59 OIL REQUIREMENTS 59 OIL INJECTION RATE 60 BREAK IN OILING 61 OIL SUPPLY PRIMING 61 BEFORE START UP 63 RUNNING CHECKS 64 ENGINE MONITORING SYSTEM 64 FUEL SYSTEM 64 EMERGENCY STOP KEY SWITCH 64 START IN GEAR PREVENTION 64 TACHOMETER P...

Page 30: ...ng System IMPORTANT Outboards with remote controls must be equipped with an I Command system a SystemCheck gauge or an equivalent engine monitor Operating the outboard without an engine monitor will void the warranty for failures related to monitored functions Refer to ENGINE MONITORING SYSTEM on p 101 WARNING The remote control used must have start in gear prevention This feature can pre vent inj...

Page 31: ...or exceeds the mini mum requirements Minimum 12 Volt Battery Recommendations Location and Preparation Proper installation will prevent battery movement while underway Secure all batteries in protected locations Place battery as close to the outboard as possi ble Battery location must provide access for peri odic maintenance Use battery mounting trays or battery boxes on all battery installations C...

Page 32: ...ions with extended length battery cables require an increased wire size Refer to the following table IMPORTANT Inadequate battery cables can affect the performance of an outboard s high amperage start circuit and the cranking speed of the outboard DO NOT use aluminum wire cables Use ONLY AWG stranded copper wire cables Battery Switches and Multiple Batteries A multiple battery setup including mari...

Page 33: ... Battery Charging on p 32 Battery Switch Requirements Battery switches must meet the following require ments The switch must be approved for marine use The switch should be a make before break design to protect the charging system from a no load condition Switch amperage rating should be adequate for the outboard it will be used on Use one battery switch for each outboard installed Use the appropr...

Page 34: ...ery Charging Evinrude E TEC V4 V6 outboards are equipped with isolated battery charging capability The iso lated charge connection must only be used to charge a single 12 volt battery or two 12 volt bat teries wired in parallel IMPORTANT Never connect an external bat tery isolator to the stator of an Evinrude E TEC outboard Accessory Charge Lead Kit P N 5006253 is routed from a connector on the ou...

Page 35: ...ON PRIMARY 1 S 000135rev1 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 One outboard Battery disconnect One outboard One primary starting battery one secondary battery SECONDARY PRIMARY S 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 1 1 1 2 2 000134N 1 2 OFF BOTH 2 Positive Battery cables Negative Battery cables Accessory charge wires P N 5006253 50 amp Fuse ...

Page 36: ... Two outboards One primary starting battery for each outboard two isolated accessory batteries ACCESSORY PRIMARY 1 PRIMARY 2 S S 1 2 OFF BOTH 1 2 OFF BOTH 1 2 ACCESSORY PRIMARY 1 PRIMARY 2 1 2 S S 000086N 1 2 OFF BOTH 1 2 OFF BOTH ACCESSORY 1 2 Positive Battery cables Negative Battery cables Accessory charge wire P N 5006253 50 AMP Fuse ...

Page 37: ...stalled fuel hoses should be as short and horizontal as possible Use corrosion resistant metal clamps on perma nently installed fuel hoses Multi outboard applications require separate fuel tank pickups and hoses A fuel selector switch may be used for kicker motors as long as it has enough flow capacity for the larger out board Fuel System Primer Outboards require a priming system capable of refill...

Page 38: ...sult in serious powerhead damage Outboard Fuel System Recommendations 0070 Typical Fuel Supply Configuration 1 Primer bulb 2 Water separating fuel filter 3 Anti siphon valve in fuel pick up of tank DRC6797 1 2 3 Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5 16 in 7 9 mm min I D 3 8 in 9 5 mm min I D Fuel fittings 1 4 in 6 4 mm min I D 9 32 in 7 1 mm min I D Fuel supply...

Page 39: ...ft 7 6 m IMPORTANT Do not add hose to an existing oil supply hose If the oil tank requires a longer oil supply hose Oil supply hose between the primer bulb and outboard must be replaced with one continuous length of 1 4 in 6 4 mm hose Maximum length of hose is 25 ft 7 6 m Replacement hose must be designated for fuel or oil use and approved for marine use Extend wiring harness with 16 gauge AWG wir...

Page 40: ... bracket Assemble cross bar onto hook rods install flat washers and lock nuts Tighten locknuts to securely hold tank 1 8 GALLON TANK Place rods into floor bracket and secure floor bracket with lag bolts Place oil tank onto floor bracket If cover is not pre assembled route oil supply hose and harness through the cover and position cover on the oil tank Attach spring loaded rods to cover COB5381 1 R...

Page 41: ... the required length of 1 in I D fill hose to route as directly and as vertically as possible Avoid inappropriate hose routings that could distort the fill tube or tank tube Refer to installation instructions provided with remote oil fill kit A slanted area of the deck will allow water to drain away from the fill and is best suited for the installation Additional Items Required 1 in I D fill hose ...

Page 42: ...or kit Cable and Wire Harness Routing Remote control cables wiring and hoses must follow a similar path into the lower motor covers Select the best routing for the specific application All cables wiring and hoses must be long enough to provide adequate slack Check clearances at all possible combinations of trim angles and steering positions Typical outboard installation 1 Oil tank 2 Anti siphon va...

Page 43: ...conduit Electric primers or man ual primers may not require this consideration Route fuel hoses with enough slack to allow the primer bulb arrow to point up during use Install the primer bulb with the arrow pointing in the direction of fuel flow to the outboard Connect the fuel supply hose from the fuel tank to the fuel supply line at the outboard IMPORTANT Do not permanently fasten this connectio...

Page 44: ...e clamping range of the clamp Oetiker Stainless Steel Stepless Clamps WARNING DO NOT re use Oetiker clamps Fuel leak age could contribute to a fire or explosion 1 Clamp identification numbers 000093 1 CLAMP NO NOMINAL O D INCHES MILLIMETERS Replacement Clamp I D Inches MM Open Closed Open Closed 346930 95 3 8 9 5 0 374 0 307 9 5 7 8 348838 105 13 32 10 5 0 413 0 346 10 5 8 8 349516 113 7 16 11 3 0...

Page 45: ...epless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accesso ries Catalog P N 787145 Position correct size clamp over hose Install hose on fitting Close clamp ear fully with Oetiker pincers pli ers Clamp Removal Method 1 Position Oetiker pincers across clamp ear and cut clamp Method 2 Lift end of stepless clamp with screw driver Method 3 Use Oetiker pincers pliers ...

Page 46: ... Refer to ABYC Standards to determine the maximum horsepower capacity for boats with out certification labeling Mounting Surface Inspect transom surface before drilling mounting holes The transom should meet ABYC Standards The transom must be flat The transom angle should be approximately 14 degrees Check transom strength and height The stern brackets must contact the flat surface of the transom M...

Page 47: ... of bottom strakes on dual outboard installations Transom Brackets and Jack Plates When mounting an outboard on boats equipped with transom brackets or jack plates refer to the manufacturer s recommendations Confirm maximum weight and horsepower capacities Jack plate assemblies must provide a one piece mounting surface to support the outboard Mounting Hardware The required outboard mounting bolts ...

Page 48: ...ting Refer to boat manufacturer for recommendations If the standard spacing does not allow full steering travel in a particular installation it may be neces sary to increase the spacing IMPORTANT Some steering systems may require additional spacing Refer to steering sys tem manufacturer for recommendations The top edge of the transom should be more than twice the width of the dual outboard centerl...

Page 49: ... If drill fixture is unavailable refer to Drilling and Hardware Diagrams on p 48 for measure ments Position drill fixture on top of transom or bracket and align indicator points with centerline The indicators are affected by the squareness of the top edge of the transom If either side of the fixture must be raised more than in 6 mm above the transom s top surface to make both indicators align the ...

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 ...

Page 51: ...t ABYC Standard P 17 Single cable mechan ical steering systems can be used on single or dual outboard installations if an ABYC approved steering link is used Dual cable mechanical steering helps provide firm steering control at high speeds Extend the steering cable and lubricate the inner core before installation IMPORTANT Install steering cable through tilt tube before mounting outboard on transo...

Page 52: ... ufacturer s recommendations and to Dual Outboard Centerlines on p 46 Drag Links Use the correct drag link to allow full steering travel Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm For single motor single cable applications the drag link should be installed in the rear hole TYPICAL Manual Hydraulic Steering 004948 Model Drag Link 60 V4 V6 ...

Page 53: ...t ing height of the outboard Mounting Bolt Installation IMPORTANT Use a marine sealant rated for above or below waterline use RTV silicone is not approved for below waterline use Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces Apply marine sealer under hex heads of bolts on the mounting plates and to the bolt shanks Assemble transom mounting plates on...

Page 54: ...o ensure proper positioning of rigging components in grommet The main wiring harness battery cables oil tank sending unit harness and any CANbus cables should be routed along the same path to the star CAUTION To prevent accidental starting while servic ing disconnect the battery cables at the battery Twist and remove all spark plug leads 1 Grommet retaining bracket 003964 1 Alternate fuel hose loc...

Page 55: ...rs to insert straight section of clip into linkage pin hole Push the clip towards the hole while lifting on the curved end with the pliers Be sure retainer clip fully engages the pin Lock the retainer by moving the angled section behind the straight section Shift Cable Installation and Adjustment Place the shift cable on the shift lever pin and install the washer and retainer clip IMPORTANT Do not...

Page 56: ...nkcase Adjust the throttle cable trunnion to align with the trunnion block Place the cable trunnion in the trunnion block IMPORTANT Move control handle to FOR WARD and pull back slowly to NEUTRAL Make sure the engine throttle lever is against the stop If not remove slack by adjusting cable trunnion Install the trunnion cover and screw Tighten the retaining screw to a torque of 60 to 80 in lbs 7 to...

Page 57: ...re connectors in brackets Route oil tank sending unit harness around the front to the port side Secure all cables with tie straps Install battery cables on starter solenoid and main ground stud IMPORTANT BE SURE all harnesses and wires are not pinched cannot contact flywheel and do not interfere with moving throttle or shift linkages Replace flywheel harness connector cover 004954 1 Seal 42079A 1 ...

Page 58: ...o the network Connect the EMM CANbus connector to the CAN bus Network Harness Route the harness under the front of the EMM and around the port side of the powerhead Secure with tie straps Use a CANbus Ignition Harness in place of the standard MWS harness to connect the outboard to the key switch and trim tilt control Seal unused SystemCheck connector with 6 Pin Connector Seal P N 586076 If install...

Page 59: ...ng har ness connector If a CANbus oil level gauge is used an optional CANbus oil level sender must be installed in the oil tank Connect the oil level sensor harness to the boat CANbus network Use Evinrude Diagnostics software to activate CANbus control functions in the EMM From the Settings screen select Engine Options 1 CANbus power supply connector 005269 1 Anchor points 005270 1 Water pressure ...

Page 60: ...posits 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 remove...

Page 61: ...s Oil Requirements Evinrude Johnson XD100 XD50 or XD30 out board oils are recommended for use in Evinrude E TEC outboards If these oils are not available you must use a TC W3 certified oil Evinrude Johnson XD100 outboard oil is highly recommended for all conditions and applications Engine Lubricant Below 32 F 0 C If the outboard will be operated in temperatures below freezing 32 F 0 C use Evinrude...

Page 62: ...Conventional use runabouts cruisers Moderate applications Powerhead oil programming labels are provided to identify EMM oil programming Install the cor rect label to alert user to specific oil requirements An XD100 Outboard Oil Decal P N 352369 is available to label boats equipped with outboards that have been programmed for the reduced oil injection ratio Install decals in a highly visible locati...

Page 63: ...from the oil tank Once oil flow is observed connect the oil tank hose to the outboard s oil supply hose and secure with 14 5 mm Oetiker clamp Oil Distribution Manifold Priming Squeeze the oil primer bulb to flow oil from the hose connection through the filter to the oil pump Visually inspect filter to ensure that all air has been purged Continue squeezing the primer until oil flows through the dis...

Page 64: ...ted through continued priming IMPORTANT All clear blue oil distribution hoses on the powerhead should fill with oil as the air is purged from the lines Repair any fuel or oil leaks The oiling system can also be primed using the Self Winterizing feature if diagnostics software is not available Refer to STORAGE on p 86 1 Oil distribution hoses 7 004965 1 Rear oil distribution manifold 005271 1 1 1 O...

Page 65: ...d for the first time refer to Oil Supply Priming on p 61 Trim and Tilt Fluid Make sure trim and tilt reservoir is full before run ning outboard Tilt the motor up and engage the tilt support Remove filler cap and check fluid level Single Piston System Add Evinrude Johnson Biodegradable TNT Fluid as needed to bring level to the bottom of the fill plug threads Three Ram System Add Power Trim Tilt Flu...

Page 66: ...outboard OFF while control is in FORWARD Try to restart the outboard Outboard should not start Shift back to NEUTRAL and restart outboard Shift to REVERSE Turn outboard OFF while con trol is in REVERSE Try to restart the outboard Outboard should not start WARNING DO NOT run outboard without a water sup ply to the outboard s cooling system Cool ing system and or powerhead damage could occur DANGER ...

Page 67: ...head reaches idle temperature Refer to SERVICE SPECIFICA TIONS on p 10 Idle Speed Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use Break In When the outboard is delivered refer the cus tomer to the break in information in the Opera tor s Guide The Engine Manageme...

Page 68: ... of 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 a...

Page 69: ...80 ft lbs 95 to 109 N m Without Keeper 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the propeller nut Without Keeper and propeller shaft are not aligned tighten the nut until they are in line Do not loosen Insert a new cotter pin through the propeller nut and shaft or propeller nut keeper and shaft Bend its ends over the nut to secure the assembly IMPORTANT After fastening propeller n...

Page 70: ... the maximum tilt position Check the adjustment by tilting the outboard fully Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it con tacts the motor well To prevent damage to equipment provide addi tional motor well clearance when needed Con sider either changing the outboard mounting position or modifying the boat if the possibility for interference and...

Page 71: ...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 72: ... the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m Test the boat and if needed repeat the procedure until steering effort is as equal as possible Outboards with High Transom Heights The trim tab may be above the surface of the water when the o...

Page 73: ...rd alignments Each applica tion must be thoroughly tested until the ideal combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small amount of toe out and adjust inward until best results are achieved A typical set up with 2 stroke outboards mounted directly on the transom often runs best with a slight amount of toe in Outboards ...

Page 74: ...72 INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 75: ... 79 TRIM AND TILT 81 BATTERY AND BATTERY CONNECTIONS 82 FUEL AND OIL SYSTEMS 82 FUEL FILTER 82 OIL FILTERS AND OIL RESERVOIR 83 AIR SILENCER 83 HOSES AND CONNECTIONS 83 SPARK PLUGS 84 INDEXING 84 EXHAUST PRESSURE FITTING 85 OPERATION TEST 85 CLEANING 85 STORAGE 86 FUEL SYSTEM TREATMENT 86 INTERNAL ENGINE TREATMENT 86 ADDITIONAL RECOMMENDATIONS 87 PRE SEASON SERVICE 87 OUTBOARD MOUNTING BOLTS 87 GE...

Page 76: ...3 Cooling system check water pump indicator water pressure 3 Anticorrosion anodes check condition 3 Gearcase check condition 3 Propeller check condition 3 Fuel and oil systems inspect and repair leaks 2 2 Emission related component 3 Check battery connections and condition 3 Access EMM information resolve any service codes 3 Electrical and ignition wires inspect for wear or chafing 3 Fuel filter r...

Page 77: ...ased antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no resistance If resistance is high check the following Remove the anode and clean the area where the anode is installed Clean the mounting screws Install the anode and test again Metallic Component Protection Protect metal compo...

