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Evinrude E-TEC E40DPLSCB, Service Manual

The Evinrude E-TEC E40DPLSCB Service Manual can be easily downloaded for free from manualshive.com. This comprehensive manual provides detailed instructions for maintenance and repair of this powerful outboard motor. Ensure optimal performance and longevity by having this essential manual on hand. Download your copy now.

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ENGINE MANAGEMENT MODULE (EMM)

85

5

ENGINE MANAGEMENT MODULE (

EMM

)

TABLE OF CONTENTS

DESCRIPTION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

EMM

 FUNCTIONS 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

EMM

 CONNECTIONS 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

LED INDICATORS 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

EMM

 INPUTS AND OUTPUTS DIAGRAM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

INTERNAL SENSORS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

EMM

 TEMPERATURE SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

55 V CIRCUIT SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

12 V CIRCUIT SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

BAROMETRIC PRESSURE SENSOR 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

EXTERNAL SENSORS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

AIR TEMPERATURE SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

ENGINE TEMPERATURE SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

LOW OIL SWITCH 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

THROTTLE POSITION SENSOR 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

CRANKSHAFT POSITION SENSOR 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

NEUTRAL SWITCH 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 91

INTERNAL 

EMM

 FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

ENGINE MONITORING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

S.A.F.E. 

WARNING SYSTEM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

SHUTDOWN MODE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
DIAGNOSTIC SOFTWARE FUNCTIONS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

COMMUNICATION 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

STATIC INFORMATION 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

DYNAMIC INFORMATION 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

STORED SERVICE CODES (FAULTS) 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

HARD FAULTS 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

PERSISTENT FAULTS 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

STATIC TESTS 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

DYNAMIC TESTS 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

OIL CONTROL SETTINGS 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

TILLER/REMOTE PROGRAMMING 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

IGNITION TIMING 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

TPS CALIBRATION 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 99

IDLE SPEED CONTROL 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FUEL INJECTOR SERVICING 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

REPORTS 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

SOFTWARE REPLACEMENT 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

EMM

 TRANSFER 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

EMM

 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Summary of Contents for E-TEC E40DPLSCB

Page 1: ......

Page 2: ......

Page 3: ...rademark 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 registere...

Page 4: ...ER SERVICE 81 5 ENGINE MANAGEMENT MODULE EMM 85 6 SYSTEM ANALYSIS 103 7 ELECTRICAL AND IGNITION 117 8 FUEL SYSTEM 153 9 OILING SYSTEM 175 10 COOLING SYSTEM 189 11 POWERHEAD 199 12 MIDSECTION 235 13 GE...

Page 5: ...E 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...

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 Damag...

Page 7: ...dly 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 ca...

Page 8: ...ect 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 posit...

Page 9: ...oard 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 wou...

Page 10: ...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 Injectio...

Page 11: ...the powerhead Model Number Shaft Color Style E40DRLSCB 20 BL Tiller Rope E40DTLSCS 20 BL Tiller Electric E40DPLSCB 20 BL Remote Electric E40DSLSCS 20 WH Remote Electric E50DTLSCS 20 BL Tiller Electri...

Page 12: ...n 91 47 mm Stroke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55...

Page 13: ...ntrolled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC10WEP 0 028 003 in 0 71 mm GEARCASE...

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 8...

Page 15: ...L TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS 14 UNIVERSAL TOOLS 14 ELECTRICAL IGNITION TOOLS 16 FUEL OIL SYSTEM TOOLS 17 POWERHEAD TOOLS 17 GEARCASE TOOLS 18 TRIM AND TILT TOOLS 20 MANUAL STARTER TOOLS...

Page 16: ...Interface cable P N 437955 45583 Universal Puller Set P N 378103 32885 Flywheel holder P N 771311 42938 Slide hammer adapter P N 340624 39435 Lifting eye P N 321537 23701 Slide hammer P N 391008 CO15...

Page 17: ...18 45240 Remover ball socket P N 342226 002584 Large puller jaws P N 432129 23148 Tilt tube service kit P N 434523 33249 Fresh water flusher P N 500542 50110 Installer ball socket P N 342225 002583 Be...

Page 18: ...ator Test Adapter P N 5005799 002273 Connector tool P N 342667 42004 Peak reading voltmeter P N 507972 49799 Crimping pliers P N 322696 30387 AMP connector tools Primary Lock Tool P N 777077 Secondary...

Page 19: ...PSI P N 5006397 90 fitting P N 353322 004560 Injector test fitting kit P N 5005844 002465 Cylinder bore gauge P N 771310 45303 Piston stop tool P N 342679 Replacement tip P N 5006098 46543 Rod cap al...

Page 20: ...ft Shimming Tool P N 5005925 1 Lower Driveshaft Shimming Bolt S2 gearcase P N352878 002601 Gearcase filler P N 501882 49790 1 Gearcase pressure tester P N 507977 Stevens P N S 34 Gearcase vacuum teste...

Page 21: ...plate P N 325867 23621 Puller P N 387206 47254 Driveshaft seal protector P N 312403 23692 Nut starting tool P N 320675 40372 Bearing Installer P N 326562 32962 Prop shaft housing seal installer P N 3...

Page 22: ...AND TILT TOOLS MANUAL STARTER TOOLS Tilt cylinder end cap remover P N 352932 for single piston tilt systems 005340 Spanner wrench P N 912084 32213 Starter rope threading tool P N 378774 23682 Starter...

Page 23: ...i 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...

Page 24: ...298 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 Gre...

Page 25: ...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...

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

Page 27: ...OSE AND WIRE ROUTING 48 CONTROL CABLE ADJUSTMENTS 48 ELECTRICAL HARNESS CONNECTIONS 50 WATER PRESSURE GAUGE 50 CANBUS CONNECTIONS 51 FUEL AND OIL PRIMING 53 FUEL REQUIREMENTS 53 FUEL SYSTEM PRIMING 54...

Page 28: ...g 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 vo...

Page 29: ...r 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...

Page 30: ...lations 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 st...

Page 31: ...r each outboard installed Use the appropriate sized wire and terminals for all connections Use AWG stranded copper wire Battery Switch Location Always locate battery switch as close to the bat teries...

Page 32: ...outboard OFF ON PRIMARY 1 S 000135rev1 1 2 OFF BOTH SECONDARY PRIMARY 1 S 2 000136rev2 One outboard Battery disconnect One outboard One primary starting battery one secondary battery SECONDARY PRIMAR...

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

Page 34: ...alled 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...

Page 35: ...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 DR...

Page 36: ...r 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 wirin...

Page 37: ...cables be sure to Route cables through the protective sleeve Use the most direct path to route the battery cables to the battery or battery switch Fuel Hose The fuel hose may be routed outside of the...

Page 38: ...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...

Page 39: ...pless 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...

Page 40: ...efer to ABYC Standards to determine the maximum horsepower capacity for boats with out certification labeling Mounting Surface Inspect transom surface prior to drilling mounting holes The transom shou...

Page 41: ...of bottom strakes on dual outboard installations Transom Brackets and Jack Plates When mounting an outboard on boats equipped with transom brackets or jack plates refer to the manufacturer s recommend...

