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ERVICE

ANUAL

ONTENTS

SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE

1 REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . 3

2 ROUTINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 ENGINE COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . 49

4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 53

5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . . 87

7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

10 EVINRUDE ICON REMOTE CONTROL SYSTEM . . . . 195

11 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

12 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

13 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

GEARCASE – STANDARD ROTATION . . . . . . . . . . . . 296

GEARCASE – COUNTER ROTATION . . . . . . . . . . . . . 319

14 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T-1

DIAGRAMS

IMPORTANT:

For complete outboard rigging and control installation information, refer to the

Predeliv-

ery and Installation Guide

included with the service manual set.

All special tools referenced in this manual can be found in the

Special Tools Guide

, P/N 5008526.

Содержание DE250CXINR

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

Страница 4: ...REMOTE CONTROL SYSTEM 195 11 POWERHEAD 215 12 MIDSECTION 259 13 GEARCASE 281 GEARCASE STANDARD ROTATION 296 GEARCASE COUNTER ROTATION 319 14 TRIM AND TILT 331 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART...

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

Страница 6: ...u ired a lways replace with a new one When repla cement p arts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and mate rial Use of sub...

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

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

Страница 9: ...prescrib ed changes such as altitude ad justments for exam ple Owner s Responsibility The owner operator is required to have outboa rd maintenance performed to maintain emission lev els within prescri...

Страница 10: ...T 3 R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex IN 2012 MODEL RUN or SUFFIX DESIGN FEATURES B Blue Paint C Counter Rotation D Evinrude E TEC E Electric Start w Remote Steering F Direct Injection G Graphite Paint H...

Страница 11: ...ainles s Steering Arm Standard Styling DE250PXINR 3 3 L 200 1 ci 542 M2 25 White ICON Control Stainles s Steering Arm Std Styling E250DCXINS 3 3 L 200 1 ci 542 M2 CR 25 White Stainles s Steering Arm S...

Страница 12: ...90 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 1 6199 to 1 6204 in 41 15 to 41 16 mm Center Crankshaft Journals 2 1870 to 2 1875 in 55 55 to 55 56 mm Bot...

Страница 13: ...ark Plug Refer to Emission Control Information Label Champion QC8WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 L2 Type Gearcase 200 HP 14 26 538 1 86 1 Refer to GEAR...

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

Страница 15: ...haft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC8WEP 0 028 0 003 in 0 71 mm GEARCASE Gear Ratio M2 Type Gearcase 13 24 542 1 85 1 Refer to GEARCASE...

Страница 16: ...auti cal orientation This manual of ten identifies p arts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No 12...

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

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

Страница 19: ...entify con trol ca ble fun ction before rigging outboard Identify each control cable Put the co ntrol handle into NEUTRAL positio n The throttle cable casing guide will retract com pletely and the shi...

Страница 20: ...and Wire Routing Refer to Control Cable Identification on p 17 Remove two screws and bracket that fasten the grommet to lower motor cover Route all hoses co ntrol cable s and wiring through a prote c...

Страница 21: ...nc e for all cables to av oid binding or chafing through all engine steering and tilting angles Control Cable Installation Refer to Control Cable Identification on p 17 Remove control cable trunnion c...

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

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

Страница 24: ...N Remot e Control Syste m Inst allation Guide If using a mechanical control system connect the I Command En gine Interface Cable to the EMM CANbus connector Use an I Command Ignition and Trim Harness...

Страница 25: ...refully align pins and socket s of conne ctors Do NOT force connectors together Tighten locking rings of buss connectors fing er tight Do NOT use locking rings to force connec tors together Do not rot...

Страница 26: ...along the same path as the battery cables For an I Command wate r pressure displa y se v eral water pressure sensor kit s are available Refer to the Evinrude Johnson Genuine Parts and Accessories cat...

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

Страница 28: ...the outside diameter of the hose when installed on the fitting Chose a clamp so that the outside diameter of the hose is approximately in the middle of the clamp ing range of the clamp A WARNING DO NO...

Страница 29: ...stepless clamps Oetiker pin cers are ava ilable in the Evinrude Johnson Genuine Parts and Accesso ries Catalog Position correct size clamp over hose Install hose on fitting Close clamp ear fully with...

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

Страница 31: ...engine is trimmed to the full down position the bow of the boat goes deeper into the water If the trim limiter rod is left out the bow could plow into the wat er cau sing the boa t to bow steer result...

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

Страница 33: ...s Each app lica tion must be thoroughly tested until the idea l combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small amoun t...