Page 78: ...between 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 67 Place outboard in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Shift the outboard to NEUTRAL with the propeller removed Turn water supply on START outboard Run it at IDLE only Shut OFF the outboard Turn off water supply and remove garden hose Leav...

Page 79: ...vapor separator flow water freely Replace water pump LUBRICATION Steering System Grease the stainless steel output end of the steer ing cable with Triple Guard grease Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease Make sure wiper nut is installed and not damaged 1 Water intake screen 2 Overboard indicator DSC02220a drc4952a...

Page 80: ... throttle and shift cables from trunnion block 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 ...

Page 81: ...er plug before removing the lower drain fill plug A tie strap can be used to check lubricant level Remove the lubricant level plug then the lubricant drain fill plug and drain the lube from the gear case into a container Inspection Inspect the lube and the magnets on the plugs for metal chips The presence of metal fuzz can indi cate normal wear of the gears bearings or shafts within the gearcase M...

Page 82: ...taminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 74 for service frequency and recommended lubricants Secure the gearcase in a vertical position Remove the lubricant level plug and the lubricant drain fill plug Slowly fill the gearcase with gearcase lube through the drain fill hole until it appears at the oil level hole Filling the gearcase too quick...

Page 83: ... bring level to the bottom of the fill plug threads Install the fill plug and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the unit at least five complete cycles to purge all air from the system When cycling the unit hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the oppo site dire...

Page 84: ...h Triple Guard grease and insulate to prevent shorts or spark arcing FUEL AND OIL SYSTEMS Routine replacement of filters reduces the possi bility of foreign material restricting the incoming fuel or oil supplies Replacement filter elements are available through Evinrude Johnson Genuine Parts Fuel Filter Evinrude E TEC 60 V outboards are equipped with an in line fuel filter Refer to FUEL COMPO NENT...

Page 85: ... free of water or other contaminants Air Silencer The air silencer on Evinrude outboards maximizes air flow while minimizing noise 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 in both the fuel and oil systems Visually inspect all components Observe all clamps hoses and connections while ...

Page 86: ...ceramic of the spark plug in line with the OPEN side of the ground elec trode This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector Apply Triple Guard grease to the gasket surface of the spark plug Install spark plug and tighten to a torque of 15 ft lbs 20 N m If the mark is in unshaded area do not tighten any more If the mark is in the...

Page 87: ...fitting for restric tion With key ON outboard NOT running the exhaust pressure sensor reading should be close to zero With the outboard running make sure the exhaust pressure reading changes with throttle setting This reading will vary based on actual outboard exhaust pressure conditions If the exhaust pressure readings are not as described clean or replace exhaust pressure fit tings Cleaning Clea...

Page 88: ...conds the System Check lights will go off Move throttle to IDLE position SystemCheck lights will light again Wait another 15 seconds SystemCheck lights will go off At this point advance throttle to FULL in neutral SystemCheck lights will flash indicating that outboard is in winterize mode Outboard will automatically go to fast idle and fog itself Allow outboard to run until it shuts itself off abo...

Page 89: ...torage make sure it is reinstalled with factory specified hardware Refer to the INSTALLATION AND PREDELIVERY section for proper set up Outboard Mounting Bolts Check and re tighten outboard mounting bolts to a torque of 40 ft lbs 54 N m Gearcase Lubricant Check the lubricant level Inspect gearcase for leaks If leak is apparent pressure and vacuum test gearcase Repair gearcase as needed Battery s Re...

Page 90: ...isconnect oil supply hose and oil return hose from outboard Drain and clean all oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil system and fuel system Refer to FUEL AND OIL PRIMING on p 58 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...

Page 91: ...R SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 90 LATCH HOOK INSTALLATION 90 UPPER COVER CAP REPLACEMENT 90 LOWER COVER SERVICE 91 LOWER COVER REMOVAL 91 LOWER COVER INSTALLATION 91 LATCH HANDLE INSTALLATION 92 TRIM SWITCH INSTALLATION 92 ...

Page 92: ...ocket Apply Ultra Lock to screw threads Place hook into position Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Upper Cover Cap Replacement Place new upper cap into position Tighten self tapping screws to a torque of 24 to 36 in lbs 2 7 to 4 N m 1 Bracket 006826 006819 1 006815 1 Upper cap screws 006820 1 1 ...

Page 93: ...ide cover slightly and disconnect trim tilt switch connector Then remove port and starboard covers Lower Cover Installation Install the lower engine covers and tighten all screws to a torque of 24 to 36 in lbs 3 to 4 N m Connect trim tilt switch connector 1 Lower cover screws 005242 005246 1 1 1 Lower cover screws 005242 005246 1 1 ...

Page 94: ...k to screw threads Place spring washer and hook into position and tighten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on switch Tighten nut to a torque of 10 to 16 in lbs 1 to 2 N m Install electrical connector Refer to CONNEC TOR SERVICING on p 164 1 Triple Guard grease 006827 006821 1 006746 006747 006748 ...

Page 95: ... START ASSIST CIRCUIT SAC 100 ROM VERIFICATION 100 IDLE CONTROLLER 100 RPM LIMITER 100 EXHAUST VALVE V4 MODELS 100 ENGINE MONITOR AND WARNING SYSTEMS 100 FAULT CODE CREATION AND STORAGE 100 ENGINE MONITORING SYSTEM 101 S A F E WARNING SYSTEM 102 SHUTDOWN MODE 102 DIAGNOSTIC SOFTWARE FUNCTIONS 103 COMMUNICATION 103 STATIC INFORMATION 103 DYNAMIC INFORMATION 104 STORED SERVICE CODES FAULTS 104 HARD ...

Page 96: ...RPM profile and engine hours Oiling ratios Exhaust valve activation V4 models EMM Connections IMPORTANT EMM connections and wiring must be clean and tight Improper electrical con nections can damage the EMM DO NOT run the outboard with loose or disconnected wiring Make sure EMM connections are clean and tight Engine wire harness to EMM connectors J1 A J1 B J2 Stator to EMM connections one 6 pin AM...

Page 97: ...Sensor AT 9 Oil Pressure Sensor component of 17 10 Engine Temperature Sensor s 11 Water in Fuel Sensor Fuel Filter 12 Trim Tilt Sending Unit 13 Water Pressure Sensor w adaptor harness 14 LED indicators 15 Fuel Pump high pressure 16 Starter Solenoid 17 Oil Injection Pump and Manifold 18 Ignition Coil 19 Fuel Injector 20 Tachometer SystemCheck Gauge 21 Diagnostic Connector 22 CANbus adaptor harness ...

Page 98: ...circuit fault is detected and the EMM 55 V Circuit Sensor Monitors the EMM s 55 V alternator circuit If system voltage exceeds 57 volts the EMM If system voltage is less than 45 V between 500 and 1000 RPM or is less than 52 V 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 less than 12 V betwe...

Page 99: ... engine fault codes The EMM provides a 5 V DC signal for sensor cir cuits It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges Inputs that fall outside of the acceptable range create service codes Air Temperature Sensor The air temperature sensor monitors the air tem perature at the throttle body If the AT sensor voltage is out of the expected range or the sen...

Page 100: ...rd will restart for one minute intervals until problem is resolved and code is cleared To clear code use the diagnostic software program If the sensor reads out of the expected range or the sensor or circuit fails the EMM If the sensor circuit indicates below expected range 4 V the EMM If the sensor circuit indicates above expected range 4 6 V the EMM Activates SHUTDOWN Stores service code 31 EMM ...

Page 101: ...speed generate a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 instances the EMM Approximate air gap between CPS and flywheel encoder ribs is 073 1 85 mm Use the Evinrude Diagnostics software Monitor screen to check CPS operation The software should show an RPM reading while the outboard is cranking If the CPS or its circuit fails...

Page 102: ...iter 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 Exhaust Valve V4 Models The EMM controls a valve that switches between two exhaust paths to provide the best exhaust tun ing for various running conditions At slower speeds and unde...

Page 103: ... EMM Refer to the EMM Service Code Chart at the back of this manual for a complete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position The horn self tests by sound ing a half second beep SystemCheck gauges self test by turning the indicator lights on simulta neously then off in sequence Service Mode SystemCheck goes into a service mode if th...

Page 104: ...e Test on p 178 Check for external fuel leakage that could allow fuel and or vapor to enter the engine through the air intake Check for internal fuel leakage from a leaking injector or vapor separator vent hose Recovery To recover from shutdown mode the EMM must NOT detect the related fault at start up The out board will not restart until the cause of the stored service code is resolved code 29 an...

Page 105: ...efore it will communicate with any outside device Power is normally sup plied to the EMM when the key switch is ON Switched B 12 V is supplied to the engine wire harness Current enters the EMM at pin 21 pur ple of the EMM J1 B connector The EMM is also turned ON when it begins to receive AC voltage from the stator while the out board is being cranked Static Information Static information is viewed...

Page 106: ...d and operating hours of first and last occurrences Hard Faults A hard fault is a service code that currently exists Hard faults become stored faults only if the out board is running Persistent Faults The Persistent Faults screen keeps a history of all previously stored codes including code number the number of times the event occurred and oper ating hours of the last occurrence Persistent faults ...

Page 107: ...the Engine Monitoring system Oil Fault This test is used to check the NO OIL circuit of the Engine Monitoring system Check Engine This test is used to check the CHECK ENGINE circuit of the Engine Monitoring system Tachometer This test is used to check operation of the tachom eter circuit Dynamic Tests Dynamic tests are performed with the outboard running Ignition Test This test momentarily disable...

Page 108: ...s Use the XD100 setting for Conventional use runabouts cruisers Moderate applications Powerhead Break In Use the diagnostic software to initiate break in oil ing Break in is a predetermined oiling program that runs for five hours of outboard operation above 2000 RPM Tiller Remote Programming This feature controls the start in gear protection function of the neutral switch Tiller operated mod els i...

Page 109: ...Crankshaft replacement Flywheel removal or replacement CPS replacement EMM replacement EMM software replacement IMPORTANT Make sure the timing pointer is set and the outboard reaches operating tempera ture before making adjustments TPS Calibration TPS Calibration synchronizes throttle plate open ing with throttle position sensor voltage Refer to TPS CALIBRATION on p 156 Perform TPS Calibration aft...

Page 110: ... the Replace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Fuel Injector Installation on p 188 Reports Engine reports provide service records and can be used to document the running history of an out board Reviewing this information can help iden tify or resolve some service issues Click the print button in a window of the diagnos tics softwar...

Page 111: ...er to the instructions provided with the program IMPORTANT Software replacement requires the use of Bootstrap Tool P N 586551 EMM Transfer EMM Transfer is used to save engine history data when the EMM must be replaced Select EMM Data Transfer from the Utilities menu Select the Collect EMM data to FILE option and follow the instructions provided with the program IMPORTANT Whenever the EMM is replac...

Page 112: ...rt side Disconnect J2 connector Installation Install J2 connector Align slots in starboard side of EMM case with iso lator mounts on electrical harness base Slide EMM into position Install two EMM retaining screws Tighten screws 12 to 16 in lbs 1 5 to 2 N m Install J1 A and J1 B connectors Install exhaust pressure hose and cooling hoses Secure with tie straps 1 EMM mounting screws 005375 1 J2 Conn...

Page 113: ...5 RUNNING 116 IGNITION OUTPUT TESTS 117 REQUIRED IGNITION SYSTEMS 117 WIRING INSPECTION 117 CRANKSHAFT POSITION SENSOR CPS TEST 118 SYSTEM VOLTAGE TEST 118 IGNITION VOLTAGE TEST 119 STATIC IGNITION TEST 119 RUNNING IGNITION TESTS 120 IGNITION PRIMARY CIRCUIT RESISTANCE TEST 121 IGNITION COIL TESTS 121 CAPACITOR TEST 122 FUEL DELIVERY TESTS 122 FUEL PUMP STATIC TEST 122 FUEL INJECTOR STATIC TEST 12...

Page 114: ...of the spark plugs Check the fuse and the emergency stop switch lanyard Operational Inspections Run the outboard to confirm actual symptoms before performing any unnecessary procedures Inspection should include the following Make sure the outboard can be cranked easily with no mechanical binding Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 115 Check...

Page 115: ...FUEL DELIVERY TESTS on p 122 Outboard runs low on power misfires Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 115 Use the Evinrude Diagnostics software Monitor screen to check system 55 V ignition 200 V and TPS voltages System and ignition voltage should be steady and TPS voltage should be between 0 2 and 4 85 V Use the diagnostics software Dynamic ...

Page 116: ...PORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to maintain a constant IDLE speed The Dynamic Tests screen includes a function to tem porarily disable the idle controller Fuel Control Adjustment Use this test is to help identify a cylinder that may be too rich or too lean This feature should not be used by itself to identify a faulty injector Evinrud...

Page 117: ...0 V or higher For NO LIGHT check for SAC circuit problem LED 2 CRANK POSITION OKAY input from CPS EMM powered ON For NO LIGHT check for Code 16 CPS intermittent loss of sync LED 3 SENSORS OKAY 5 V For NO LIGHT check for Code 12 TPS circuit fault Code 13 TPS below expected range Code 14 TPS above expected range Code 19 In Gear tiller models Code 23 EMM temp sensor circuit fault Code 24 EMM temp bel...

Page 118: ...ange Code 14 TPS above expected range Code 16 CPS intermittent loss of sync Code 23 EMM temp sensor circuit fault Code 24 EMM temp below expected range Code 37 Water in fuel Code 41 PORT temp sensor circuit fault Code 42 PORT temp below expected range Code 47 AT sensor circuit fault Code 48 AT sensor below expected range Code 49 AT sensor above expected range Code 57 high RPM with low TPS setting ...

Page 119: ...ed provides 55 VDC to the oil injection pump the fuel injec tors and the ignition module of EMM Capacitor Connected to 55 V circuit white red to stabilize current on 55 V circuit Negative terminal of capacitor must be grounded Ignition Primary Voltage Output from EMM EMM provides 200 VDC 10 V output to orange ignition primary wires Ignition Coil EMM provides input to primary winding of coil Output...

Page 120: ...ude Diagnostics software Monitor screen to check system voltage Results KEY ON not running 30 V 2 system volt age is GOOD KEY ON not running less than 30 V 2 check 12 V power to EMM Repair connection or wiring Possible fault in EMM SAC circuit RUNNING 55 V 2 system voltage is GOOD RUNNING less than 55 V 2 check stator output to EMM Repair connection or wiring Possible faulty stator or EMM Refer to...

Page 121: ...MM ignition circuit Check system voltage 55 V input to ignition circuit on pin 4 of EMM J1 B connector Static Ignition Test Perform the static ignition test using Evinrude Diagnostics software and an inductive timing light IMPORTANT DO NOT use a spark checker tool with E TEC models Radio Frequency Interfer ence RFI generated by the arcing current can cause erratic behavior in the EMM The outboard ...

Page 122: ...ve timing light strobe Look for a consistent flash and only one flash per revolution The strobe of the timing light should be the same for each cylinder IMPORTANT Test on primary circuit if strobe from secondary circuit appears faulty Results Steady voltage and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 122 Check for internal engine damage Steady voltag...

Page 123: ... or wiring Primary circuit resistance reading less than 2 Ω or within specification and EMM ignition output volt age is 130 V or higher Refer to Ignition Coil Tests on p 121 Repair high tension spark plug lead or replace ignition coil and or high tension spark plug lead assem bly Ignition Coil Tests Connect a digital multimeter between coil primary terminal and clean engine ground IMPORTANT A read...