Page 42: ...ring systems may require additional spacing Refer to steering sys tem manufacturer for recommendations The top edge of the transom should be more than twice the width of the dual outboard centerline s...

Page 43: ...raised more than in 6 mm above the transom s top surface to make both indicators align the transom must be modified IMPORTANT DO NOT assume that the top edge of the transom is straight Position the d...

Page 44: ...72 Plate 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 32...

Page 45: ...LT MODELS IMPORTANT This is not a template 1 Center of Transom 2 Top of Transom 3 11 32 Bolt Hole Locations 5 156 IN 5 5 32 131 mm 4 031 IN 4 1 32 102 4 mm 2 IN 50 8 mm 7 625 IN 7 5 8 193 7 mm 5 156 I...

Page 46: ...re designed to be compatible with mechanical steer ing systems that meet ABYC Standard P 17 Sin gle cable mechanical steering systems can be used on single or dual outboard installations if an ABYC ap...

Page 47: ...ufacturer s recommendations and to Dual Outboard Centerlines on p 40 Drag Links Use the correct drag link to allow full steering travel Install cable wiper nut on tilt tube and connect drag link to t...

Page 48: ...t 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 ea...

Page 49: ...utboard to tran som The kit also includes clamp pads P N 315774 which must be used to secure mounting bolts in slots at the bottom of the outboard stern brackets Install the mounting bolts through the...

Page 50: ...ents IMPORTANT DO NOT attach cables to throttle and shift levers until all cables wires and hoses have been routed and grommet has been placed into the lower engine cover Pull firmly on shift cable ca...

Page 51: ...ps Place washer on pin Position retainer clip with straight section on the bottom and angled section on the top Use long nose pliers to insert straight section of clip into linkage pin hole Push the c...

Page 52: ...l Arrange connectors in flywheel cover Install electrical cover and secure with screws IMPORTANT BE SURE all harnesses and wires are not pinched cannot contact flywheel and do not interfere with movin...

Page 53: ...hose Secure CANbus connectors to back side of engine harness with tie strap Adjust harness routing as needed and secure tie straps Use a CANbus Ignition Harness in place of the standard MWS harness t...

Page 54: ...check that CANbus network harness is not pinched behind air silencer Make sure both harnesses are in front of tab and CAN bus ignition harness is in wire channel Use Evinrude Diagnostics software to...

Page 55: ...eposits which can damage the out board Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of othe...

Page 56: ...ith the starter Oil Requirements Evinrude Johnson XD100 XD50 or XD30 out board oils are recommended for use in Evinrude E TEC outboards If these oils are not available you must use a TC W3 certified o...

Page 57: ...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 require...

Page 58: ...ype of oil being used Start the outboard and use the oil priming function in the software for a minimum of 90 seconds to make sure the system is completely primed Observe oil flow through the oil dist...

Page 59: ...OIL warning has been tested Refer to Oil Requirements on p 54 When starting the outboard for the first time refer to Oil Supply Priming on p 56 Trim and Tilt Fluid Make sure trim and tilt reservoir i...

Page 60: ...back to NEUTRAL and restart outboard Shift to REVERSE Turn outboard OFF while con trol is in REVERSE Try to restart the outboard Outboard should not start Tachometer Pulse Setting Confirm accuracy of...

Page 61: ...PECIFICA 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...

Page 62: ...to determine the engine s full throttle RPM The outboard should be trimmed for top speed Select a propeller that suits the customer s application and allows the engine to run near the midpoint of the...

Page 63: ...between propeller blade and the anti ventilation plate Install the propeller nut and tighten to a torque of 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the propeller nut and propeller s...

Page 64: ...contact point Loosen cam screw and rotate eccentric cam to adjust full down gauge position If the needle was above the lowest mark move the thick part of the cam TOWARD the contact point Tighten the s...

Page 65: ...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...

Page 66: ...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...

Page 67: ...T 71 GEARCASE LUBRICANT 71 TRIM AND TILT 73 BATTERY AND BATTERY CONNECTIONS 74 FUEL AND OIL SYSTEMS 74 FUEL FILTER 74 OIL FILTERS AND OIL RESERVOIR 74 AIR SILENCER 75 HOSES AND CONNECTIONS 75 SPARK PL...

Page 68: ...screens check condition 3 Cooling system check water pump indicator water pressure 3 Anticorrosion anodes check condition 3 Gearcase check condition 3 Propeller check condition 3 Fuel and oil systems...

Page 69: ...sed 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...

Page 70: ...etween 20 to 40 psi 140 to 275 kPa Flushing Outboard Running Refer to Propeller Hardware Installation on p 61 Place outboard in VERTICAL DOWN position in a well ventilated area Thread garden hose into...

Page 71: ...vapor separator flow water freely Replace water pump LUBRICATION Steering System Grease the stainless steel output end of the steer ing cable with Triple Guard grease Use an appropriate cleaning solv...

Page 72: ...tle and shift lever pins Carefully remove casing guides from pins IMPORTANT DO NOT disturb cable trunnion adjustments Shift remote control into FULL THROTTLE REVERSE position to fully extend the plast...

Page 73: ...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 cas...

Page 74: ...taminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 66 for service frequency and recommended lubricants Secure the gearcase in a vertical position Remove...

Page 75: ...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 th...

Page 76: ...riple 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...

Page 77: ...ve 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 connectio...

Page 78: ...spark plug opposite the fuel injector nozzle Put an ink mark on the ceramic of the spark plug in line with the OPEN side of the ground elec trode This mark will be used to orient the spark plug with t...

Page 79: ...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 FU...

Page 80: ...rage 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 bolt...

Page 81: ...Disconnect 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 o...

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

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

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

Page 85: ...side cover Connect trim tilt switch connector Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enough to hold the grommet in place S...

Page 86: ...Place spring washer and hook into position and tighten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on switch Tighten nut to a t...

Page 87: ...WITCH 90 THROTTLE POSITION SENSOR 90 CRANKSHAFT POSITION SENSOR 91 NEUTRAL SWITCH 91 INTERNAL EMM FUNCTIONS 92 ENGINE MONITORING SYSTEM 93 S A F E WARNING SYSTEM 94 SHUTDOWN MODE 94 DIAGNOSTIC SOFTWAR...

Page 88: ...t water valve activation 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 disconne...

Page 89: ...TPS 6 Neutral Switch 7 Air Temperature Sensor AT 8 Oil Pressure Switch component of 11 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fue...

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

Page 91: ...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 se...

Page 92: ...has been run for more than 3 hours with NO OIL faults codes 34 117 the EMM Throttle Position Sensor The throttle position sensor is connected to the throttle plate shaft The sensor receives a voltage...

Page 93: ...onitor screen of Evinrude Diagnostics software to check CPS operation The software should show an RPM reading while the outboard is cranking If the CPS or its circuit fails no RPM reading will appear...

Page 94: ...es when engine RPM returns to the specified range Neutral RPM Limiter This feature prevents engine damage due to excessive RPM if accelerated in NEUTRAL Neu tral engine speed is limited to 1800 RPM Ex...

Page 95: ...e 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 s...

Page 96: ...the cause Perform Fuel System Pressure Test on p 161 Check for external fuel leakage that could allow fuel and or vapor to enter the engine through the air intake Check for internal fuel leakage from...