Page 124: ...ontinuity If the resistance reading starts as a negative num ber or the reading goes down in value the capac itor already retains some stored energy Ground the capacitor and test again FUEL DELIVERY TESTS Refer to Relieving Fuel System Pressure on p 183 Check the Evinrude Diagnostics software Stored Faults screen for current service codes before troubleshooting Correct any problems and clear the c...

Page 125: ...njector activation should be carefully confirmed Results No injectors actuate Use the Monitor screen of the diagnostics soft ware to make sure voltage is present on the system voltage circuit Refer to Running Fuel System Tests on p 123 Some injectors actuate some do not Test the resistance of individual injector circuits between the injector connector and injector con trol wire at the EMM See Fuel...

Page 126: ...n some injector wires Test the resistance of individual injector circuits between the injector connector and injector con trol wire at the EMM Check battery cable connections Make sure all grounds are clean and tight See Fuel Injector Resistance Test on p 180 Steady light activation on all injector wires and consistent voltage readings EMM injector control function is good Use the diagnostics soft...

Page 127: ...ystem self test The valve remains in High Speed Mode when cranking starting and idling When TPS exceeds approximately 2 to 5 the EMM moves the valve to Low Speed Mode When speed exceeds approximately 5000 rpm the EMM moves the valve to High Speed Mode The EMM controls the timing of the valve based on engine load Engine load is calculated from sensor inputs Operational Symptoms If the exhaust valve...

Page 128: ...126 SYSTEM ANALYSIS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 129: ... 137 12 V CHARGING CIRCUIT 137 AUXILIARY BATTERY CHARGE WIRE 138 55 V ALTERNATOR CIRCUIT 138 ELECTRIC START CIRCUIT 139 ELECTRIC START TESTS 141 REMOTE CONTROL SWITCH TESTS 143 TILT TRIM RELAY TEST 145 EXHAUST VALVE RELAY TESTS 146 SYSTEMCHECK CIRCUIT TESTS 148 TACHOMETER CIRCUIT TESTS 150 FLYWHEEL AND STATOR SERVICING 151 FLYWHEEL REMOVAL 151 STATOR SERVICE 152 FLYWHEEL INSTALLATION 152 TIMING AD...

Page 130: ... F 60 84 In lbs 7 9 5 N m B 12 16 In lbs 1 5 2 N m J 15 30 Ft lbs 20 41 N m 10 16 In lbs 1 2 N m 60 84 In lbs 7 9 5 N m A F See Text E A 24 26 Ft lbs 33 35 N m 60 84 In lbs 7 9 5 N m X A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock T Liquid Neoprene X See Service Manual Text 005198 ...

Page 131: ...ple 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 004100 N 60 84 in lbs 7 9 5 N m 168 192 in lbs 19 21 5 N m F 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m T ...

Page 132: ...ector 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 In...

Page 133: ...Red 3 Diagnostic connector White 4 Ground water in fuel digital Black 5 Oil level switch Tan Black 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Bootstrap connector programming Blk Orange 9 Stop circuit Blk Yellow 10 Throttle position sensor TPS 5 V Red 11 Ground analog Black 12 Engine temperature sensor port Pink Black 13 CANbus NET L Blue 14 CANbus NET H White 15 Water pre...

Page 134: ...n ground Black 19 Ignition cylinder 2 Orange Blue 20 Injector cylinder 4 Green V4 Purple V6 21 Switched B 12V Purple 22 Injector ground Black 23 Oil solenoid Blue 24 Ignition ground Black 25 Ignition cylinder 6 none V4 Orange Green V6 26 Ignition cylinder 1 Orange Blue 004046 Pin No Description of Circuit Wire Color 1 B Red 2 none N A 3 Isolated B Red Black 4 Battery ground Black 5 Battery ground ...

Page 135: ...en terminal pins 17 18 and 24 of the EMM J1 B connector and port and starboard cylinder head ground screws Sensor circuit grounds Check continuity between terminal pins 4 and 11 of the EMM J1 A connector and the appropriate sensor ground connections Refer to wiring diagrams Additional Ground Tests Check connections and continuity at the following locations Trim and Tilt module ground at main groun...

Page 136: ...al multimeter to measure sensor resis tance between the yellow and white wires The complete circuit can be tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mounted to throttle body housing and requires no adjustment Air gap or clearance to flywheel is fixed at approximately 0 073 in 1 85 mm The acceptable clearance is 0 036 to 0 110 in 1 to 2 8 mm ThrottlePositionSenso...

Page 137: ...stance reading must change evenly as the sensor lever is moved Engine Temperature Sensor Test Remove the electrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperature Sensor AT Test Remove the electrical connector from the air tem perature sensor Use a digital multimeter to measure sensor resis tance Engine Temperature Sensor Resista...

Page 138: ... ohm or less To check for a grounded winding connect one meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no continuity If meter reads continuity replace stator Stator Voltage Output Test Use a digital multimeter to check stator output voltage Set meter to read 110 VAC output Disconnect CPS Disconnect stator 6 pin connector from the engine har...

Page 139: ...m EMM and the positive B battery cable terminal of starter solenoid IMPORTANT This outboard has dual output charging Each output is isolated and regulated Each output is 25 A Combined output is approxi mately 50 A Refer to engine wiring diagram Fluke model 334 or 336 Snap On model MT110 or EETA501 and various other amp meters should be available through local tool suppliers Reconnect the battery c...

Page 140: ...attery wire must be at least 10 gauge and it must be protected by a 50 A fuse or circuit breaker at the battery With outboard running at 1000 RPM voltage must read higher than with key OFF and increase steadily to approximately 14 5 V as the outboard RPM increases If there is no increase turn the key switch to OFF and test red black wire between the EMM and auxiliary battery connection Continuity ...

Page 141: ...D PURPLE wire 15 Neutral Safety Switch remote control 7 6 pin connectors 16 RED starter motor cable 8 Ignition switch 17 Electric starter motor 9 PURPLE wire switched B 20 21 22 23 24 25 26 14 15 16 17 18 19 8 9 10 11 12 13 1 2 3 4 5 6 7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5...

Page 142: ...Contains the following circuits Red purple output wire from fuse provides 12 V to instrument harness Purple wire provides switched 12 V to solenoid terminal A and EMM Yellow red wire provides switched 12 V to EMM Brown white wire from terminal 11 of EMM J1 B connector provides switched ground NEG to starter solenoid terminal B Instrument Wire Harness Contains the following circuits Red purple wire...

Page 143: ...arter positive cable terminal and the other lead on the battery positive cable terminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to terminal A of solenoid and ground NEG to terminal B of solenoid Measure resis tance between the starter positive cable termi nal and the positive battery cable terminal The solenoid must close with ...

Page 144: ...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 available through local tool suppliers Attach or hold a vibration tachometer such as a Frahm Reed tachometer to the starter Complete the circuit with a heavy jumper ...

Page 145: ...nd terminal S Meter should indicate continuity IMPORTANT The choke function or terminal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or continuity light to test the continuity of the circuit while positioning the remote control in NEUTRAL FORWARD and REVERSE IMPORTANT Turn propeller shaft or disconnect shift cable to allow proper remote control shift action while outb...

Page 146: ...lts are incorrect Emergency Stop Switch Test This switch can be part of the key switch or installed as a separate switch Either style con nects the M terminals of the key switch The emergency stop switch function grounds the stop circuit wire black yellow when the lanyard clip is removed One M terminal is the ground wire black and one M terminal is the stop circuit wire black yellow Install the cl...

Page 147: ...con nection to TNT motor Terminals 87 and 30 are considered normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure red and black wires are connected to 12 V battery power supply Set voltmeter to 12 VDC scale Connect test leads to terminals A and B of TNT motor connector Use a wi...

Page 148: ...blue black wire is NOT grounded fused 12V is supplied to the exhaust valve actuator through the orange red wire and the actuator is grounded through the black wire on relay 1 When the blue black wire IS grounded relay 1 and relay 2 are activated Relay 2 supplies fused 12V to the exhaust valve actuator through the red wire and the actuator is grounded through the orange red wire 1 Exhaust valve rel...

Page 149: ...p 147 EMM Outputs to Relay Module Test Use back probe to obtain results at engine har ness connector Start and run engine Use the Evinrude Diagnostics software Monitor screen to observe exhaust valve position indicator High Low Supply voltage Check for voltage red meter lead to pin 1 red purple wire black meter lead to pin 2 black white Result should be 12 VDC High speed mode Check for voltage red...

Page 150: ...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 151: ... wire of the SystemCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and the MWS har ness receives a signal from the EMM The EMM receives information from the temperature sensor on the cylinder head Using a jumper wire connect tan wire pin 6 of the engine harness connector...

Page 152: ...n yellow wire of the Sys temCheck connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits TACHOMETER CIRCUIT TESTS Check voltage at the battery Use this reading as a reference for battery voltage Connect the red meter lead to the tachometer pur ple wire and the black meter lead to the tachome ter black wire key ON outboard NOT running If mete...

Page 153: ...ical con nectors Disconnect the stator connector two port side trim system connectors port engine temperature sen sor and the port ground terminal Remove the four screws holding the electrical har ness base Lift the electrical harness base out of the way Use Flywheel Holder P N 771311 or equivalent and a socket to remove the five flywheel retaining nuts and washers Discard flywheel nuts Install bu...

Page 154: ...on cylinder block Apply Nut Lock to screw threads Install screws and tighten in crossing pattern to a torque of 24 to 36 in lbs 3 to 4 N m Flywheel Installation If studs must be replaced in crankshaft apply Ultra Lock to threads and tighten by hand no more than 48 in lbs 5 5 N m Remove any debris from the flywheel magnets and the flywheel and crankshaft mating surfaces Apply Nut Lock to the raised...

Page 155: ...electrical harness base and secure with four screws Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Reconnect the stator connector two port side trim system connectors port engine temperature sen sor and the port ground terminal Reconnect the crankshaft position sensor throttle position sensor air temperature sensor and oil pump electrical connectors Install the EMM Refer to EMM SERVICI...

Page 156: ...ndicator points The point labeled V4 is used for 60 V4 models The unlabeled point is used for 60 V6 models Disconnect the battery cables at the battery Remove spark plugs Rotate the flywheel clock wise to 30 ATDC Install Piston Stop Tool P N 342679 into the spark plug hole of the number 1 cylinder Rotate flywheel counterclockwise until the num ber 1 piston contacts the tool Keep pressure on the fl...

Page 157: ...sition Loosen the pointer retaining screw and adjust the pointer location to align with the cast in TDC boss on the flywheel Tighten retaining screw Repeat the entire adjustment process to make sure pointer is aligned correctly Install spark plugs Refer to Spark Plug Indexing on p 84 Timing Verification Use Evinrude Diagnostics software to synchronize the mechanical timing of the outboard with the...

Page 158: ...i brate the TPS Install the air silencer Set TPS Calibration after replacing or adjusting any throttle body or throttle linkage parts ELECTRIC STARTER SERVICING Starter Removal IMPORTANT Do not clean the starter drive while the starter motor and drive are installed on the powerhead The cleaning agent could drain into the starter motor washing dirt from the drive into the starter bearings and commu...

Page 159: ...g Starter Disassembly Lift and remove the wave washer and bushing Place an appropriate sized deep socket on the spacer Hit the socket with a mallet to lower the spacer and expose the retaining ring under the spacer Remove the retaining ring spacer and spring from pinion shaft 30373 30372 30371 30360 30369 ...

Page 160: ...o 2 external retaining ring pliers remove the retaining ring and drive gear from the armature shaft Remove the two thru bolts Mark the end cap ori entation and remove the cap Gently tap the starter frame with a rubber mallet to loosen it Find the insulator cap end of the shaft or inside the end cap Inspect and replace if necessary 30368 30367 30366 30365 30354B ...

Page 161: ...amage Replace brushes if damaged or worn Replace weak brush springs Inspect and replace locating ring on armature shaft if necessary Clean the commutator with 300 grade emery cloth If commutator surface is unevenly worn or pitted turn it on a lathe Remove any trace of oil or metal dust from the commutator Check the armature on a growler for shorted turns using a test light or meter Inspect armatur...

Page 162: ...ld be worn distorted or dirty Locate the cause of binding and correct it before completing the assembly Inspect and replace end cap thrust washer if dis torted or worn excessively Inspect and replace armature shaft snap ring if worn or distorted Starter Assembly IMPORTANT If removed apply Locquic Primer and Screw Lock to the brush card screws before installing Route the brush leads and install the...

Page 163: ...d frame Install insulator cap on end of shaft Apply a light coat of Moly Lube to the end cap bearing and install the end cap Install the two thru bolts Tighten to a torque of 50 to 65 in lbs 5 6 to 7 3 N m Lightly coat the drive gear with Triple Guard grease and install it on the armature shaft Install the retaining ring flat side up with No 2 external retaining ring pliers Lightly coat the gear h...

Page 164: ...ightly coat the pinion shaft splines helix with Starter Bendix Lube Lower the pinion into place without displacing the driven gear or thrust washer Lightly coat the pinion housing bearing with Starter Bendix Lube and install the pinion housing screws and lock washers Tighten the screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Install the bracket Apply Nut Lock to the thru bolts Install the nuts...

Page 165: ...c Primer and Nut Lock to the threads of the four starter mounting screws Position the starter and install the screws and lock washers First tighten the top two screws then the bottom two screws to a torque of 168 to 192 in lbs 19 0 to 21 5 N m Attach starter positive cable to post with lock washer and nut tighten securely Coat connec tions with Black Neoprene Dip 1 Screws 005373 1 1 ...

Page 166: ...ntly pull on wire Terminal Installation Push terminal through seal until it locks into place Fill connector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push wedge in until latched Wedge in 2 pin receptacle is not symmetrical position latch shoul ders next to terminals Crimping Terminals Strip insulation back 3 16 in 5 mm Place termi nal in 18 gauge notch of Crimping Pliers ...

Page 167: ...ector housing Release locking tab and pull on wire to remove from connector housing Terminal Installation Align terminal with connector housing Push con nector and seal into housing until seated Align anti backout device with connector housing and terminals Use Secondary Lock Installer P N 777079 to seat device in connector Crimping Terminals Crimping Superseal 1 5 terminals requires the PRO CRIMP...

Page 168: ...s seated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 connector of the EMM is a AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull connector from 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 housin...

Page 169: ...ls Disconnect Lift latch s Remove connector Connect Confirm the seal is in place Push connector onto housing until latched Terminal Removal A tab on the back side of the terminal engages a shoulder in the connector housing to hold the ter minal in place The terminal is removed by push ing wire and terminal through connector housing Insert a thin wire such as a paper clip into the connector above t...

Page 170: ...e 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 area of the terminal Capture all wire strands in crimp leave no loose strands Crimp wire and insulation securely using crimping pliers...

Page 171: ...TEST 179 VAPOR SEPARATOR VENT CHECK 179 FUEL INJECTOR PRESSURE TEST 180 FUEL INJECTOR RESISTANCE TEST 180 CIRCULATION PUMP RESISTANCE TEST 181 LIFT PUMP PRESSURE TEST 181 LIFT PUMP VACUUM TEST 181 LIFT PUMP DIAPHRAGM TEST 182 ANTI SIPHON VALVE TEST 182 FUEL COMPONENT SERVICING 183 RELIEVING FUEL SYSTEM PRESSURE 183 IN LINE FUEL FILTER SERVICE 184 OPTIONAL FUEL FILTER SERVICE 184 FUEL LIFT PUMP SER...

Page 172: ...R VAPOR SEPARATOR A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant L Pipe Thread Sealing Compound P Permatex 2 004940 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m F L L 60 80 in lbs 7 9 N m ...

Page 173: ...in lbs 11 13 5 N m 10 18 in lbs 1 2 N m 96 120 in lbs 11 13 5 N m C Bond seals to air silencer F K B B A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease K Purple Screw Lock 004941 Important DO NOT lubricate TPS to throttle shaft surface Start at center and use a spiral torque pattern ...

Page 174: ...Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Engine Lubricant S STP Oil Treatment 004942 R R R R R R S S S S S S S R R R S 60 84 in lbs 7 9 5 N m H 24 26 Ft lbs 33 35 N m 120 in lbs 14 N m 1 2 3 24 36 in lbs 2 7 4 N m S A A Tighten in 3 stages S Supply R Return ...

Page 175: ...el supply to vapor separator Vapor separator Vent hose to throttle body 8 9 10 11 12 13 14 Electric fuel circulation pump 20 to 35 psi Fuel supply manifold Fuel injector s Fuel return manifold Pressure regulator high pressure Test fitting low pressure Test fitting high pressure 11 5 2 1 4 3 14 6 13 10 10 10 10 Fuel Supply Fuel Return 3 7 8 9 9 9 12 11 5 2 1 4 3 14 6 13 10 10 10 10 10 10 Fuel Suppl...

Page 176: ...12 Capacitor Grounds neg Fuel Injector grounds High pressure fuel pump 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 9 20 21 22 23 24 25 26 26 27 28 29 30 31 32 33 34 2 4 1 3 J2 J1 B J1 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 5 6 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 2 1 1 2 3 4 5 6 7 8 10 11 ...

Page 177: ...60 V6 models cylinders 4 and 6 Vacuum from the fuel lift pump pulls fuel from the fuel tank Once fuel reaches the pump internal pump pressure forces the fuel from the pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure components of the fuel system from contaminants Refer to INSPECTION AND MAIN TENANCE SCHEDULE on...

Page 178: ...vapor separator The cooling passage of the separator self drains when the outboard is stored vertically Refer to HOSE ROUTING AND WATER FLOW DIAGRAMS on p 216 Venting The fuel vapor vent regulates fuel vapor pressure in the reservoir 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 vap...

Page 179: ...rnal coil to ground Fuel Manifolds The fuel supply and return manifolds route fuel through the high pressure side of the fuel system Fuel Supply Manifold The fuel supply manifold supplies pressurized fuel to the inlet port of each fuel injector Fuel Return Manifold The fuel return manifold provides a route for fuel passing through the fuel injectors to flow back to the fuel chamber of the vapor se...

Page 180: ...e See Relieving Fuel System Pressure on p 183 After relieving fuel system pressure install a 0 to 60 psi 0 to 415 kPa Fuel Pressure Gauge P N 5007100 or equivalent to the upper fuel pres sure test fitting START outboard and check pressure System pressure should be 20 to 35 psi 138 to 241 kPa 006619 WARNING Use caution when working on any pres surized fuel system Wear safety glasses and work in a w...

Page 181: ...n p 181 If the above tests are good and vapor separator remains full of fuel check for damaged circula tion pump Replace vapor separator assembly No pressure Check electrical circuit and ground connections for circulation pump If voltage is present and pump does not run repair connection or replace vapor separator assembly Relieve fuel system pressure before removing fue pressure gauge Refer to Re...

Page 182: ...efer to FUEL DELIVERY TESTS on p 122 for additional test procedures Fuel Injector Resistance Test Disconnect the battery cables at the battery Use a digital multimeter to measure the injector coil resistance Use a digital multimeter with appropriate adapter leads to measure the injector circuit resistance Measure resistance between pin 2 of injector con nector and the appropriate pin location of E...

Page 183: ...mp Vacuum Test on p 181 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 pump No pressure Check pulse hoses and fittings restrictions Check fuel flow through fuel lift pump Use fuel primer or primer bulb to force fuel through pump Momentarily prime or squeeze primer bulb to che...

Page 184: ...f a damaged pump is sus pected This test does not check the performance of internal fuel pump check valves Remove both pulse hoses from the crankcase fit tings Apply 15 psi 103 kPa to each of the pulse hoses of the pump Replace lift pump if either side of pump fails to hold pressure Anti Siphon Valve Test Remove anti siphon valve from fuel tank Install adapter fittings and a 36 in 91 4 cm length o...

Page 185: ...o a suitable con tainer Slowly open gauge s venting valve Clean up any spilled fuel 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 ...

Page 186: ...arating cannister fuel filter to 60 V out boards Removal Disconnect the battery cables at the battery Use an appropriate filter wrench to turn the filter in a counterclockwise direction Remove the filter carefully to prevent spilling the filter s contents Inspect contents for any presence of water If water is present identify the source and correct the problem Take additional fuel samples and drai...

Page 187: ...or Service Removal Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 183 Disconnect circulation pump electrical connector Remove clamp and fuel supply manifold from top of circulation pump Remove clamp and vapor vent hose from separator cover Remove clamps and vapor separator cooling water hoses Remove clamps and fuel return mani...

Page 188: ... of sealing O rings on fuel mani fold fittings Lubricate O rings with outboard 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 Install the fuel manifolds to the fuel pump assem bly and secure with clamps Fuel supply manifold to circula...

Page 189: ...ring fuel inlet and outlet ports of injectors or fuel manifolds Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber Removal Disconnect the battery cables at the battery Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 183 Remove fuel manifolds Refer to Fuel Manifold Service on p 186 Disconnect the fuel injector coil electrical con...

Page 190: ... mount housing Remove adaptor from injector Remove crush ring and O rings from injector Inspect and clean injec tor filter Install new crush ring and O rings Lubri cate O rings with STP Oil Treatment Install injector into mount housing Press on injec tor face until injector seats in mount housing Installation IMPORTANT All injectors must be installed in the correct cylinder by serial number Improp...

Page 191: ...ad Tighten screws in stages starting with the lower screw First torque is 5 ft lbs 7 N m Second torque is 10 ft lbs 14 N m Final torque is 24 to 26 ft lbs 33 to 35 N m Reconnect fuel injector coil electrical connectors If ignition coil lead was removed from connector refer to CONNECTOR SERVICING on p 164 Install fuel manifolds Refer to Fuel Manifold Ser vice on p 186 IMPORTANT Install injector ser...

Page 192: ...electrical harness base to reed plate assembly Remove oil distribution hoses from oil pump mani fold and reed plate bracket Refer to OIL COMPO NENT SERVICING on p 211 Remove oil recirculation hose from starboard side of reed plate assembly Remove screws and reed plate assembly from the crankcase Disassembly All reed plate assembly and reed valve assem blies must be cleaned before reassembly DO NOT...

Page 193: ...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 Assembly Remove old adhesive from reed valve retaining screws Prime screw threads with Locquic Primer and let dry Apply Nut Lock to threads Position reed valve on reed plate and install screws Tighten screws to a torque of 30 to 42 in lbs 3 5 to 4 7 N m Inst...

Page 194: ...bracket and install in oil pump manifold Refer to OIL SUPPLY DIAGRAMS V4 on p 196 or OIL SUPPLY DIAGRAMS V6 on p 198 Install oil filter and oil and fuel supply hoses Install crankshaft position sensor Install vapor separator vent hose and oil recircula tion hose Secure with tie straps Connect throttle linkage and throttle position sen sor connector Secure connector to reed plate bracket with tie s...

Page 195: ...05 LOW OIL WARNING 205 NO OIL WARNING 205 CYLINDER AND CRANKCASE 205 OIL RECIRCULATION SYSTEM 206 OIL CONTROL SETTINGS 207 OIL PRIMING 207 OILING RATES 207 BREAK IN OILING 207 OILING SYSTEM TESTS 207 OIL INJECTION PUMP STATIC TEST 207 OIL INJECTION PUMP VOLTAGE TEST 208 OIL INJECTION PUMP CIRCUIT RESISTANCE TEST 208 OIL SUPPLY VACUUM TEST 209 OIL INJECTION PUMP FUNCTION TEST 210 OIL INJECTION FITT...

Page 196: ...ide for Oil Requirements P N 351520 TCW3RL OIL XD 30 XD 50 Yellow XD 100 Blue IMPORTANT This outboard has been programmed for the use of Evinrude Johnson XD100 outboard oil ONLY Failure to use Evinrude Johnson XD100 outboard oil may harm engine performance and shorten engine life P N 352369 EVINRUDE COM 60 80 in lbs 7 9 N m XD 100 Boat Label Engine Oil Programming Labels IMPORTANT This outboard ha...

Page 197: ...id BLUE Oil Pressure Sensor 5 V analog RED Oil Pressure Sensor Signal TAN WHITE Capacitor 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 4 8 20 21 22 23 24 25 26 26 27 28 29 30 31 32 33 34 J2 J1 B J1 A 1 2 3 4 5 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3 5 6 4 3 7 005358 ...

Page 198: ...cylinder sleeves Primary oil manifold delivers oil to Auxiliary oil manifold 1 2 3 and 4 crankcase fittings 7 5 6 8 1 2 3 4 5 Primary Oil Manifold Rear Oil Manifold 1 2 3 4 5 1 Cylinder 2 2 Cylinder 4 3 Cylinder 3 4 Cylinder 1 5 Upper main bearing 1 Cylinder 4 2 Cylinder 1 3 Cylinder 2 4 Cylinder 3 5 Auxliary oil manifold 1 Oil tank assembly 2 Oil pick up 3 Oil supply hose 4 Oil filter 5 Oil pump ...

Page 199: ...OILING SYSTEM OIL SUPPLY DIAGRAMS V4 197 9 005354 Port Side View Starboard Side View ...

Page 200: ...anifold delivers oil to Auxiliary oil manifold 1 2 3 4 5 and 6 crankcase fittings 6 8 3 1 2 3 4 5 6 7 Primary Oil Manifold Rear Oil Manifold 1 2 3 4 5 6 7 1 Cylinder 2 2 Cylinder 4 3 Cylinder 6 4 Cylinder 5 5 Cylinder 3 6 Cylinder 1 7 Upper main bearing 1 Cylinder 6 2 Cylinder 5 3 Cylinder 4 4 Cylinder 1 5 Cylinder 2 6 Cylinder 3 7 Auxliary oil manifold 1 Oil tank assembly 2 Oil pick up 3 Oil supp...

Page 201: ...OILING SYSTEM OIL SUPPLY DIAGRAMS V6 199 9 005356 Port Side View Starboard Side View ...

Page 202: ...200 OILING SYSTEM OIL RECIRCULATION DIAGRAMS V4 OIL RECIRCULATION DIAGRAMS V4 005351 Port Side View Starboard Side View Oil from auxiliary oil manifold Check valve ...

Page 203: ...ATION DIAGRAMS V4 201 9 005350 Check valves Intake manifold to lower main bearing Check valves Main bearings to cylinders Direction of flow All check valves are oriented with direction of flow towards cylinders Direction of flow ...

Page 204: ...202 OILING SYSTEM OIL RECIRCULATION DIAGRAMS V6 OIL RECIRCULATION DIAGRAMS V6 Port Side View Starboard Side View Oil from auxiliary oil manifold Check valves 005353 ...

Page 205: ...ATION DIAGRAMS V6 203 9 005352 Check valves Intake manifold to lower main bearing Check valves Main bearings to cylinders Direction of flow All check valves are oriented with direction of flow towards cylinders Direction of flow ...

Page 206: ...bracket and hardware Protective cover 1 8 gallon tank only Primer bulb and supply hose Oil Injection Pump The oil injection pump is an electric 55 V actua tor style pump It draws oil from the oil tank through the oil supply hose 25 ft 7 6 m maxi mum and supplies pressurized oil to the oil mani fold The EMM supplies 55 V and controls activation of the pump The oil manifold distributes the oil suppl...

Page 207: ...evel in the oil tank This sending unit turns on the Engine Monitor LOW OIL display when the oil level falls below one quarter capacity An optional oil tank sending unit kit is available to display actual oil level through an I Command net work NO OIL Warning The EMM monitors the electrical circuit of the oil pressure sensor If the sensor or circuit fails or if there is a lack of oil pressure in th...

Page 208: ...e lower cylinder port to the upper cylin der port Crankcase Main Bearing Recirculation The movement of oil through the main bearings is controlled by internal passages external fittings and hoses and check valves Oil moves from the crankcase areas of the higher cylinders through grooved passages in the crank case to the center and lower main bearings Addi tional oil moves through intake manifold p...

Page 209: ...ral hours of operation above idle speed OILING SYSTEM TESTS IMPORTANT Always perform visual inspections to identify oiling system leaks Make sure the oil tank is filled and oil supply is not contaminated Oil Injection Pump Static Test IMPORTANT Static tests are performed with the outboard not running Use Evinrude Diagnostics software to activate the Oil Injector test This test starts the EMM contr...

Page 210: ...rcuit includes EMM alternator output the engine wire harness the injection pump wind ing and connectors and the oil injector control cir cuit of the EMM Check continuity of all wiring and connections Disconnect the battery cables at the battery Use an appropriate test probe to make a connec tion to pin 1 of the oil injection pump connector Calibrate ohmmeter to the LOW OHMS scale and measure the r...

Page 211: ...ster to the outboard side of oil supply hose and draw 7 in Hg 24 kPa vacuum on the hose for at least five minutes Repair or replace any leaking components Reinstall the oil hose Check height of pickup assembly Place a new seal on oil tank and reinstall pickup with filter into oil tank Install and tighten screws WARNING Wear safety glasses to avoid personal injury and set compressed air pressure to...

Page 212: ...oil check for a kinked or restricted hose before replacing the oil injection pump assembly Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remove oil distribution hose from crankcase fit ting Temporarily install a length of oil hose on the fitting Use a Syringe P N 346936 filled with isopropyl alcohol to force fluid t...

Page 213: ...r manifold hose does not use a hose support IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is fully inserted into manifold Insertion depth is 5 8 in 16 mm Visually inspect for hose supports WARNING To prevent accidental starting while ser vicing disconnect the battery cables at the battery Oil Distribution Hose Length Primary oil manifold to cylind...

Page 214: ...m the crankcase fittings Remove oil injection pump screws bracket and clamps Remove the oil injection pump assembly IMPORTANT The oil injection pump and mani fold is an assembly and cannot be serviced as individual components Installation Route oil distribution hoses from the oil distribu tion manifold to the crankcase oil delivery fittings as they were before removal Refer to OIL SUP PLY DIAGRAMS...

Page 215: ...ector IMPORTANT Use oil primer bulb to purge air from oil supply hose before reconnecting hose to oil pump Reconnect oil supply hose to the inlet fitting of oil pump Fasten with Oetiker clamp Make sure oiling system is primed Check oil flow through oil distribution hoses Check oil system operation and routing of oil hoses Refer to Oil Supply Priming on p 54 Run the outboard and check for leaks Rep...

Page 216: ...214 OILING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 217: ...OSTATS 219 BLOCK VENTING 219 WATER PRESSURE CONNECTION 219 OPERATION 220 CYLINDER BLOCK CYLINDER HEAD COOLING 220 EMM AND VAPOR SEPARATOR COOLING 220 ENGINE TEMPERATURE CHECK 221 SOFTWARE METHOD 221 PYROMETER METHOD 221 IDLE OPERATING TEMPERATURE TROUBLESHOOTING BELOW RANGE 222 THERMOSTAT SERVICING 223 DISASSEMBLY 223 INSPECTION 223 ASSEMBLY 223 PRESSURE RELIEF VALVE SERVICING 224 DISASSEMBLY 224 ...

Page 218: ...e valve 8 Cylinder head water outlet 9 Cylinder block vent 10 Water supply to EMM 11 Water supply EMM to vapor separator 12 Vapor separator to overboard indicator 6 6 6 8 10 11 12 7 9 1 3 2 4 5 1 2 3 4 5 6 7 8 9 10 11 12 Water intake screens Water pump Water tube Adapter housing Cylinder block Thermostat Pressure valve Cylinder head water outlet Cylinder block vent Water supply to EMM Water supply...