Page 97: ...mally supplied to the EMM when the key switch is turned ON Switched B 12 V enters the EMM at pin 28 purple of the EMM J1 B connector The EMM is also turned ON when it begins to receive AC voltage from...

Page 98: ...red 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 Faul...

Page 99: ...ngine 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 Monitorin...

Page 100: ...se the XD100 setting for Conventional use runabouts cruisers Moderate applications Powerhead Break In Use the diagnostics software to start break in oil ing after a powerhead rebuild The break in oili...

Page 101: ...he 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...

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

Page 103: ...refer to the instructions provided with the program IMPORTANT Software replacement requires a Bootstrap Tool P N 586551 EMM Transfer EMM Transfer is used to save engine history data when the EMM must...

Page 104: ...hind oil tank bosses Installation Installation is the reverse of removal Pay close attention when performing the following tasks Make sure isolator mounts are placed in slots in of EMM case Slide EMM...

Page 105: ...07 RUNNING 108 IGNITION OUTPUT TESTS 109 IGNITION SYSTEM REQUIREMENTS 109 WIRING INSPECTION 109 CRANKSHAFT POSITION SENSOR CPS TEST 110 SYSTEM VOLTAGE TEST 110 STATIC IGNITION TEST 111 RUNNING IGNITIO...

Page 106: ...f 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 shoul...

Page 107: ...on test indicates steady spark refer to FUEL DELIVERY TESTS on p 114 Outboard runs low on power misfires Check the EMM LED Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 1...

Page 108: ...ORTANT 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 th...

Page 109: ...rd is running for 2 seconds During starting all four LEDs should light and then go off in sequence LED 1 CHARGING OKAY Stator signal 30 V or higher LED 2 CRANK POSITION OKAY input from CPS EMM powered...

Page 110: ...T For LIGHT ON check for possible fault codes Code 12 TPS circuit fault Code 13 TPS below expected range Code 14 TPS above expected range Code 16 CPS intermittent loss of sync Code 23 EMM temp sensor...

Page 111: ...ltage from EMM white red provides 55 VDC to the high pressure fuel pump the oil injection pump the fuel injectors and the igni tion coils Capacitor Connected to 55 V circuit white red to stabilize cur...

Page 112: ...ostics software Monitor screen to check system voltage Results KEY ON not running approximately 1 V less than battery voltage system voltage is GOOD KEY ON not running no voltage check 12 V power to E...

Page 113: ...Refer to Communication on p 95 Connect timing light pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test and observe timing light strobe for consistent flash IM...

Page 114: ...e and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 114 Inspect for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace sp...

Page 115: ...diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil tests available Before replacing an ignition coil be sure 55 V is supplied to the white red wire of the...

Page 116: ...nuity between pin 2 of fuel pump connector and ground Use the fuel pump static test to activate the control function of the EMM Resistance should drop as EMM connects the control circuit to ground Ref...

Page 117: ...hed by the EMM The Dynamic Tests screen allows the control signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always check the...

Page 118: ...voltage at pin 2 blue red wire of the the water valve connector Voltage should drop while the static test is active Exhaust Water Valve Dynamic Test Use the diagnostics program to perform a dynamic te...

Page 119: ...NEUTRAL START CIRCUIT TEST 133 NEUTRAL START SWITCH TEST 134 EMERGENCY STOP SWITCH TEST 134 TILT TRIM RELAY TEST 135 EXHAUST WATER VALVE TEST 136 SYSTEMCHECK CIRCUIT TESTS 136 GAUGE SELF TEST CHECK 1...

Page 120: ...to 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m T A N IMPORTANT DO NOT lubr...

Page 121: ...o 4 N m 60 to 84 in lbs 7 to 9 5 N m F 30 to 42 in lbs 3 4 to 4 8 N m 24 to 36 in lbs 2 7 to 4 N m B 15 to 30 ft lbs 20 to 41 N m X J 002249a A Triple Guard Grease B Gasket Sealing Compound C Adhesive...

Page 122: ...ctor 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...

Page 123: ...5 Pin No Description of Circuit Wire Color 1 vacant 2 Diagnostic connector Red 3 Diagnostic connector White 4 vacant 5 vacant 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Boots...

Page 124: ...18 vacant 19 Ignition cylinder 2 Orange Green 20 Injector ground Black 21 Injector ground Black 22 vacant 23 Oil solenoid Blue 24 vacant 25 vacant 26 Ignition cylinder 1 Orange Blue 001877 Pin No Des...

Page 125: ...or and the main harness ground Sensor circuit grounds Check continuity between terminal pins 26 and 27 of the EMM J1 A connector and the appropriate sensor ground connections Refer to wiring diagrams...

Page 126: ...ital 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 th...

Page 127: ...or lever Resistance 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 t...

Page 128: ...h 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 outp...

Page 129: ...A ammeter in series between the red wires of engine wire harness alternator output from EMM and the positive B battery cable terminal of starter solenoid Fluke model 334 or 336 Snap On model MT110 or...

Page 130: ...n p 126 55 V Alternator Circuit Check battery ground cable for continuity With the key switch ON check battery voltage at battery 12 V then check voltage on white red wires at J2 connector of EMM Use...

Page 131: ...6 M A S C M B 1 2 3 4 5 6 8 13 15 9 12 17 34 33 32 31 30 29 28 27 26 006403 1 Marine battery 10 26 pin J1 B EMM connector 2 RED wire POS 11 34 pin J1 A EMM connector 3 BLACK wire NEG 12 Engine Managem...

Page 132: ...Engine Wire Harness Contains the following circuits Red purple output wire from fuse provides 12 V to instrument harness Purple wire provides switched 12 V to EMM Yellow red wire provides switched 12...

Page 133: ...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 grou...

Page 134: ...ter 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 va...

Page 135: ...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 conti...

Page 136: ...ts are incorrect Emergency Stop Switch Test This switch can be part of the key switch or installed as a separate switch Either style con nects the M terminals of the key switch The emergency stop swit...

Page 137: ...on 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 Modul...

Page 138: ...rd before performing the following tests Refer to the Engine Wiring diagram and the MWS Instrument Wiring diagram in the back of this manual IMPORTANT Use jumper wires made with the appropriate termin...

Page 139: ...ween pin 8 of the 8 pin connector and pin 1 of the 2 pin connec tor If battery voltage is present at the purple wire and the tan blue wire has continuity between the two connectors replace SystemCheck...

Page 140: ...itch ON Using a jumper wire con nect tan black wire pin 4 of the engine harness connector to a clean engine ground The LOW OIL light should turn on after 40 seconds If the LOW OIL light does not turn...

Page 141: ...reads low or no signal confirm output on gray wire at pin 16 of EMM J1 A connector Reading OK Check condition of tachometer circuit gray wire Repair as needed Reading not OK Check connection at EMM re...

Page 142: ...7637 and the center hole of the crankshaft Assemble the following components from Univer sal Puller Set P N 378103 Body P N 307636 Screw P N 307637 Handle P N 307638 Three screws P N 309492 Three wash...

Page 143: ...edge of flywheel key parallel with centerline of crankshaft Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let dry Align the flywheel keyway and install flywheel Coat t...