Page 219: ...essure valve 8 Cylinder head water outlet 9 Cylinder block vent 10 Water supply to EMM 11 Water supply EMM to vapor separator 12 Vapor separator to overboard indicator 12 11 10 9 8 7 6 6 5 4 3 2 1 Outgoing water warm hot Incoming water cool 1 2 3 4 5 6 7 8 9 10 11 12 Water intake screens Water pump Water tube Adapter housing Cylinder block Thermostat Pressure valve Cylinder head water outlet Cylin...

Page 220: ...0 RPM and as a centrifugal pump at HIGHER speeds Refer to WATER PUMP SERVICE on p 304 for water pump servicing Water Supply Tube The water pump outlet connects with the water supply tube located in the outboard s midsection Grommets seal the water tube to the water pump housing and the inner exhaust housing Water supplied to the water tube provides all cool ing water to the adapter housing and cyl...

Page 221: ...m perature at lower speeds below 2500 RPM Overheating A restricted or faulty thermostat typ ically results in LOW SPEED overheating Overcooling Debris may prevent the thermostat from closing completely Block Venting A fitting and hose from the top of the block allows the constant movement of water and or air from the block Circulated water flows through the EMM and Vapor Separator before exiting t...

Page 222: ...d At higher speeds water pressure opens the pressure relief valve at approximately 2500 RPM Water flows through the valve and bypasses the thermostats Hoses route the water flow from the pressure valve to the vertical water passages below the thermostats All water flows through the cylinder heads to the outlet passages of the block and then exits through the adapter housing This pressure controlle...

Page 223: ...ng system If engine temperature tests within range but the SystemCheck gauge indicates a WATER TEMP warning refer to WATER TEMP HOT Circuit Test on p 149 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature displays at IDLE speed should be 160 F 20 F 71 C 11 C Typical temperature displays at WOT speed should be 120 F 20 F 50 C 11 C Operating temperatu...

Page 224: ...rating range replace pressure relief valve assembly and plunger seal To test pressure relief valve operation monitor temperature at the thermostat housing with Tem perature Gun P N 772018 or digital pyrometer Confirm normal IDLE operating temperature Slowly increase engine speed from IDLE up through 3000 RPM Engine temperature should decrease from normal IDLE temperatures as pressure relief valve ...

Page 225: ...D facing thermostat Refer to Cylinder Head Installation on p 242 Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly Assembly is the reverse of disassembly Pay close attention when performing the following additional tasks Coat threads of each cylinder head thermostat cover with Gasket Sealing Compound Install...

Page 226: ...e away from the pressure relief valve Remove screws and cover from pressure valve assembly Remove the pressure relief valve assembly Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly Assembly is the reverse of disassembly Pay close attention when performing the following additional tasks Tighten cover screws...

Page 227: ...238 BEARINGS 238 POWERHEAD ASSEMBLY 239 CRANKSHAFT ASSEMBLY 239 PISTONS AND CONNECTING RODS 240 CYLINDER HEAD INSTALLATION 242 CRANKSHAFT AND CONNECTING RODS 243 CRANKCASE ASSEMBLY 246 SHIFT LINKAGE INSTALLATION 248 THROTTLE LINKAGE INSTALLATION 248 FINAL POWERHEAD ASSEMBLY 249 UPPER MOUNT SERVICING 250 POWERHEAD INSTALLATION 251 POWERHEAD VIEWS 255 V4 STARBOARD HOSE ROUTINGS 255 V4 PORT HOSE ROUT...

Page 228: ...A B 60 84 In lbs 7 9 5 N m A A B 20 22 Ft lbs 27 30 N m 120 144 In lbs 14 16 N m F F 120 144 In lbs 14 16 N m Q M 31 35 Ft lbs 42 47 5 N m H A 40 50 In lbs 4 5 5 5 N m A B 60 84 In lbs 7 9 5 N m A L 40 50 In lbs 4 5 5 5 N m L 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m B 005230 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubrican...

Page 229: ... 11 DSS135 A Triple Guard Grease B Gasket Sealing Compound E Red Ultra Lock G Needle Bearing Grease H Outboard Engine Lubricant X See Service Manual Text 005229 H H G H 30 32 Ft lbs 41 43 N m H X B A A H A A H E 48 In lbs 5 5 N m ...

Page 230: ... 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 on p 183 To prevent accidental starting while ser vicing disconnect the battery cables at the battery 005248 005272 1 Tilt limit switch connector 2 Sending unit connector 00525...

Page 231: ...g an Allen 1 4 in hexagonal wrench Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist Remove the four small powerhead screws seven large powerhead screws and the upper mount screws Use a suitable tool to carefully separate the pow erhead from exhaust housing IMPORTANT Do not damage the powerhead adapter mating surfaces when separating 1 Actuator connector 00524...

Page 232: ... coils and fuel injectors Refer to Fuel Injector Service on p 187 IMPORTANT Mark injectors for cylinder loca tion before removal All injectors must be installed in their original location Improper injector installa tion can result in powerhead failure Remove throttle linkage Refer to Throttle Link age Removal on p 230 Remove shift linkage Refer to Shift Linkage Removal on p 230 Remove the throttle...

Page 233: ...cylinder block It may be necessary to tap on crankshaft with a rawhide or rubber mallet to loosen Carefully remove the crankcase from the cylinder block to avoid damaging the crankshaft seal rings Cylinder Head Removal Remove thermostat cover and thermostat assem bly Refer to THERMOSTAT SERVICING on p 223 Loosen in stages and remove cylinder head retaining screws Remove the cylinder head Discard t...

Page 234: ... rod assembly IMPORTANT Reattach each rod cap to its rod as soon as the piston is removed Each cap is unique and can only be installed on its mated rod Do not allow rod to contact inside surface of cylin der or crankshaft IMPORTANT Identify all internal components so that if reused they can be reinstalled in their original positions Repeat steps for each remaining piston and con necting rod Use an...

Page 235: ...e 28 needle bear ings or the two wrist pin washers If any of the bearings are worn or lost replace all 28 bearings during reassembly Crankshaft Removal Carefully lift crankshaft straight up and remove from crankcase Remove upper seal from crankshaft Discard the seal A new upper seal must be installed on assembly Remove the lower bearing seal housing Remove the housing O ring Discard O ring 46520 W...

Page 236: ...and replace if nec essary To remove the sleeve use Slide Hammer P N 432128 and Large Puller Jaws P N 432129 Remove the lower main bearing only if it needs to be replaced Use external retaining ring pliers to remove the lower bearing retaining ring IMPORTANT If the lower main bearing is removed from the crankshaft it must be dis carded DO NOT reuse it Use a bearing separator to support the bearing ...

Page 237: ... 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 visible in the cylinder wall The pattern should be uniform in both dir...

Page 238: ...event corrosion POWERHEAD INSPECTION For dimensions refer to SERVICE SPECIFICA TIONS on p 10 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 componen...

Page 239: ...der bore for an out of round oversize or tapered condition Be sure the gauge is per fectly square in the bore when measuring Measure each cylinder in at least two areas Each area should be measured twice The difference between the two measurements in each area is the cylinder out of round dimension The cylinder must not be out of round by more than 0 004 in 0 10 mm The dimensional difference betwe...

Page 240: ...n 0 08 mm for each 0 001 in 0 025 mm increase in cylinder bore diameter DO NOT exceed cylinder oversize dimension Use a machinist s straightedge to check for proper ring clearance Position piston rings on 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 Ins...

Page 241: ...nstaller 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 Use retaining ring pliers to install bearing retaining ring with sharp edge facing away from bearing Lubricate a new driveshaft O ring and lightly lu...

Page 242: ...not apply sealer to outside diameter of the seal Pistons and Connecting Rods IMPORTANT It is very important that the pis tons in this engine are installed in the correct loca tion and direction New pistons are stamped PORT or STBD and EXH These markings should be turned toward the exhaust side center of the block The splash bowl on the dome of the piston will be located toward the flywheel and opp...

Page 243: ...rist pin Place connect ing rod with bearings washers and tool into the piston with the alignment dots facing the top of the piston Install wrist pin through piston and connecting rod pushing bearing tool out through the piston Use Wrist Pin Cone P N 318600 and Driver P N 318599 to install new wrist pin retaining rings in each wrist pin hole Gap of retaining ring faces away from notch in piston 1 O...

Page 244: ...linder walls and Ring Com pressor P N 336314 with outboard lubricant Center connecting rod in piston and locate piston rings on dowel pins Place appropriate ring com pressor on piston Slide piston and rod assembly into the correct cyl inder as marked during disassembly Guide con necting rod through cylinder block to avoid scratching cylinder wall Cylinder Head Installation Install a new thermostat...

Page 245: ...Rods Apply Gasket Sealing Compound to lower oil seal groove in cylinder block DO NOT put any sealer in upper seal groove Check that main bearing alignment dowel pins are seated in the block Push all pistons to the top of cylinders Remove numbered connecting rod caps Gently lower crankshaft into place Turn all crankcase seal ring gaps to face up Align tab on lower bearing seal housing with hole in ...

Page 246: ...T Be sure alignment dot on rod cap matches dot on rod and that both dots face fly wheel IMPORTANT Tightening rod cap screws with out Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent dam age to the connecting rod and crankshaft To maintain accurate torque values keep torque wrench extension length to a minimum Install Rod Cap Alignment Fixture P N 396749 before tig...

Page 247: ... is centered on the side of the rod Tighten forcing screw until jaws contact con necting rod Slide frame down until adjustment stop contacts the rod cap The groove lines on the jaws must be centered on the rod crankpin diameter Tighten the forcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 N m IMPORTANT Make sure that frame is squarely in position and that rod and cap are aligned Loosen both ...

Page 248: ... and let air dry IMPORTANT DO NOT allow solvent to get on internal components Clean only the mating flanges Apply Gasket Sealing Compound to lower oil seal groove in crankcase DO NOT put any sealer in upper seal groove Use a small brush with a tapping motion to apply a thin even coat of Gel Seal II sealant to the crank case mating flange The sealer must not come within 1 4 in 6 4 mm of bearings IM...

Page 249: ...crews in stages to a final torque of 31 to 35 ft lbs 42 to 47 5 N m Start in the center and work outward in a spiral pattern Apply Nut Lock to crankcase flange screws Install screws and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Test that the crankshaft spins freely without bind ing IMPORTANT After powerhead has been assembled allow at least two hours for Gel Seal II to cure before runnin...

Page 250: ...sher and tighten screw to a torque of 120 to 144 in lbs 13 5 to 16 5 N m Throttle Linkage Installation Apply Nut Lock to threads of throttle lever screw Insert spring into cavity of throttle lever Install lever screw and washer on crankcase and hook spring on rib as shown Tighten screw to a torque of 120 to 144 in lbs 13 5 to 16 5 N m Apply Nut Lock to threads of throttle cam screw Install cam scr...

Page 251: ... to Fuel Injector Installation on p 188 IMPORTANT All injectors must be reinstalled in their original location Improper injector installation can result in powerhead failure Install oil pump rear oil manifold and oil injection hoses Refer to OIL COMPONENT SERVICING on p 211 Install flywheel and stator Refer to FLYWHEEL AND STATOR SERVICING on p 151 Install electrical harness with flywheel cover ba...

Page 252: ... housings with a large blunt punch to loosen the mount retainer Dislodge mount assemblies and remove Inspect mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble 1 Mount retainer screw 005309 WARNING Wear safety glasses to avoid injury 005311 1 005312 39820 ...

Page 253: ...sket around the exhaust port only Install gasket on adapter To ensure proper sealing mating sur faces must be clean and dry IMPORTANT V4 and V6 base gaskets are NOT interchangeable Be sure to use the correct part Coat the driveshaft splines with Moly Lube Do not apply lubricant to end of driveshaft Use Lifting Tool P N 342672 and hoist to slowly lower powerhead onto exhaust housing If neces sary r...

Page 254: ...ment Pins and tighten screws 5 through 7 to a torque of 20 to 22 ft lbs 27 to 30 N m Ttighen the four small powerhead screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Tighten the upper mount screws to a torque of 110 to 130 ft lbs 149 to 176 N m Make sure that screw heads are tight against steering arm IMPORTANT Retighten powerhead mounting screws after outboard has been run at full operat ing t...

Page 255: ...shaft spins freely in neutral Fill exhaust valve actuator electrical connector with Electrical Grease and install on actuator V4 models IMPORTANT Leave enough slack in harness so that lower cover will not pull it away from actua tor Connect the power trim connectors Install air silencer and air temperature sensor 1 Shift rod screw 005253 1 Actuator connector 005247 1 1 1 Tilt limit switch connecto...

Page 256: ...rk plugs Refer to Spark Plug Indexing on p 84 Adjust timing pointer and check engine timing Refer to TIMING ADJUSTMENTS on p 154 Use Evinrude Diagnostics software to start pow erhead break in oiling Refer to Powerhead Break In on p 106 Prime oiling system Refer to Oiling System Oil Supply Priming on p 61 Run outboard and check for water fuel or oil leaks Make sure engine reaches correct operating ...

Page 257: ...255 POWERHEAD POWERHEAD VIEWS 11 POWERHEAD VIEWS V4 Starboard Hose Routings 006790 ...

Page 258: ...256 POWERHEAD POWERHEAD VIEWS V4 Port Hose Routings 02406 006791 ...

Page 259: ...POWERHEAD POWERHEAD VIEWS 257 11 V4 Starboard 006792 ...

Page 260: ...258 POWERHEAD POWERHEAD VIEWS V4 Port 02406 006793 ...

Page 261: ...POWERHEAD POWERHEAD VIEWS 259 11 V4 Front 006794 ...

Page 262: ...260 POWERHEAD POWERHEAD VIEWS V4 Rear 006795 ...

Page 263: ...POWERHEAD POWERHEAD VIEWS 261 11 V4 V6 Top Hose Routings 006796 ...

Page 264: ...262 POWERHEAD POWERHEAD VIEWS V4 V6 Top 006797 ...

Page 265: ...POWERHEAD POWERHEAD VIEWS 263 11 V6 Starboard Hose Routings 006798 ...

Page 266: ...264 POWERHEAD POWERHEAD VIEWS V6 Port Hose Routings 006799 ...

Page 267: ...POWERHEAD POWERHEAD VIEWS 265 11 V6 Starboard 006801 ...

Page 268: ...266 POWERHEAD POWERHEAD VIEWS V6 Port 006800 ...

Page 269: ...267 POWERHEAD POWERHEAD VIEWS 11 V6 Front 006802 ...

Page 270: ...268 POWERHEAD POWERHEAD VIEWS V6 Rear 006803 ...

Page 271: ...4 EXHAUST HOUSING 275 EXHAUST HOUSING REMOVAL 275 EXHAUST HOUSING DISASSEMBLY 276 CLEANING AND INSPECTION 277 EXHAUST HOUSING ASSEMBLY 277 EXHAUST HOUSING INSTALLATION 280 STERN BRACKET 281 STERN BRACKET REMOVAL 281 STERN BRACKET DISASSEMBLY 281 STERN BRACKET ASSEMBLY 283 EXHAUST RELIEF MUFFLER ASSEMBLY 286 ...

Page 272: ...bs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m A A A A A B 120 144 In lbs 13 5 16 5 N m A 110 130 Ft lbs 149 176 N m 216 240 In lbs 25 27 N m U F A IMPORTANT Use Triple Guard grease on all pivot points A Triple Guard Grease B Gasket Sealing Compound F Blue Nut Loc...

Page 273: ...In lbs 7 9 5 N m A 60 84 In lbs 7 9 5 N m A 60 84 In lbs 7 9 5 N m A P 216 240 In lbs 24 5 27 N m A 60 84 In lbs 7 9 5 N m A A Q A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock L Pipe Thread Sealing Compound P Permatex 2 Q Gel Seal II 005203 ...

Page 274: ...272 MIDSECTION SERVICE CHART ...

Page 275: ...llar Remove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer from Tilt Tube Service Kit P N 434523 onto the starboard end of the tilt tube Remove steering cable wiper nut from tilt tube Thread the adapter from Tilt Tube Service Kit P N 434523 onto the port end of the tilt tube WARNING Support the outboard with a suitable hoist 1 Locking tabs 30749 3074...

Page 276: ...e a wood or leather mallet to tap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft lbs 61 to 68 N m Replace steering cable wiper nut on port end of tilt tube Apply one drop of instant bonding adhesive in receiving channels of tilt limit switch collar and install collar and tilt cam on ...

Page 277: ...VAL AND INSTAL LATION on p 301 The powerhead must be removed Refer to POWERHEAD REMOVAL on p 228 Remove and discard four lower mount screws Remove the exhaust housing Remove lower mount covers and inspect the lower mounts If replacement is necessary lubricate mount with soapy water and carefully pry at both ends to remove 20 Models 23036 25 Models 32590 005223 32578 ...

Page 278: ...e exhaust housing Remove the water tube Inspect water tube grom met and replace if necessary V4 MODELS Remove circlip and washers from exhaust valve shaft on starboard side of inner exhaust housing Remove exhaust valve shaft and washer from port side of inner exhaust housing Remove exhaust valves from inside the inner exhaust housing 1 Actuator screws 005206 1 Adapter retaining screws 005205 00520...

Page 279: ...ss by measuring the run out on the top edge of housing The maximum allowable run out is 0 009 in 0 228 mm If you do not have access to a dial indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a distorted housing Replace it IMPORTANT A distorted exhaust housing will cause the upper driveshaft splines to wear exces sively and will damage the crankshaft spli...

Page 280: ...sing with lever angled toward top of housing Secure shaft with spring washer flat washer and circlip ALL MODELS Apply Adhesive 847 to the bottom flange of the inner exhaust housing Install a new seal Apply Triple Guard grease to outer seal surface Install the water tube 005215 005216 005212 1 Circlip 2 Spring washer 005211 1 Adhesive 847 2 Triple Guard grease 005217 1 Water tube grommet 005210 2 1...

Page 281: ...hat exhaust valve linkage is oriented as shown Apply Triple Guard grease to threads of adapter retaining screws Tighten two forward screws to a torque of 216 to 240 in lbs 24 5 to 27 N m and rear screw to a torque of 60 to 84 in lbs 7 to 9 5 N m If removed coat the lower mounts with soapy water and press into the exhaust housing with the OUTSIDE mark facing outward Install the mount covers Apply N...

Page 282: ...ers Tighten screws to 60 to 84 in lbs 7 to 9 5 N m IMPORTANT Fill actuator electrical connec tors with Electrical Grease before installation Exhaust Housing Installation Bring the exhaust housing into position with the stern bracket Install four new lower mount screws with lock patch Tighten screws to a torque of 38 to 45 ft lbs 51 to 61 N m Install powerhead Refer to POWERHEAD INSTALLATION on p 2...

Page 283: ...275 Remove power trim tilt unit Refer to TRIM AND TILT section Stern Bracket Disassembly Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaft and thrust washer It may be necessary to tap the steering shaft out using a wood dowel and mallet Pry out upper and lower steering shaft seals and discard Remove the upper and lower steering shaft bush...

Page 284: ...the braided tube Remove the tilt limit switch and retainer from the swivel bracket Disconnect the trail lock spring and remove it from the swivel bracket Remove trail arm retainer Remove the trail lock arm and bushings from the swivel bracket 1 Anode 30762 1 Tilt tube bushing 30761 30760 1 1 1 Tilt limit switch 2 Retainer 30758 1 Trail lock spring 2 Trail arm retainer 30756 1 Trail lock bushing 30...

Page 285: ...re proceeding make sure all components have been thoroughly cleaned Replace any seals that have been removed Inspect all thrust washers and bushings for evi dence of deterioration Install the detent roller and spring and the tilt sup port with bushing in the swivel bracket Tighten bushing to a torque of 28 to 30 ft lbs 38 to 41 N m 1 Trim rod roller 30754 1 Tilt support bushing 30753 1 1 30752 1 T...

Page 286: ...the tilt limit switch and retainer on the swivel bracket Tighten screws to a torque of 40 to 50 in lbs 4 5 to 5 5 N m Route the trim sender wires through the braided tube and install the sender unit in the port stern bracket Install the upper and lower steering shaft bushings and new seals in the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compound...

Page 287: ...ply Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket Align the bracket with the steering arm and tighten the nut to a torque of 130 to 150 ft lbs 176 to 204 N m Fill the swivel bracket with Triple Guard grease through the grease fitting on the bracket s port...

Page 288: ...embly The muffler assembly connects to the exhaust relief hoses at the base of the powerhead The overboard indicator and flush port in the exhaust relief grommet connect to the vapor sepa rator with a hose This hose is not connected to the muffler assembly Periodically inspect hoses and connections for condition Replace muffler or hoses as needed 1 Exhaust relief grommet 005220 1 Exhaust relief ho...

Page 289: ...RVICE 314 SHIFT HOUSING GEAR AND PROPELLER SHAFT REMOVAL 315 WATER INTAKE SCREENS 315 GEARCASE HOUSING INSPECTION 316 SHIFTER BEARING AND SEAL SERVICE 316 SHIFT HOUSING DISASSEMBLY 316 SHIFT HOUSING ASSEMBLY 317 PINION BEARING REMOVAL 319 PINION BEARING INSTALLATION 320 DRIVESHAFT BEARING HOUSING SERVICE 321 PROPELLER SHAFT BEARING HOUSING SERVICE 322 DRIVESHAFT SHIMMING 325 GEARCASE ASSEMBLY 327 ...

Page 290: ...L SERVICING 341 SHIFT HOUSING DISASSEMBLY 341 SHIFT HOUSING ASSEMBLY 342 PINION BEARING 344 PROPELLER SHAFT BEARING HOUSING AND FORWARD GEAR O TYPE 344 PROPELLER SHAFT BEARING HOUSING AND FORWARD GEAR M AND M2 TYPE 348 DRIVESHAFT SHIMMING 351 GEARCASE ASSEMBLY 353 WATER INTAKE SCREENS 353 SHIFT HOUSING GEAR AND PROPELLER SHAFT INSTALLATION 353 SHIFT ROD COVER 353 PINION GEAR AND DRIVESHAFT INSTALL...

Page 291: ...n lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A A 14 18 In lbs 1 5 2 N m X G A B 120 144 In lbs 13 5 16 5 N m 37 41 Ft lbs 50 56 N m A A 006595 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock ...

Page 292: ...6 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A J 14 18 In lbs 1 5 2 N m X G A B E E B 15 20 In lbs 1 7 2 3 N m 18 20 Ft lbs 24 27 N m A 70 80 Ft lbs 95 109 N m A A 006592 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red ...

Page 293: ... 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A J 14 18 In lbs 1 5 2 N m X B 100 Ft lbs 136 N m J G 144 168 In lbs 16 19 N m F X B B E E B A B 108 132 In lbs 12 15 N m 15 20 In lbs 1 7 2 3 N m 18 20 Ft lbs 24 27 N m A 70 80 Ft lbs 95 109 N m A A 006593 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 84...

Page 294: ...n lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A J X G A A E E B 15 20 In lbs 1 7 2 3 N m 18 20 Ft lbs 24 27 N m 70 80 Ft lbs 95 109 N m A A 006596 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Need...

Page 295: ...in lbs 6 8 9 5 N m B B 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m B 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 27 N m A G A B B 108 132 In lbs 12 15 N m B B E 18 20 Ft lbs 24 27 N m A C A 70 80 Ft lbs 95 109 N m A 006829 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock...

Page 296: ... 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A J 14 18 In lbs 1 5 2 N m X G A A E E B 15 20 In lbs 1 7 2 3 N m 18 20 Ft lbs 24 27 N m A 70 80 Ft lbs 95 109 N m A 006591 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ult...

Page 297: ...4 In lbs 7 9 5 N m 120 144 In lbs 13 5 16 5 N m G 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B C A A A J 14 18 In lbs 1 5 2 N m J G X 200 Ft lbs 271 N m B X 006590 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Mol...

Page 298: ...bs 24 27 N m A 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m B 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 108 132 In lbs 12 15 N m A A E 18 20 Ft lbs 24 27 N m A G A C J 30 34 Ft lbs 41 46 N m 70 80 Ft lbs 95 109 N m A 006830 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F ...

Page 299: ...N m A B B 18 20 Ft lbs 24 27 N m A 26 28 Ft lbs 35 38 N m 40 50 Ft lbs 54 68 N m B B 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 60 84 in lbs 6 8 9 5 N m B 30 34 Ft lbs 41 46 N m C 70 80 Ft lbs 95 109 N m A 100 Ft lbs 136 N m J 006831 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Loc...

Page 300: ...standard gearset V6 14 26 538 60 V6 90 V6 20 in 60 V6 90 V6 25 in L2 high speed profile external water screens pressed in propeller bearing housing performance gearset V6 583 ratio is original equipment on 225HO 250 300 HP 14 26 538 and 14 24 583 90 V6 20 in 60 V6 90 V6 25 in 90 V6 30 in M heavy duty gearset V6 13 24 542 60 V6 25 in 90 V6 25 in 30 in Counter Rotation CR shafts bearings and heavy d...

Page 301: ...GEARCASE GEARCASE TYPES 13 Housing Profiles 4 124 19 079 V4 S S2 Type V6 O Type V6 L Type 19 20 4 918 V6 L2 Type 0 54 0 58 Ratios 4 918 19 20 V6 M Type 19 20 5 078 V6 M2 Type 5 082 19 20 19 20 4 625 006832 ...

Page 302: ...etermine source of leak If the gearcase pressure gauge does not indicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leakage Make necessary repairs and repeat test Install vacuum test gauge Apply 3 to 5 in of vac uum 76 to 127 mm Hg with pump Check for leakage If leakage occurs apply oil around suspected seal If leak then stops or oil is drawn in that seal is defective Repea...

Page 303: ...le screw Remove the four gearcase retaining screws Remove the gearcase assembly from the exhaust housing being careful not to bend the shift rod or damage the water tube The lower inner exhaust housing may come out with the gearcase WARNING To prevent accidental starting while ser vicing twist and remove all spark plug leads During service the outboard may drop unexpectedly Avoid personal injury a...

Page 304: ...de the gearcase into place making sure Driveshaft 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 Use Gearcase Alignment Kit P N 5007231 to accurately align gearcase housing to exhaust housing Position alignment bolts 2 as indicated IMPORTANT Remove and replace ...

Page 305: ...tment refer to Trim Tab Adjustment on p 70 IMPORTANT Standard rotation and counter rotation trim tabs must not be interchanged This would result in inadequate cooling water supply to the propeller hub Place the shift rod in the shift rod lever Install the retaining pin and washer Tighten pin to a torque of 60 to 84 in lbs 7 to 9 5 N m IMPORTANT During break in period of a reas sembled gearcase cha...

Page 306: ...ortion and impeller material transfer Inspect the housing for cracks or melting Assembly Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs IMPORTANT Do not allow any sealer to get into the air bleed groove in the impeller housing If this groove is blocked by adhesive the pump will lose its prime and will not pump water Install the O ring in groove in the impeller housin...

Page 307: ...all the special shaped O ring seal Apply Gasket Sealing Compound to both sides of a new impeller plate gasket Install the gasket and impeller plate Apply Triple Guard grease to a new impeller O ring Slide the O ring down the driveshaft and slide half way over installed drive cam to tempo rarily hold cam in place The sharp edge of the cam is the leading edge in clockwise rotation Slide the water pu...

Page 308: ... be checked Refer to SHIFT ROD ADJUSTMENT on p 306 SHIFT ROD ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge P N 389997 With the gearcase in NEUTRAL rotate the shift rod up or down as necessary for correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTAN...

Page 309: ...k for twisted splines and damaged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase 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...

Page 310: ...g Remove wedge screw and washer Remove the propeller shaft bearing housing from the gearcase using the following Puller body screw and handle from Universal Puller Set P N 378103 Two 5 16 18 x 11 in 279 mm threaded rods two large 5 16 in I D flat washers and two 5 16 18 nuts obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing a...

Page 311: ... holding the propeller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using Propeller Shaft Bearing Housing Puller Kit P N 354060 DO NOT use tools designed to push on the pro peller shaft Pushing force against the propeller shaft could damage the forward gear thrust bear ing or thrust washer IMPORTANT The L2 type gearcase uses the adaptor ring included with pull...

Page 312: ...gear from gearcase Pinion Gear and Driveshaft Removal S2 Type IMPORTANT To separate the upper driveshaft from the lower driveshaft the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft Remove the four driveshaft bearing housing screws and bearing housing Remove upper retainer L2 Type Gearcase 006836 M2 Type Gearcase 006837 006838 1 Driveshaft bearing housing...

Page 313: ... gear thrust bearing and thrust washer Push down on shift rod to move the clutch dog to reverse position Pull propeller shaft aft to disen gage from forward gear and shift housing Allow shaft to drop against lower gearcase housing This will assist in the removal of the pinion gear Use the required tools to remove the pinion screw and gear from the lower driveshaft 005424 Upper Driveshaft Removal 0...

Page 314: ...veshaft Wrench is fully seated in head of pinion screw Use a long 3 4 in combination wrench to hold lower Driveshaft Spline Tool and a 1 2 drive wrench to turn the Lower Driveshaft Wrench in a counterclockwise direction Loosen screw com pletely Remove the four driveshaft bearing housing screws and then the bearing housing Remove shims thrust washer and thrust bearing with the lower driveshaft 1 Lo...

Page 315: ...P N 341438 to loosen the pinion nut from the bottom of the driveshaft Pad handle of holder to prevent damage to gearcase Remove the four driveshaft bearing housing screws Remove driveshaft from the gearcase The bear ing housing shims thrust bearing and thrust washer will come out with the driveshaft If driveshaft cannot be removed refer to Locked Driveshaft Removal on p 314 005420 1 Holding socket...

Page 316: ...and the gearcase until the driveshaft pops loose from the pinion If upper driveshaft becomes separated from lower driveshaft use Lower Driveshaft Puller P N 342681 to remove Install puller into lower driveshaft and turn 90 to position hook under pin in driveshaft Thread Slide Hammer P N 391008 into puller and remove driveshaft Driveshaft Service To separate the upper driveshaft if needed from the ...

Page 317: ...move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out Unscrew the shift rod from the detent lever Remove screws cover and shift rod from the gearcase Discard the cover gasket Remove and discard the shift rod O ring from inside of cover Remove propeller shaft assembly from gearcase Water Intake Screens Remove and clean water intake screens Replace ...

Page 318: ... Type gearcase housings IMPORTANT DO NOT force gauging shaft into alignment hole Shaft MUST slide easily into hole of gauging head If shaft does not slide into hole gearcase housing is damaged and must be replaced SHIFTER BEARING AND SEAL SERVICE Shift Housing Disassembly IMPORTANT The shift housing and bearing are serviced as an assembly If either are worn or damaged replace the complete assembly...

Page 319: ...inspection O L and M Type Shift Housing Assembly IMPORTANT Clean and inspect all parts before beginning assembly procedures Replace any damaged parts Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at 90 angle into the housing as shown while depressing the ball and spring with a suitable tool Once the shifter d...