Page 144: ...Label this mark A Rotate the flywheel clockwise until the piston contacts the tool Mark the flywheel directly across from the pointer Label this mark B Rotate fly wheel counterclockwise slightly to r...

Page 145: ...e timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS Calibration Use Evinrude Diagnostics software to tell the EMM what throttle position se...

Page 146: ...bles at the battery Remove lower motor covers and air silencer Refer to Lower Cover Removal on p 82 Remove the starter positive cable from post on starter Remove the battery negative cable from the do...

Page 147: ...e any trace of oil or metal dust from commutator Check the armature on a growler for shorted turns using a test light or meter Inspect armature insu lation for indications of overheating or damaged wi...

Page 148: ...w Lock to the brush card screws before installing Place armature in frame Apply Moly Lube to the armature bushing Route the brush leads and install the springs and brushes IMPORTANT Incorrect orientat...

Page 149: ...in lbs 11 to 12 5 N m Lubricate the splines helix of starter pinion shaft with Starter Bendix Lube DO NOT use liquid or aerosol spray lubricants Install pinion spacer and spring Install spacer and ret...

Page 150: ...DEUTSCH Connectors IMPORTANT Electrical Grease is recom mended Incorrect grease application can cause electrical or warning system problems To disconnect the connector press the latch and pull the co...

Page 151: ...in 14 16 gauge notch of crimping pliers AMP Connectors IMPORTANT Always use the appropriate meter test probes and adapters when testing com ponents fitted with these terminals Electrical grease is NO...

Page 152: ...sembly P N 58583 1 comes with die assembly P N 58583 2 SUPER SEAL The J1 A and J1 B connectors of the EMM are AMP Super Seal connectors Disconnect Depress BOTH latches and pull connector from plug Con...

Page 153: ...tor Pull terminal from housing Terminal Installation Align terminal with connector housing and push terminal with seal into connector housing until seated Packard Connectors IMPORTANT Always use the a...

Page 154: ...Install wire gasket on wires and feed wires through the correct terminal position of the con nector housing Terminal is crimped onto wire and then pulled back into connector housing until lock ing tab...

Page 155: ...TEST 161 PRESSURE REGULATOR TEST 162 VAPOR SEPARATOR VENT CHECK 162 FUEL INJECTOR PRESSURE TEST 162 FUEL INJECTOR RESISTANCE TEST 163 CIRCULATION PUMP RESISTANCE TEST 163 LIFT PUMP PRESSURE TEST 163 L...

Page 156: ...4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F 002154a Tighten in 3 stages A Triple Guard Grease...

Page 157: ...1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Adhesive 84...

Page 158: ...uel lift pump 2 to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel injector s...

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

Page 160: ...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...

Page 161: ...level begins to increase An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps maintain consis tent fuel pressure in the fuel s...

Page 162: ...njector by serial number Then the EMM is programmed to compensate for variations in fuel flow Each injector and its loca tion on the outboard is identified by the EMM DO NOT install an injector withou...

Page 163: ...t on p 164 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying enough fuel to vapor sepa...

Page 164: ...vapor separator if the venting of fuel is continuous Fuel Injector Pressure Test This test requires Injector Test Fitting kit P N 5005844 Disconnect the battery cables at the battery Relieve fuel sys...

Page 165: ...it being tested Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter to measure the fuel pump circuit and coil resistance Lift Pump Pressure Test Inst...

Page 166: ...ft pump Temporarily install a vacuum gauge T fitting and 8 in 20 3 cm of clear vinyl hose between the fuel supply hose and fuel lift pump inlet Secure con nections with tie straps to prevent fuel or a...

Page 167: ...e anti siphon valve from fuel tank Install adapter fittings and a 36 in 91 4 cm length of clear hose to the inlet side tank end of valve Fill clear hose with water to a height of 20 in 500 mm Water mu...

Page 168: ...suitable con tainer Slowly open gauge s venting valve Clean up any spilled fuel with shop towels WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use caution when...

Page 169: ...fuel leaks Connect battery cables Run outboard and check for fuel leaks Fuel Lift Pump Service The fuel lift pump is serviceable as a complete assembly or can be repaired with a fuel pump repair kit R...

Page 170: ...vapor separator housing retainer clip Remove vapor separator fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts Installation Installation is the...

Page 171: ...sembly on p 187 Fuel Injector Service Mark fuel injectors to show cylinder locations IMPORTANT Fuel injectors must be installed in the correct cylinder locations Use Evinrude Diag nostics Software to...

Page 172: ...tor from mounting cup Thread adaptor and stud into face of injector Hold mounting cup securely Use slide hammer to sep arate injector from mount housing Remove adaptor from injector Remove crush ring...

Page 173: ...e Guard grease Install washers one per screw on injec tor retaining screws Install screws and washers through mounting flange of injector and into cylin der head Tighten screws in stages starting with...

Page 174: ...e assembly and reed valve assem blies must be cleaned prior to reassembly DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning Remove the reed valve retainer screws and rem...

Page 175: ...urface must be flat 0 004 in 0 10 mm Assembly Remove old adhesive from reed valve retaining screws Install gasket on reed plate assembly DO NOT use sealer on the gasket Prime screw threads with Locqui...

Page 176: ...er screws first and expand out ward Final torque is 60 to 120 in lbs 7 to 13 5 N m Install upper main bearing vent hose and secure with tie strap Connect throttle linkage and electrical connectors Pla...

Page 177: ...NING 181 CYLINDER AND CRANKCASE 181 OIL RECIRCULATION SYSTEM 182 OIL CONTROL SETTINGS 182 OIL PRIMING 182 OILING RATES 182 BREAK IN OILING 182 OILING SYSTEM TESTS 183 OIL INJECTION PUMP STATIC TEST 18...

Page 178: ...CHART SERVICE CHART 002482a A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant S STP Oil Treatment 30 42 in lbs 3 5 5 N m 30 4...

Page 179: ...M OIL SUPPLY DIAGRAMS 177 9 OIL SUPPLY DIAGRAMS 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 5 6 2 4...

Page 180: ...178 OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM 002483a Starboard view Port view...

Page 181: ...injector control BLUE Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK No oil signal to SystemCheck gauge TAN YELLOW 1 2 3 5 6 7 8 12 13...

Page 182: ...ctric 55 V actua tor style pump It draws oil from the oil tank and supplies pressurized oil to the oil manifold The EMM supplies 55 V and controls activation of the pump The oil manifold distributes t...

Page 183: ...must cycle for a minimum of three pulses with the oil level above one quarter If outboard has been run for more than 3 hours with NO OIL faults codes 34 117 the EMM Cylinder and Crankcase The oil dist...

Page 184: ...ing in crankcase cover at upper main bearing hose routed to reed plate fitting This circuit vents the upper main bearing cavity to promote oil flow Refer to the OIL RECIRCULATION DIAGRAM on p 178 OIL...

Page 185: ...ue wire at the oil tank connector pin 2 If the light flashes the EMM and oil injection cir cuits are not at fault Refer to Oil Injection Pump Voltage Test on p 183 Oil Injection Pump Voltage Test Chec...