Page 320: ...insert the retaining pin Push shifter detent down Rest the cradle on the shift shaft Place the shift lever arms into the recesses of the shift cradle Pull shifter detent back up to NEU TRAL 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 ...

Page 321: ...d the gears Slide the propeller shaft onto the shift shaft align the hole in the shaft with the hole in the clutch dog install the pin and then a new clutch dog retaining spring Place three coils over each end of the pin MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE Pinion Bearing Removal Remove pinion bearing retaining screw Assemble Pinion Bearing Remover and Installer P N 391257 in the gea...

Page 322: ...91260 4 Rod P N 326582 5 Installer Remover P N 326574 6 1 4 20 x 1 1 4 in Hex Head Screw 824163 1 Flange nut P N 326586 2 Plate P N 391260 3 Rod P N 326582 4 Remover P N 326579 DR3419 1 2 3 4 5 6 1 2 3 4 S2 Type Gearcases 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 6 Installer Remover P N 326574 7 1 4 20 X 1 1 4 in Hex head screw ...

Page 323: ... the tool contacts the spacer Remove the tool Position new O ring on the pinion bearing retain ing screw Apply Gasket Sealing Compound to O ring Apply Nut Lock to screw threads Install the screw and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Driveshaft Bearing Housing Service The driveshaft bearing is not serviceable Replace the bearing housing assembly if the bearing is worn or damaged A...

Page 324: ...ler Shaft Bearing Housing Service 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 IMPORTANT Inspect bearings in place If a bearing is removed for any reason it must be dis carded Remove either bearing using Puller Bridge P N 4...

Page 325: ...t might cut O ring Remove any nicks or burrs on front of bearing housing Bearing Installation Oil then install new bearings in bearing housing Place the lettered end of the bearing case on the bearing installer then press the bearing into the housing until the tool seats When installed the lettered end of the bearing should be visible STANDARD ROTATION HOUSING Bearing Installation Tool P N 326562 ...

Page 326: ...llation Tool to install new seals back to back in bearing housing Seal Installation Tool P N 326551 S2 Type gearcases P N 336311 O L and M Type gearcases P N 354056 M2 O L L2 and M type gearcases with longer propeller shaft housing Install inner seal with lip facing toward the bearing housing then outer seal with lip facing away from the bearing housing Apply Triple Guard grease to seal lips 1 For...

Page 327: ...used in final assembly Use Shimming Screw P N 352878 service tool for shimming procedure O L L2 M AND M2 TYPE GEARCASES IMPORTANT Degrease pinion and driveshaft tapers prior to assembly Check tapers for any damage or material transfer Replace any dam aged components before proceeding Assemble the driveshaft bearing housing thrust washer thrust bearing and pinion onto the drive shaft Use Driveshaft...

Page 328: ...ral locations If variance is greater than 0 002 in 0 050 mm replace the pinion or driveshaft as necessary and repeat check Subtract the average clearance measurement from 0 020 in 0 508 mm to determine the cor rect shim thickness required Select the fewest number of shims to achieve the correct thickness Remove the driveshaft from the tool and add the required shims between the bearing housing and...

Page 329: ...ation of the shaft assembly Be sure the thrust bearing and the thrust washer are in the proper position Insert the shaft assem bly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing Shift Rod Cover Lubricate a new shift rod cover O ring with Triple Guard grease Install the O ring into the shift rod cover IMPORTANT Make sure O ring is fully seated ...

Page 330: ...e gearcase M2 TYPE GEARCASES Apply Adhesive 847 to seal groove of shift rod cover Place a new shift rod cover seal in groove ALL GEARCASES 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 locator pin hole in the gearcase Apply Gasket Sealing Comp...

Page 331: ...e housing This will allow the installation of the pinion gear IMPORTANT Forward gear and thrust bearing and washer can become misaligned Make sure forward thrust washer and thrust bearing and for ward gear are properly aligned with shift housing before continuing gearcase assembly Install pinion gear in gearcase housing Install driveshaft with thrust bearing thrust washer and correct shim s in gea...

Page 332: ...t Seat hex tip of wrench in head of pin ion screw IMPORTANT Make sure Lower Driveshaft Wrench is fully seated in head of pinion screw Use a long 3 4 in combination wrench to hold Driveshaft Spline Tool and a 1 2 drive torque wrench to turn the Lower Driveshaft Wrench in a clockwise direction Torque pinion screw to 37 to 41 ft lbs 50 to 56 N m Temporarily remove the four driveshaft bearing housing ...

Page 333: ...lower driveshaft position new retainers circlip type on upper driveshaft as shown Hold lower retainer and align upper driveshaft with lower driveshaft Force upper driveshaft down until seated Driveshaft should lock in place 1 Retainer s 005412 005413 1 Upper Driveshaft Installation 0054 ...

Page 334: ...allation O L L2 M and M2 Type Refer to DRIVESHAFT SHIMMING on p 325 Install new seals in driveshaft bearing housing Refer to Driveshaft Bearing Housing Service on p 321 Place the driveshaft thrust bearing thrust washer and correct shim s on the driveshaft as shown Using Driveshaft Seal Protector P N 318674 slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase A...

Page 335: ...stall nut on the driveshaft Turn the driveshaft by hand to thread the nut on to shaft Apply Gasket Sealing Compound to the threads of the driveshaft bearing housing screws Tighten screws in stages to a torque of 120 to 144 in lbs 13 5 to 16 5 N m Use Driveshaft Holding Socket P N 311875 Pin ion Nut Holder P N 334455 and Wrench Retainer P N 341438 to tighten the pinion nut to a torque of 100 to 110...

Page 336: ...tall housing into gearcase Align screw holes with retainer slots in gearcase Housing must be completely seated to install retainer tabs Install two retainers washers and screws Apply Ultra Lock to threads and tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N m Loosen retainer screws 1 4 turn Install wedge screw and washer Apply Ultra Lock to threads and tighten screw to a torque of 15 to 20...

Page 337: ...Install housing into gearcase Align screw holes with retainer slots in gearcase Use Installer Handle P N 345822 Propeller Shaft Bearing Housing Installer P N 354058 Gearcase Fixture P N 354059 and an appropriate floor press 10 ton or greater to install housing into gearcase Align and level gearcase assembly in fixture as shown Secure fixture to floor press Housing must be completely seated in gear...

Page 338: ...housing O rings Install O rings in grooves in the housing Grease the machined side surfaces of bearing housing Place bearing housing in gearcase Align retaining holes in bearing housing with screw holes in gearcase Thread Alignment Pins P N 354140 into gearcase Use Installer Handle P N 345822 Propeller Shaft Bearing Housing Installer P N 354057 Gearcase Fixture P N 354059 and an appropriate floor ...

Page 339: ...18 to 20 ft lbs 24 to 27 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 300 WATER PUMP SERVICE on p 304 SHIFT ROD ADJUSTMENT on p 306 GEARCASE REMOVAL AND INSTALLATION on p 301 Gearcase Lubricant on p 87 Propeller Hardware Installation on p 67 Trim Tab Adjustment on p 70 During break in period of a reassembled gear case change the gearcase lubrican...

Page 340: ...ft bearing housing Remove wedge screw and washer To remove the propeller shaft bearing housing and forward gear from gearcase thread Propeller Shaft Adapter P N 432398 onto Slide Hammer P N 432128 until it seats Thread adapter com pletely onto propeller shaft and pull propeller shaft bearing housing and forward gear assem bly out of gearcase Propeller Shaft Bearing Housing Removal M2 Type IMPORTAN...

Page 341: ...shaft until seated Assemble puller kit components Hold adaptor with wrench and turn nut clockwise to pull bearing housing Pull propeller shaft and bearing housing far enough to loosen the PRESSED bearing housing from the gearcase housing Remove propeller shaft forward gear and bearing housing assembly from gearcase Pinion Gear Removal and Driveshaft Servicing Refer to Pinion Gear and Driveshaft Re...

Page 342: ...rod from the gearcase Discard the cover gasket Remove the shift rod O ring from inside of cover and discard Use an appropriate tool to apply downward pres sure on the detent while pulling on the propeller shaft assembly Remove propeller shaft assembly from the gearcase Water Intake Screens Remove and clean water intake screens Replace if damaged GEARCASE HOUSING INSPECTION Refer to GEARCASE HOUSIN...

Page 343: ...ush the pin out of the clutch dog Remove all parts Remove the gear thrust bearing and thrust washer from the shift housing IMPORTANT The shift housing supports the reverse gear on counter rotation gearcases Remove the shift lever pin from the housing Remove shift shaft cradle and shift lever Move shifter detent as needed to help ease removal of parts WARNING Wear safety glasses to avoid injury 1 C...

Page 344: ...detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent into the housing as shown while depressing the ball and spring with a suit able tool Once the detent is past the ball remove the tool and position detent to engage NEUTRAL Thoroughly grease 25 needle bearings with Nee dle Bearing grease and place in the bearing case Rest the cradl...

Page 345: ...ase 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 correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing rear of the shaft IMPORTANT The clutch dog is not symmetri c...

Page 346: ...inion Bearing Installation on p 320 Propeller Shaft Bearing Housing and Forward Gear O Type Disassembly Remove and discard the bearing housing O ring Remove the anode and discard if more than two thirds deteriorated Clamp the bearing housing by the anode bosses in a vise as shown Remove the forward gear assembly by unscrewing it with Spanner Wrench P N 432400 Remove gear housing retaining ring Rem...

Page 347: ...r or damage Remove the forward gear bearing only if it needs to be replaced If removal of the bearing is neces sary use Large Puller Jaws P N 432129 and Puller Bridge P N 432127 with an appropriate base Leave the rollers in to allow for good contact with the puller jaws Push propeller shaft out of the bearing housing Remove the thrust washer and thrust bearing 31963 31961 31960 31958 13479 1 Thrus...

Page 348: ...g Use Bearing Installation Tool P N 339778 to install the bearing lettered side facing tool Install the thrust bearing on the forward gear Place the bearing housing on the forward gear Install 0 030 in 0 7 mm of shims and the thrust bearing in the flange Install the thrust bearing on the forward gear Install set screws and tighten to a torque of 144 to 168 in lbs 16 5 to 19 N m Use no thread seal ...

Page 349: ... shims Remove the 0 030 in 0 7 mm of shims from the assembly Reassemble the gear assembly using a combination of shims to achieve the required thickness Apply Nut Lock to the threads of the set screws and torque to 144 to 168 in lbs 16 3 to 19 N m Apply Needle Bearing grease to the thrust bear ing Position bearing around shoulder on the pro peller shaft Apply Needle Bearing grease to the thrust wa...

Page 350: ... size Tighten screws to a torque of 108 to 132 in lbs 12 to 15 N m Propeller Shaft Bearing Housing and Forward Gear M and M2 Type Disassembly Remove and discard the bearing housing O ring Remove the anode and discard if more than two thirds deteriorated Clamp the propeller shaft bearing housing by the anode bosses in a vise as shown Remove the forward gear bearing housing assembly from pro peller ...

Page 351: ...orward gear bearing housing assem bly on a flat level surface Mirror or glass can be used Use depth gauge to measure distance from flange of housing to flat surface as shown Add the appropriate shims to create a dimension of 0 140 in 3 556 mm To determine thickness of shims use the following example 1 389 in reading on the gauge 0 011 in shims required 1 400 in required dimension Apply Needle Bear...

Page 352: ... Thrust bearing must remain around shoulder on the pro peller shaft Apply gearcase lubricant to the threads of the for ward gear bearing housing Install forward gear assembly with correct shims in bearing housing M type uses retainer ring and shims IMPORTANT To prevent damage to threads install forward gear bearing housing assembly by hand until fully seated against propeller shaft bearing housing...

Page 353: ... N 393185 Shim gauge bars are precision made and should be handled carefully The length of each bar is stamped near the part number This dimension is 0 020 in 0 508 mm shorter than the actual shimmed length of the driveshaft IMPORTANT Clean pinion and driveshaft before assembly Replace any damaged parts Assemble the driveshaft bearing housing thrust washer thrust bearing and pinion onto the drive ...

Page 354: ...and repeat check if variance is greater than 0 004 in 0 010 mm Check squareness of the pinion to the driveshaft Hold the shim gauge bar against the bearing housing between the screw holes while rotating just the driveshaft and pinion assembly Mea sure clearance between the gauge bar and the pinion at several locations If variance is greater than 0 002 in 0 050 mm replace the pinion or driveshaft a...

Page 355: ...lly into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing Shift Rod Cover Refer to Shift Rod Cover on p 327 Pinion Gear and Driveshaft Installation Refer to Pinion Gear and Driveshaft Installation O L L2 M and M2 Type on p 332 Propeller Shaft Bearing Housing and Gear Installation O and M Type Lightly apply Gasket Sealing Compound to a new bearing housing O...

Page 356: ...to 27 N m Confirm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m Propeller Shaft Bearing Housing and Gear Installation M2 Type IMPORTANT The propeller shaft bearing hous ing on M2 type gearcases is PRESSED into the gearcase housing Lightly apply Triple Guard Grease to new bearing housing O rings Install O rings in grooves in the housing Grease the machined side surfaces of bearin...

Page 357: ...nstall retainer screws Bearing housing is approximately level with gearcase Apply Ultra Lock to threads and install two retain ing screws Tighten screws to a torque of 18 to 20 ft lbs 24 to 27 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 300 WATER PUMP SERVICE on p 304 SHIFT ROD ADJUSTMENT on p 306 GEARCASE REMOVAL AND INSTALLATION on p 301 Gearc...

Page 358: ...356 GEARCASE COUNTER ROTATION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other ...

Page 359: ...N BRACKETS 367 TROUBLESHOOTING 367 THREE PISTON SYSTEM 367 SINGLE PISTON SYSTEM 371 ELECTRICAL CIRCUIT TESTS 371 RELAY TESTING 371 TRIM AND TILT MOTOR CURRENT DRAW TESTS 371 TRIM AND TILT MOTOR NO LOAD TEST 372 TRIM GAUGE TEST 373 TRIM SENDER TEST 374 TRIM AND TILT SERVICE 374 SERVICING THREE PISTON SYSTEM 377 DISASSEMBLY 377 TILT PISTON REMOVAL 380 TILT PISTON IDENTIFICATION 381 TILT PISTON ASSEM...

Page 360: ... AND TILT SERVICE CHART SERVICE CHART 20 115 HP MODELS SINGLE PISTON SYSTEM 005002 A Triple Guard Grease W Biodegradable TNT Fluid 30 50 In lbs 4 5 6 N m A A W 45 55 In lbs 5 1 6 2 N m 45 55 In lbs 5 1 6 2 N m ...

Page 361: ...D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease 60 70 Ft lbs 81 95 N m DO NOT OVER TIGHTEN 84 108 In lbs 9 5 12 N m 58 87 Ft lbs 79 118 N m 35 52 In lbs 4 0 5 9 N m 60 84 In lbs 7 9 5 N m 45 55 In lbs 5 1 6 2 N m 35 52 In lbs 4 0 5 9 N m 60 84 In lbs 7 9 5 N m 12 24 In lbs 1 4 2 7 N m A 58 87 Ft lbs 79 118 N m F F ...

Page 362: ... 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 before n...

Page 363: ...s UP Fluid is pushed from the top of the tilt cylinder by the piston and returns to the pump through the open DOWN check valve In the trim range fluid is pushed from the top of the trim cylinders by the pistons and returns to the reservoir Only fluid from the top of the tilt cylinder is returned to the pump Because the cylinder rod displaces some fluid that volume is less than the volume of the bo...