Page 186: ...pair faulty wiring or replace faulty pump For a higher than expected reading test resis tance of the injection pump If injection pump resistance reading is approximately 22 injec tion pump winding is...

Page 187: ...manifold Use a Syringe P N 346936 filled with isopropyl alcohol to force fluid through hose and fitting LOW OIL Sending Unit Test Remove the oil from the oil tank Turn the key switch ON The dash mount...

Page 188: ...rom the manifold make sure hose support is in the end of the hose Installation Cut Replacement Oil Hose P N 778708 to the correct length Insert hose support in manifold end of hose IMPORTANT DO NOT re...

Page 189: ...ly Nut Lock to threads Install screws and tighten to a torque of 30 to 42 in lbs 3 5 to 5 N m Install protective sleeves and route oil distribution hoses from the oil distribution manifold to the cran...

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

Page 191: ...192 WATER PRESSURE CONNECTION 192 OPERATION 193 CYLINDER BLOCK CYLINDER HEAD COOLING 193 EMM AND VAPOR SEPARATOR COOLING 193 ENGINE TEMPERATURE CHECK 194 SOFTWARE METHOD 194 PYROMETER METHOD 194 IDLE...

Page 192: ...MS 9 1 2 3 4 5 6 8 7 10 60 65 HP 004971 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake scre Water pump Exhaust housing Cylinder block Pressure relief va Thermostat Water...

Page 193: ...to WATER PUMP SERVICE on p 278 for servicing IMPORTANT The water pump housing includes a small hole to the rear of the water outlet This hole provides cooling water for the tip of the exhaust passage...

Page 194: ...A fitting and hose connected to the top of the exhaust cover allows the constant movement of water and or air from the block Circulated water flows through the EMM and vapor separator before exiting t...

Page 195: ...water flows down through the cylinder head to a passage in the cyl inder block Water flows through the block to the exhaust housing and then out of the outboard At higher speeds water pressure opens...

Page 196: ...ystemCheck gauge indicates a WATER TEMP warning refer to WATER TEMP HOT Circuit Test on p 138 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature sensor...

Page 197: ...e Relief Valve Inspection The pressure relief valve should be closed at IDLE speed Water should not flow past the plunger and seal Start the outboard and check IDLE operating tem perature If IDLE temp...

Page 198: ...ng thermostat Refer to Cylinder Head Installation on p 217 Inspection Inspect all parts for cracks heat damage or signs of corrosion Replace damaged parts Clean debris from housing and parts Assembly...

Page 199: ...of corrosion Replace damaged parts Clean debris from housing and parts Assembly Assembly is the reverse of disassembly Pay close attention when performing the following additional tasks Install a new...

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

Page 201: ...GS 212 BEARINGS 213 POWERHEAD ASSEMBLY 213 CRANKSHAFT ASSEMBLY 213 PISTONS AND CONNECTING RODS 215 CYLINDER HEAD INSTALLATION 217 CRANKSHAFT AND CONNECTING ROD INSTALLATION 218 CRANKCASE ASSEMBLY 221...

Page 202: ...Apply to crankcase mating flange M Apply to water passages F 60 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m F 60 84 In lbs 7 9 5 N m B J 18 20 ft lbs 24 5 27 N m B 002283 A Triple Guard Grease B Gask...

Page 203: ...d Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease H 30 32 Ft lbs 41 4...

Page 204: ...sing Remove pin and washer from shift rod lever to release the lower shift rod WARNING Protect against hazardous fuel spray Before starting any fuel system service carefully relieve fuel system pressu...

Page 205: ...ctronic components under the flywheel Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist Loosen the screws holding the exhaust water valve to the exhaust housing M...

Page 206: ...linder 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 Lin...

Page 207: ...er pin punch to push crank case taper pin toward the front side of the engine Remove crankcase flange screws Loosen in stages and remove the main bearing nuts and washers Separate crankcase and cylind...

Page 208: ...et P N 331638 to loosen in stages the rod cap retaining screws DO NOT remove the screws Use one hand to support the piston and remove the rod cap screws with your other hand Remove each piston and rod...

Page 209: ...f necessary use Wrist Pin Pressing Tool P N 326356 to remove the wrist pin bearing Be careful not to lose any of the 28 needle bear ings or the two wrist pin washers If any of the bearings are worn or...

Page 210: ...e housing O ring Discard O ring Use a punch to remove the housing seal Discard seal Inspect housing and replace if necessary Remove O ring from crankshaft sleeve and inspect it Replace the O ring if i...

Page 211: ...s 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...

Page 212: ...asket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block and crankcase Carefully remove any carbon accumulation from the tops and ring grooves of the pis...

Page 213: ...head warpage must not exceed 0 006 in 0 15 mm per inch of measurement Replace head if warpage exceeds this dimension Crankshaft Measure the diameter of each crankpin and main bearing journal The lowe...

Page 214: ...quare the ring in the cylinder Use a feeler gauge to measure the ring end gap Ring end gap should be 0 011 to 0 023 in 0 28 to 0 58 mm IMPORTANT Ring end gap increases approxi mately 0 003 in 0 076 mm...

Page 215: ...cant IMPORTANT Use new wrist pin retaining rings gaskets seals and O rings during assembly Crankshaft Assembly Oil the end of the crankshaft Use Crankshaft Bearing Sleeve Installer P N 338647 and plac...

Page 216: ...ant and install them in their original positions The split sleeve ring grooves must face toward driveshaft lower end of crankshaft when installed Lightly coat the outside edge of a new lower hous ing...

Page 217: ...direction New pistons are stamped EXH This marking should be turned toward the exhaust side of the block The splash bowl on the dome of the piston will be located toward the flywheel and opposite the...

Page 218: ...ecting 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 u...

Page 219: ...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 blo...

Page 220: ...der block so crankcase mating flange is facing up Apply Gasket Sealing Compound to lower oil seal groove in cylinder block DO NOT put any sealer in upper seal groove Check that main bearing alignment...

Page 221: ...PORTANT 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...

Page 222: ...rod cap The groove lines on the jaws must be centered on the rod crankpin diameter Tighten the forcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 N m IMPORTANT Make sure that frame is squarely in...

Page 223: ...sealer in upper seal groove Use a small brush with a tapping motion to apply a thin even coat of Gel Seal II sealant to the crank case mating flange The sealer must not come within 1 4 in 6 4 mm of be...

Page 224: ...e 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 Se...

Page 225: ...retaining screw to a torque of 60 to 84 in lbs 7 to 9 5 N m Apply Triple Guard grease to shoulder of shift arm screw and Nut Lock to threads Install arm screw and washer and tighten screw to a torque...

Page 226: ...ge Refer to Throttle Linkage Installation on p 223 Install fuel injectors and ignition coils Refer to Fuel Injector Installation on p 171 IMPORTANT All injectors must be installed in their original lo...

Page 227: ...ate flywheel in a clockwise direction to align crankshaft and driveshaft splines Apply Triple Guard grease to the threads and Gasket Sealing Compound to the shank of the powerhead screws Loosely insta...

Page 228: ...Lock to threads of exhaust water valve screws and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Connect cooling water hoses to exhaust housing Connect the power trim connectors and exhaust water...

Page 229: ...inkage as follows Loosen adjustment screws on shift lever Be sure that ball is centered in detent assembly Adjust shift lever so that the screw hole in shift rod lever lines up with the hole in the ge...

Page 230: ...228 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Short Block Starboard Short Block...

Page 231: ...229 POWERHEAD POWERHEAD VIEWS 11 Port Dressed Powerhead Starboard Dressed Powerhead...

Page 232: ...230 POWERHEAD POWERHEAD VIEWS Port Rope Start Models Starboard Rope Start Models...

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

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

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

Page 236: ...234 POWERHEAD POWERHEAD VIEWS Top Rope Start Models...

Page 237: ...TILT 246 STERN BRACKET MANUAL TILT MODELS 247 CLAMP SCREW 247 STERN BRACKET DISASSEMBLY MANUAL TILT 247 STERN BRACKET ASSEMBLY MANUAL TILT 250 TILT ASSIST CYLINDER 253 TILLER HANDLE SERVICE STANDARD 2...

Page 238: ...CHART STERN BRACKET POWER TILT MODELS 144 168 In lbs 16 19 N m F 10 16 In lbs 1 2 N m 45 50 Ft lbs 61 68 N m A A A 45 50 Ft lbs 61 68 N m Use Triple Guard grease on all pivot points A Triple Guard Gre...

Page 239: ...lbs 16 19 N m 144 168 In lbs 16 19 N m F 40 45 Ft lbs 54 61 N m See Text A 144 168 In lbs 16 19 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue N...

Page 240: ...pound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex No 2 Q Gel Seal II 004304 60 84 in lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B F 16 18 ft lbs 22 24 5...

Page 241: ...s 2 3 3 4 N m 36 48 In lbs 4 5 4 N m 36 40 Ft lbs 49 54 N m 18 20 Ft lbs 24 5 27 N m 24 36 In lbs 2 7 4 N m A F F F A A D D 18 20 Ft lbs 24 5 27 N m Switched 12V For CANbus To Engine Key Switch Connec...

Page 242: ...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 Thread Slide Hammer P N 432128...

Page 243: ...d 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...

Page 244: ...EMOVAL AND INSTALLA TION on p 276 Remove the powerhead Refer to Powerhead POWERHEAD REMOVAL on p 202 Remove the three lower mount cover screws Separate lower mount covers from swivel bracket Check con...

Page 245: ...e and bracket in position Apply Nut Lock to screws install and tighten 60 to 84 in lbs 7 to 9 5 N m Exhaust Relief Muffler Remove exhaust relief muffler cover to inspect fil ter element Clean or repla...

Page 246: ...Place lower thrust washer on the steering shaft and place the lower front mount into position Install lower side mount covers Install and tighten the screws in stages to a torque of 16 to 18 ft lbs 2...

Page 247: ...om the bracket Pull the steering arm out of the swivel bracket Use an appropriate tool to pry the upper and lower seals from the swivel bracket To separate the swivel bracket from the stern bracket re...

Page 248: ...brackets Place a thrust washer between each of the stern brackets and the swivel bracket Install the tilt tube Tighten the tilt tube nuts 40 to 45 ft lbs 54 to 61 N m then back off 1 8 to 1 4 turn Ap...

Page 249: ...new swivel plate with screw and tighten securely Stern Bracket Disassembly Manual Tilt Remove bumpers from the upper mount retaining screws Remove screws upper mount and ground lead from the bracket S...

Page 250: ...el bracket Drive the steering friction bushing up and out of the swivel bracket Remove the thrust rod from the stern brackets Remove one tilt tube nut and remove tilt tube from the stern brackets and...

Page 251: ...nd bush ing from the swivel bracket Remove the starboard stop link retaining screw and nut from the swivel bracket Remove the cotter pins from both reverse lock pins Remove the reverse lock pins and s...

Page 252: ...nstall the two cotter pins in the reverse lock pins Install the bushing the port stop link and the tilt run lever in the swivel bracket The tilt run lever should be in the RUN position Install the wav...

Page 253: ...19 N m Tighten the tilt tube nuts to a torque of 45 to 50 ft lbs 61 to 68 N m Install the thrust rod in the stern brackets Install the larger shoulder screw through the port stop link wave washer and...

Page 254: ...pper thrust washer on the pivot shaft Slide the pivot shaft through the swivel bracket Lubricate the swivel bracket through the four lubri cation fittings with Triple Guard grease Apply Nut Lock to th...

Page 255: ...ove set screw from starboard stern bracket lower pivot pin access hole and use an appropri ate tool to remove lower pivot pin If lower pivot cannot be removed because of cor rosion or damage stern bra...

Page 256: ...e lever Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove throttle cable and wires from grommet in lower engine cover Remove the screw attaching steeri...

Page 257: ...7 to depress the grip detents Tighten screw and remove the grip by pulling grip Remove the helix halves rollers and guides Pull the throttle pin out of the cable Remove stop switch cover screws and co...

Page 258: ...ith a mallet and a punch Inner handle is bonded to the outer handle After removing chip away remnants of inner handle Remove throttle cable seal from the inner handle Inspection Inspect the throttle c...

Page 259: ...the retainer clip Install the throttle control plate on outer handle Push the throttle cable pin through the end of the throttle cable Lubricate end of the pin guides rollers helix grooves and inner...

Page 260: ...he steering bracket Attach the steering handle to the bracket Tighten screw to a torque of 36 to 40 ft lbs 49 to 54 N m Route throttle cable and electrical harness through grommet in lower motor cover...

Page 261: ...rottle cam is against idle stop when anchor screw aligns with throttle body boss Then rotate anchor four turns toward the end of the cable Install washer cable anchor and cable anchor screw on throttl...

Page 262: ...Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove shift and throttle cables and wire harness from grommet in lower engine cover WARNING To avoid accid...

Page 263: ...bly Loosen throttle friction control so there is no restriction on grip IMPORTANT Do not back screw out com pletely Nut is under spring tension Remove seven screws and bottom cover of tiller handle Re...

Page 264: ...nd guides Pull the throttle pin out of the cable Remove the throttle friction control Remove the throttle cable retaining clip Pry the cable trunnion out of the steering handle and remove cable The tr...

Page 265: ...shift cable retainer from shift cable trun nion Remove cotter pin from shift handle pin Remove shift cable Remove shift handle screw and washer Remove shift handle bushing and washer Remove shift han...

Page 266: ...ds of shift pin and install shift pin into shift handle Tighten to a torque of 18 to 22 ft lbs 24 5 to 29 N m Coat detent ball spring and guide with Triple Guard grease and install into shift handle P...

Page 267: ...top of tab must be flush with top of flange Apply Nut Lock on the screw threads install the washer and screw IMPORTANT Turn self tapping screw counter clock wise until threads of screw engage threads...

Page 268: ...steering handle Wire guide should slide easily into place If any binding is felt inspect trim switch wiring for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Make su...

Page 269: ...y Lube Place the guides over the roller pin and into the slots of the inner handle Place the rollers on the ends of the roller pin Assemble the helix halves on the handle and slide the grip over the h...