Page 364: ...e trim cylinders Fluid from the bottom of the cylinders returns through the open UP check valve to the pump In the tilt range all of the fluid from the bottom of the tilt cylinder returns through the UP check valve to the pump Since more fluid is returning to the pump than is required to fill the top of the cylinder the excess fluid is vented through the DOWN relief orifice to the reservoir In the...

Page 365: ... tilt cylinder extends The fluid above the piston is com pressed producing high pressure This high pressure fluid passes through the impact relief valves in the tilt piston dissipating much of the energy of the impact To return the outboard to its original position the hydraulic unit must be operated in the DOWN direction 1 Impact relief valves DRC3467 1 1 ...

Page 366: ... down the filter valve opens and allows fluid to flow from the reservoir to the top of the tilt cylinder The outboard will tilt down to the top of the trim range Thermal Expansion Relief Ambient air temperature increase can cause fluid expansion within the hydraulic assembly If the fluid expands when stored in the tilt range the fluid under all of the pistons and above the tilt pis ton cannot expa...

Page 367: ...of the cylinders Trimming Outboard OUT Pull gearcase out farther than the desired final position up into the tilt range if necessary Close the manual release valve Manually push the gearcase in or down until it is supported by the trim system Open the manual release valve only enough to let the outboard trim in to desired position Tilting Outboard UP Tilt outboard up and hold it with a suitable ho...

Page 368: ...lease valve Fluid flows from the bottom of the tilt cylinder in the tilt range to the top of the tilt cylinder The excess fluid equal to the volume of the piston rod is vented to the reservoir In the trim range the fluid from the bottom of all three cylinders is vented to the reservoir except for the amount required to fill the top of the tilt cyl inder After opening the manual release valve close...

Page 369: ...use has not been determined the Symp toms Chart on p 368 should help locate the problem Keep a manual release valve and a valve body in stock for troubleshooting Use these parts when the Service Procedures on p 368 call for the substitution of known good parts If the trim tilt does not work and its motor neither runs nor hums troubleshoot the problem by refer ring to TILT TRIM RELAY TEST on p 145 ...

Page 370: ... fold assembly was faulty Remove temporary assembly and replace it with correct one STEP 6 Install replacement pump manifold assembly and retest If all symptoms are not corrected recon sider the problem using the new symptoms STEP 7 Install O ring kit Look for any cylinder damage Look for chips in fluid or impact valves Look for other abnormal conditions If all symptoms are not corrected reconside...

Page 371: ...reservoir cap one full turn Loosen the manual release valve three turns Some fluid will bypass the reservoir cap These steps will relieve the pressure in the unit Remove the manual release valve retaining ring using retaining ring pliers Remove the manual release valve Install pres sure gauge and adapter A to check problems in the UP circuit IMPORTANT Torque gauge and adapter lightly to 5 to 10 in...

Page 372: ...n and up several times to purge air With all rods fully extended run the unit down momentarily to reduce pressure Check fluid level again and add fluid if necessary Remember that all rods must be completely extended to check fluid level Starting with the tilt cylinder fully extended run the unit DOWN The gauge should show 0 to 200 psi 0 to 1379 kPa as the tilt cylinder is retracting The gauge shou...

Page 373: ...positive terminal The green trim motor wire remains grounded When the but ton 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 posi...

Page 374: ... 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 condition and fully charged to per form this test Connect a 0 to 50...

Page 375: ...otor 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 ter...

Page 376: ...r must show a reading above 80 Ω With the outboard fully UP meter must show a reading below 10 Ω If results agree refer to Trim Gauge Test on p 373 If results are different replace trim sender TRIM AND TILT SERVICE Removal Remove lower engine cover and disconnect the trim tilt connectors Refer to LOWER COVER SERVICE on p 91 Remove the rubber grommet from the blue green trim tilt cable connector Re...

Page 377: ...Unscrew the manual release valve raise the unit and lock it in place with the tilt support Remove the ground wire from the trim tilt unit 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 25078 27381 1 Ground wire 25057 1 25064 25065 25077 ...

Page 378: ...a torque of 45 to 50 ft lbs 61 to 68 N m Install external snap rings on lower pin with sharp edge of ring facing out Extend tilt cylinder rod to match 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 Attach ...

Page 379: ...andling power trim tilt components If painting the unit is required paint it after it is completely assembled Painting of individual com ponents may cause flakes of paint to enter the hydraulic passages during assembly Tape the trim tilt piston rods before painting 27381 002152 WARNING Before removing the manual release valve operate the unit to the full UP position then run the unit down momentar...

Page 380: ...rings are damaged replace the manual release valve Remove reservoir cap and drain the fluid into a container Inspect the O ring in the cap Remove the three Pozidriv screws securing the reservoir to cylinder body Remove reservoir Remove the reservoir O ring from the cylinder body Check machined surfaces for nicks and scratches Use a 6 mm hex wrench to remove the plug from the cylinder body Inspect ...

Page 381: ...the machined surfaces on the manifold for nicks and scratches The pump manifold is not serviceable Do not remove the pump or any control valves from the manifold Clean the screen with a mild solvent and inspect it for tears clogging or other damage Remove the three Allen head screws securing the pump manifold assembly to cylinder body IMPORTANT Individual parts in the pump man ifold assembly are n...

Page 382: ...unscrew the tilt rod end cap Drain the fluid from above the piston Slowly pull the piston out with a rag wrapped around the rod and the top of the cylinder Drain the remaining fluid from the cylinder Inspect the bore of the tilt cylinder for excessive scoring If the bore of the tilt cylinder is scored or damaged the hydraulic assembly must be replaced Clamp the rod eye tightly in a soft jaw vise R...

Page 383: ...gers are identical Lubricate and install a new outer O ring on the tilt piston Place one ball one plunger and one spring in each hole in the piston as indicated Three of the four springs are one length and the fourth spring is shorter On assembly the shorter spring can be positioned in any hole in the piston Set piston aside 41784 1 Small inner O ring 2 Large outer O ring 41819 WARNING Different t...

Page 384: ...side of the end cap Use a wire brush to clean all thread locking mate rial from the threads on the tilt rod Lubricate the inside surface of the end cap Lubri cate and install Tilt Cylinder Seal Protector P N 326005 Use a deep well socket and a plastic mallet to drive the end cap onto the rod then remove the seal protector Slide the end cap down the tilt rod Remove any lubricant from the threads on...

Page 385: ...im Tilt Steering Fluid on top of the tilt piston Fluid should not leak past the impact relief balls while seated If fluid does leak disassemble the piston assembly and inspect the relief ball seats Set the tilt rod assembly aside Trim Rod Removal Unscrew trim cylinder end caps using Trim Cylin der End Cap Remover Installer P N 436710 or Universal Spanner Wrench P N 912084 and a breaker bar Small p...

Page 386: ...clamp the rod tightly in a vise Remove the thrust pad from the trim rod then remove the end cap Remove the rod from the vise Use a small screw driver to carefully pry the scraper out of the end cap Discard the scraper Use a suitable tool to remove the inner quad ring and the outer O ring Discard the quad ring and O ring Trim Rod Assembly Lubricate and install a new quad ring and scraper in the end...

Page 387: ...ide the end cap onto the rod and install thrust pad Torque thrust pad 84 to 108 in lbs 9 5 to 12 N m Manifold and Reservoir Installation Lubricate five new manifold body O rings Place them in the cylinder body Attach the valve pump assembly to the cylinder body with three Pozidriv screws Torque screws to 60 to 84 in lbs 7 to 9 5 N m Oil and install the manual release valve Thread the valve just pa...

Page 388: ...the cylinder body with three Pozidriv screws Torque the screws to 35 to 52 in lbs 4 0 to 5 9 N m Trim Rod Installation Lubricate the trim rod pistons Place the rod assemblies into the body Push them in until the end caps just clear the tops of the cylinders Fill the cylinders with Power Trim Tilt Steering Fluid Failure to fill the cylinders could cause diffi culty in purging air from the unit Scre...

Page 389: ...Steering Fluid Failure to fill the cylinder could cause difficulty purging air from the unit Screw tilt cylinder end cap into cylinder body Use Tilt Cylinder End Cap Remover Installer P N 326485 or Universal Spanner Wrench P N 912084 Torque cap to 58 to 87 ft lbs 79 to 118 N m Motor Installation Position the pump manifold so the pump mounting surface is level Install the coupler into the pump Fill...

Page 390: ... the reservoir to the bottom of the fill hole with Power Trim Tilt Steering Fluid Install and tighten the reservoir cap Turn the manual release valve in until it seats Cycle the unit up and down several times to purge air Operate the unit to the full UP position then run down momentarily to release pressure Check the fluid level again and add fluid if necessary Remember that all rods must be compl...

Page 391: ...oth when handling power trim tilt components If painting the unit is required paint it after it is completely assembled Painting of individual com ponents may cause flakes of paint to enter the hydraulic passages during assembly Tape the trim tilt piston rods before painting IMPORTANT Before removing manual release valve relieve pressure by fully extending cylinder Screw the manual release valve i...

Page 392: ...O rings on the housing Remove the four large motor flange retaining screws Remove the motor and discard O ring screws and washers Remove drive coupler from either the motor or the pump assembly Assembly IMPORTANT Use only Evinrude Johnson Bio degradable TNT Fluid to fill the hydraulic system Install drive coupler in pump assembly Install a new motor O ring 004285 004284 004282 004281 004280 ...

Page 393: ... 5 1 to 6 2 N m Install new retaining ring in groove Fill the oil reservoir up to the fill plug with Evinrude Johnson Biodegradable TNT Fluid Install and tighten the fill plug Do not torque the plug at this 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 tight...

Page 394: ...392 TRIM AND TILT ADJUSTMENTS ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p 69 Refer to Tilt Limit Switch Adjustment on p 68 ...

Page 395: ...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 396: ...S 2 ...

Page 397: ...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 398: ...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 399: ...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 400: ...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 401: ... 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 402: ...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 403: ...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 404: ...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 405: ...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 406: ...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 407: ... 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 408: ... 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 409: ...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 410: ... 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 411: ...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 412: ... 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 413: ...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 414: ...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 415: ...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 416: ...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 417: ...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 418: ...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 419: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 420: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 421: ...ng 205 Engine Temperature Check 218 Engine Temperature Sensor 135 Exhaust Housing Assembly 277 Cleaning and Inspection 277 Disassembly 276 Installation 280 Removal 275 Exhaust Pressure Fitting 85 Exhaust Valve EMM Control 100 Relays 146 Service 277 280 Tests 125 146 Exterior Finish Protection 75 F n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 422: ... n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 423: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Packard Connector Servicing 167 Pinion Gear Bear...

Page 424: ...s 134 Air Temperature Sensor 97 135 Barometric Pressure Sensor 97 Crankshaft Position Sensor 99 118 134 EMM 96 Engine Temperature Sensor 97 135 Exhaust Pressure Sensor 85 97 Oil Pressure 98 204 Tests 134 Throttle Position Sensor 99 134 156 Serial Number Location 9 Service Charts Electrical and Ignition 128 Fuel System 170 Gearcase 289 Midsection 270 Oiling System 194 Powerhead 226 Shift Housing As...

Page 425: ...tance Test 134 Tilt Limit Switch Adjustment 68 Cam Installation 273 274 Tilt Support 360 Tilt Tube Installation 274 Lubrication 78 Removal 273 Timing Adjustments Timing Pointer 154 Timing Verification 155 TPS Calibration 156 Tools Alignment Pin Kit P N 5007167 252 Alignment Pins P N 354140 336 Backing Plate P N 325867 314 Bearing Installation Tool P N 326562 323 Bearing Installation Tool P N 33975...

Page 426: ...Hammer P N 432128 234 274 338 Small Puller Jaws P N 432131 322 Spanner Wrench P N 432400 344 348 350 Stator Test Adaptor P N 5006211 136 Syringe P N 346936 210 Temperature Gun P N 772018 221 222 Terminal Release Tool P N 351413 166 Test Propeller 10 Thermal Joint Compound P N 322170 222 Thread Alignment Pins P N 354140 354 Tilt Cylinder End Cap Remover Installer P N 326485 380 387 Tilt Cylinder Se...

Page 427: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 428: ......

Page 429: ... 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 430: ...Check voltage at injectors Excessive fuel or oil engine flooded Check for leaking injectors leaking fuel or oil lift pump or leaking vapor separator vent refer to FUEL SYSTEM Low or no 55 V alternator output Check voltage on 55 V circuit SAC refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuits refer to SYSTEM ANALYSIS and ELECTRICA...

Page 431: ...Check primer bulb anti siphon valve and fuel pick up check for fuel system air leaks Low or no alternator output 55 V Check voltage on 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit white red refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Restricted or leaking fuel injector s Check injectors refer to FUEL SY...

Page 432: ...ut 55 V Check voltage on 55 V circuits refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Contaminated or poor fuel quality Check or replace fuel supply Low fuel pressure Check pressure refer to FUEL SYSTEM Air in fuel system Check for air in fuel supply manifold refer to FUEL S...

Page 433: ...ion Check ignition refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS Restricted or leaking fuel injectors Check injectors refer to FUEL SYSTEM Low fuel pressure Check circulation pump operation refer to FUEL SYSTEM EMM programming timing or operation Check EMM program and timing check inject...

Page 434: ...m air leaks Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring Check CPS air gap Low alternator output 55 V Check voltage on 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION EMM program timing or operation Check EMM program and timing check injector coefficients and mo...

Page 435: ...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 436: ...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 437: ......

Page 438: ...839 CANbus Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 1 4 watt resistor 10 Amp Fused B 12V ...

Page 439: ...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 440: ...ation Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will not start Correct problem and clear codes Indicates 30V or higher on 55V circuit Indicates CPS working and EMM SYNC 1 2 3 4 Start assist circuit SAC OK V models only Stop circuit OK Sensor circuits ...

Page 441: ...ater in Fuel Sender Optional 28 Trim Sending Unit 29 Tilt Limit Switch 30 Trim Tilt Motor Connector 31 Exhaust Valve Actuator 32 Exhaust Valve Relay Module 004980 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 3 4 25 10 1 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 20 18 19 2 1 2 3 4 5 6 7 8 9 1 2 30 29 28 27 26 22 21 24 23 3 4 5 6 7 8 9 11 12 13 15 17 23 20 21 2...

Page 442: ...r 6 25 Ignition Coil 3 26 Low Oil Switch 27 Water in Fuel Sender Optional 28 Trim Sending Unit 29 Tilt Limit Switch 30 Trim Tilt Motor Connector 004981 18 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 3 4 25 10 1 20 21 22 23 24 25 26 27 28 29 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 20 18 19 2 1 2 3 4 5 6 7 8 9 1 2 30 29 28 27 26 22 21 24 23 3 4 5 6 7 8 9 11 12 13 15 17 23 20 21 22 23 24 25 ...

Page 443: ...e 3 LED 1 ON Running LOW BATTERY 5 minutes Battery voltage 15 5 V Check battery connections and wiring 28 Shift switch malfunction LED 3 ON Running 10 seconds Check shift switch linkage and switch activation Check continuity of switch normally open continuity depressed Not used on 60 V4 remote models or 60 V6 models 29 EMM Temperature OVER range 3 3 LED 4 FLASHING WATER TEMP HOT FLASHING 5 seconds...

Page 444: ... range LED 3 ON Running 10 seconds 0 4 V 73 Oil pressure ABOVE expected range LED 3 ON Running 10 seconds 4 6 V 74 Water pressure sensor circuit fault detected LED 3 ON Running 10 seconds 0 15 V 4 85 V 75 Water pressure BELOW expected range LED 3 ON Running 10 seconds 0 4 V 76 Water pressure ABOVE expected range LED 3 ON Running 10 seconds 4 6 V 77 S A C overcurrent fault 3 LED 1 OFF Key On ON Run...

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