Page 270: ...straight or angled 15 port or starboard by moving the adjust ment plate Place tiller bracket on steering arm from the bot tom Thread steering arm screws with washers into steering arm and tighten to...

Page 271: ...lower anchor pocket Adjust the trunnion nut so the cas ing fits onto the shift lever pin Secure shift cable to the shift lever pin For proper installation review the following steps Place washer on p...

Page 272: ...lash Adjust cable anchor so throttle cam is against idle stop when anchor screw aligns with throttle body boss Then rotate anchor four turns toward the end of the cable Install washer cable anchor and...

Page 273: ...djustment Tiller models are equipped with a throttle friction adjustment knob located on the steering handle Tighten the knob to reduce the effort required to hold a throttle setting Turn the knob clo...

Page 274: ...272 MIDSECTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 275: ...VAL 282 PINION GEAR AND DRIVESHAFT REMOVAL 283 SHIFT HOUSING GEAR AND PROPELLER SHAFT REMOVAL 284 INTERNAL GEARCASE SERVICE 285 PINION BEARING REMOVAL 285 PINION BEARING INSTALLATION 285 SHIFT HOUSING...

Page 276: ...bs 13 5 16 5 N m A B C 60 84 In lbs 7 9 5 N m D B C B A B 96 120 In lbs 11 13 5 N m 60 84 In lbs 7 9 5 N m B A 18 20 Ft lbs 24 5 27 N m B 40 45 In lbs 54 60 N m 35 40 Ft lbs 47 54 N m B 48 80 In lbs 5...

Page 277: ...thread pressure test gauge fitting and seal in lubricant level hole Pressurize 3 to 6 psi 21 to 42 kPa If pressure gauge indicates leakage submerge the gearcase in water to determine source of leak I...

Page 278: ...MPORTANT Before installing gearcase shift rod adjustment MUST be checked Refer to SHIFT ROD ADJUSTMENT on p 280 Coat the driveshaft splines with Moly Lube DO NOT coat top surface of the driveshaft as...

Page 279: ...n shift shaft connection area Apply Gasket Sealing Compound to threads of the gearcase retaining screws Tighten the screws to a torque of 3 8 in screws 18 to 20 ft lbs 24 to 27 N m 7 16 in screw 28 to...

Page 280: ...Slide the water pump off the driveshaft Remove the impeller drive cam impeller plate and gasket Discard the gasket Remove all the parts from the housing Inspection Check impeller for overheating hub...

Page 281: ...eller into the liner with the slot for the impeller cam facing out Apply a thin bead of Adhesive 847 in the seal groove and install the special shaped O ring seal Apply Gasket Sealing Compound to both...

Page 282: ...groove of the impeller housing grommet Install the grommet on the impeller housing IMPORTANT Before installing gearcase shift rod adjustment MUST be checked Refer to SHIFT ROD ADJUSTMENT on p 280 SHIF...

Page 283: ...d threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss of boat and outboard control and gearcase damage Hydrostatic Seal Grooves M...

Page 284: ...rsal Puller Set P N 378103 Remove the two retaining rings using Retaining Ring Pliers P N 331045 Remove the retainer plate from the gearcase COA3571 9437 CAUTION Retaining rings are under extreme pres...

Page 285: ...of the driveshaft Pad handle of the wrench to prevent damage to gearcase Remove the four driveshaft bearing housing screws Remove pinion nut and driveshaft from the gear case The bearing housing shims...

Page 286: ...d between the puller and the gearcase until the driveshaft pops loose from the pinion Shift Housing Gear and Propeller Shaft Removal Push down on the shift rod This will move the detent lever downward...

Page 287: ...r intake screen for blockage and remove it by depressing the tabs on either side of the screen and pushing upward Pinion Bearing Installation Install the water intake screen Drop it into the water int...

Page 288: ...w and tighten to a torque of 48 to 80 in lbs 5 5 to 9 0 N m Shift Housing Disassembly IMPORTANT The shift housing and forward gear bearing are serviced as an assembly If either are worn or damaged rep...

Page 289: ...sembly procedures Replace any damaged components Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at 90 angle int...

Page 290: ...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 o...

Page 291: ...Large Puller Jaws P N 432129 Discard the seal Remove and discard the O ring from the bearing housing Clean the bearing housing in solvent to remove sealer from the seal bore and the O ring groove Lig...

Page 292: ...hten jaws securely behind the bearing Remove front bearing using Puller Bridge P N 432127 and Bearing Puller P N 432130 Place the puller plate on top of the housing to sup port the bridge and tighten...

Page 293: ...hould be visible Bearing Installation Tool P N 326562 Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to install new sea...

Page 294: ...housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 40 to 45 ft lbs 54 to 60 N m IMPORTANT The original pinion nut may be used for shimming but must...

Page 295: ...ims between the bearing housing and the thrust washer IMPORTANT Use extreme care when remov ing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 312403 Check clearance aga...

Page 296: ...into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Place the cover seal on the...

Page 297: ...or P N 312403 slide the driveshaft bearing housing onto the driveshaft and into position in the gearcase Align the embossed word FRONT toward the shift rod Do not install screws at this time Lightly c...

Page 298: ...the propeller shaft until it engages the pinion gear Slide the bearing housing retainer plate into posi tion over the propeller shaft Using Retaining Ring Pliers P N 331045 install the two retaining r...

Page 299: ...e top Place the housing into gearcase and tap the housing with a soft face mallet to seat the O ring Apply Gasket Sealing Compound to the threads and seals of the four propeller housing retaining scre...

Page 300: ...298 GEARCASE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 301: ...RVOIR FLUID 301 MANUAL RELEASE VALVE 301 STERN BRACKETS 301 ELECTRICAL CIRCUIT TESTS 301 RELAY TESTING 301 TRIM AND TILT MOTOR CURRENT DRAW TESTS 301 TRIM AND TILT MOTOR NO LOAD TEST 302 TRIM GAUGE TE...

Page 302: ...nd tilt range by opening the manual release valve a minimum of three turns When this cycle is complete the manual release valve must be closed and tightened to a torque of 45 to 55 in lbs 5 to 6 N m b...

Page 303: ...the trim UP button is pressed the UP relay is energized and connects the blue trim motor wire to the battery positive terminal The green trim motor wire remains grounded When the but ton is released t...

Page 304: ...iston Malfunctioning check valves 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 highe...

Page 305: ...t a jumper wire between terminals S and G Gauge should indicate full trim UP position If results are different replace the trim gauge If results agree refer to Trim Sender Test Trim Sender Test IMPORT...

Page 306: ...ets Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw Disassembly Thoroughly clean the unit before disassembling Scrub all outside surface...

Page 307: ...r Remove the manual release valve Inspect the manual release valve Discard the O rings on the housing Remove the four large motor flange retaining screws Remove the motor and discard O ring Remove dri...

Page 308: ...screws and lock washers Tighten the screws to a torque of 35 to 52 in lbs 4 to 6 N m Oil O rings and install them on the manual release valve Oil and install the manual release valve Tighten the valv...

Page 309: ...ylinder and thrust rod bushings with Triple Guard grease Install the bushings Install the ground lead Position the hydraulic unit between the stern brackets Lubricate the angle adjustment rod with Tri...

Page 310: ...308 TRIM AND TILT ADJUSTMENTS ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p 62...

Page 311: ...MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 310 RECOIL STARTER REMOVAL 311 RECOIL STARTER DISASSEMBLY 311 RECOIL STARTER CLEANING AND INSPECTION 313 RECOIL STARTER ASSEMBLY 313 RECOIL STARTER INSTA...

Page 312: ...ERVICE CHART SERVICE CHART E Red Ultra Lock F Blue Nut Lock V Lubriplate 777 96 to 120 in lbs 11 to 13 5 N m V V F 60 to 84 in lbs 7 to 9 5 N m 120 to 144 in lbs 13 5 to 16 N m F 120 to 144 in lbs 13...

Page 313: ...er rope and remove the handle Release the slip knot and ease the rope back in until the rewind spring is fully unwound If necessary remove the starter handle bracket from the starter housing Remove th...

Page 314: ...ring and remove ring from the starter Remove the friction plates and friction plate spring washer Hold the pulley in the starter housing while turning the starter over legs down Hold fingers clear of...

Page 315: ...s of rope to a length of 1 2 in 12 mm Examine the pulley and the starter housing Look for sharp edges and rough surfaces that could fray the starter rope File and polish to remove Examine the starter...

Page 316: ...ts the starter winder base Remove the crank retainer screw and the crank and pin assembly from the starter winder base Remove the starter winder base from the vise Install the rewind spring into the s...

Page 317: ...77 to boss of the starter pawl Place spring washer on the boss of the starter pawl Place the starter pawl in the pulley Place the starter housing spring in the starter housing Install the starter pawl...

Page 318: ...ulley counterclockwise until the rewind spring is tight Back off the rewind spring until the rope cavity of the pulley is aligned with the rope guide Thread the starter rope through the pulley rope gu...

Page 319: ...to 16 N m Place the starter assembly onto the outboard Install the starter housing retaining screws wash ers and lock washers Be sure to place washers between the starter housing and the flywheel cov...

Page 320: ...318 MANUAL STARTER NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Page 321: ...6 OUTBOARD FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILT TRIM SHOCK ABSORPTION SYSTEM AND SAFETY S 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFET...

Page 322: ...S 2...

Page 323: ...elf but also to protect the people around you It is impossible for this manual to cover every potentially hazardous situation you may encounter However your understanding and adherence to the recommen...

Page 324: ...ORWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of...

Page 325: ...o STOP propeller What could happen If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How can loss of speed control be mi...

Page 326: ...eel and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams opera...

Page 327: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom can change a set up which was OK earlier If moved up or down even...

Page 328: ...kage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is stored base ment or cottage could be i...

Page 329: ...tion as shown in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked...

Page 330: ...er engine cover If tank cap has an air vent valve make sure it is closed Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is trapped in tank a...

Page 331: ...s transom Outboard may S L I D E on transom Boat may turn and be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Page 332: ...d may come loose Mount on flat surface only Use shims to make surface flat Use bolts nuts and washers supplied with outboard They are usually special and will not rust or weaken Check for a high speed...

Page 333: ...suddenly Boat may SINK At high speeds sudden trimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test...

Page 334: ...and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key s...

Page 335: ...un into something How can failure of the emergency stop system be minimized When rigging or after servicing Read understand and follow manufacturer s instructions Follow warnings marked closely Assemb...

Page 336: ...Reading and understanding instructions Re reading warnings marked Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Repla...

Page 337: ...t hit you as it swings If engine does not have fixed lifting bracket and you use Universal Puller P N 378103 and Lifting Eye P N 321537 or Lifting Eye and Adapter Assembly P N 396748 use only the spec...

Page 338: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils ca...

Page 339: ...ust fumes from the engine or other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In high con...

Page 340: ...Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in...

Page 341: ...er leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Ba...

Page 342: ...tches cigarettes blow torches welders Electric motors with unsealed cases Electric generators with unsealed cases Light switches Appliance pilot lights or electric ignitors furnace dryer water heaters...

Page 343: ...re to use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little childre...

Page 344: ...ual as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to c...

Page 345: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 346: ...cators 107 Strategy 104 Diagnostic Software Break In Programming 56 59 182 CANbus Activation 52 Communication With Outboard 95 Crankshaft Position Sensor 110 Cylinder Drop Tests 106 Fuel Injector Prog...

Page 347: ...sts 161 Priming 54 Relieving Pressure 166 Requirements 32 Troubleshooting 106 114 161 Vapor Separator 158 168 Fuse 123 G n n n n n n n n n n n n n n n n 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 348: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 349: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 350: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n 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 351: ...essor P N 336314 217 Rod Cap Alignment Fixture P N 396749 219 Seal Installation Tool P N 326551 291 Seal Installer P N 342665 289 Secondary Lock Installer P N 777079 150 Secondary Lock Tool P N 777078...

Page 352: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Vapor Separator Description 158 Installation 168 Removal 168 W n n n n n n n n n n n n n n n n n n...

Page 353: ...A Check wiring then replace faulty fuse Wiring harness Check for 12 V at terminal B of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendi...

Page 354: ...king Check voltage at injectors Excessive fuel or oil engine flooded Check for leaking injectors leaking fuel or oil lift pump or leaking vapor separator vent refer to FUEL SYSTEM Low or no 55 V alter...

Page 355: ...heck 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...

Page 356: ...t 55 V Check voltage on 55 V circuits refer to SYSTEM ANALYSIS and ELECTRICAL AND IGNITION Capacitor or 55 V circuit wiring Check capacitor and 55 V circuit refer to SYSTEM ANALYSIS and ELECTRICAL AND...

Page 357: ...IS and ELECTRICAL AND IGNITION Fuel injector electrical circuit or control function Check voltage at injectors refer to SYSTEM ANALYSIS Restricted or leaking fuel injectors Check injectors refer to FU...

Page 358: ...up check for fuel system air leaks Restricted or leaking fuel injector s Check injectors refer to FUEL SYSTEM Faulty wiring connections grounds or CPS air gap Check all grounds connections and wiring...

Page 359: ...tube 4 Cylinder block 5 Pressure valve 6 Thermostat 7 Water supply to EMM 8 Water supply EMM to vapor separator 9 Overboard indicator outgoing water from vapor separator 10 Water valve Hose Routing an...

Page 360: ...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 361: ...39 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 wa...

Page 362: ...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 363: ...B M M C A S OFF M B S A C M ON M B S A C M START M B S A C M 4 5 6 1 2 3 MWS Key Switch and Neutral Safety Switch 000691...

Page 364: ...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 MW...

Page 365: ...Throttle Position Sensor 3 Neutral Switch 4 Stator 5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 D...

Page 366: ...tion Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will...

Page 367: ...Temperature ABOVE range 3 3 LED 4 ON Running WATER TEMP HOT 8 seconds EMM Temperature 176 F 80 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running LOW BATTERY 5 min...

Page 368: ...nces 83 Ignition timing circuit 3 OPEN LED 2 ON Running 10 instances 90 Water injection solenoid SHORTED LED 2 ON Running 8 seconds Check circuit resistance 295 20 77 F 25 C 91 Fuel pump circuit OPEN...

Page 369: ......

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