Страница 34: ...n Gear Prevention Start outboard and shift to FORWARD Turn outboard OFF while control is in FORWARD Try to restart the o utboard Outboard should not start Shift back to NEUTRAL and restart outboard Sh...

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

Страница 36: ...un outboard at IDLE only until full operating tem perature is reached Reinstall plug and n ozzle Position th e plug a nd nozzle to allow the water stream to be seen from the helm Leave the outbo ard i...

Страница 37: ...water travels to the powerhead Water can drain from aux il iary inlets resulting in engine overheat A st eady stre am of water should flo w f rom th e overboard indicator while the engine is running...

Страница 38: ...lering bracket with Triple Guard grease Throttle and Shift Linkage Disconnect the battery cables at the battery Remove cable trunnion cover Carefu lly re move throttle and shift cables from trunnion b...

Страница 39: ...earcase Lubricant Draining IMPORTANT Always check the fill le vel of the gearcase lub ricant at the u pper plug befo re removing the lower drain fill plug A tie st rap can be used to check lubricant l...

Страница 40: ...nspect ion is re commended when lubricant is contaminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 16 for service freque ncy and recommended lubricants S...

Страница 41: ...he fill plug threads Install the filler cap and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the un it at lea st five complet e cycles to purge all air from the syste...

Страница 42: ...e cera mic of the spark plug in line with the OPEN sid e of the ground ele c trode This mark will be used to orient the spark plug with the OPEN sid e of the ground electrode facing the fuel injector...

Страница 43: ...rviceable oil filters are locate d in th e oil inje c tion tank and in the oil supply line before the oil lift pump s Air Silencer The air silencer on Evinrude outboards maximizes air flow while minim...

Страница 44: ...ing for re stric 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 chang es wit h throt...

Страница 45: ...the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no re sistance If resistance is high check the followi...

Страница 46: ...t art the outb oard All four SystemCheck lights will turn on an d the out board will run at idle speed After ap proximately 15 seco nds the System Check lights will go off Move thro ttle to IDLE posit...

Страница 47: ...r pickup system gearcase speedometer models only Lubricate all grease fittings and linkages Inspect ou tboard st eering system and co n trols Repla ce all damaged and wo rn compo nents Refer to man uf...

Страница 48: ...ings IMPORTANT If outboa rd ca nnot b e st arted or serviced immediately it should be resubmerged in fresh water to avoid exposure to the atmosphere Engine Dropped Overboard Not Running Disconnect the...

Страница 49: ...our Engine Dropped Overboard Running Follow the same procedures as Engine Dropped Overboard Not Run ning However if there is any binding when th e flywheel is rotated it may indicate a bent connecting...

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

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

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

Страница 53: ...cover slightly an d d isconnect trim tilt switch con nector Then remove port and starboard covers Lower Cover Installation Install t he lo wer engine covers and tighten all screws to a torque of 24 t...

Страница 54: ...o sc rew threa ds Pl ace spring washer and ho ok into position and tig hten screw to a torque of 180 in lbs 20 N m Trim Switch Installation Place switch into position through cover Install nut on swit...

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

Страница 56: ...ne hours Oiling ratios Shift interrupt function Anti knock compensation EMM Connections IMPORTANT EMM connections an d wiring must be clean and tigh t Improper electrical con nections can damage the E...

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

Страница 58: ...nso r circu it 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 volt age is less than 45 V between 5 00...

Страница 59: ...haust Pressure Sensor The exhaust pressure se nsor mon itors exhaust pressure during all running conditions to compen sate for engine loads If the sen sor reads less than 85 in wa ter or greater than...

Страница 60: ...RPM for 3 seconds the EMM If cylinder he ad temperature exceeds 248 F 120 C for 3 seconds the EMM The outboard will not restart until the engine tem perature returns to normal Refer to SHUTDOWN MODE...

Страница 61: ...N the EMM If the outboard is started the code is saved If the key ON voltage is greater than 0 78 V when the engine is started speed is limited to idle If code 11 is present as both a Active Fault and...

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

Страница 63: ...ngs are a ltered to maintain a specific RPM when e ngine is cold or warm The contro ller is inactive when TPS is advanced from idle position RPM Limiter This featu re of EMM pr ogramming prevents engi...

Страница 64: ...y the EMM Refer to the EMM Servic e Code Chart at the back of th is manual for a co mplete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position...

Страница 65: ...o enter th e engine throug h the air intake Check for internal fuel leakage from a le aking injector or vapor separator vent hose Recovery To recover from shu tdown mode the EMM must NOT detect the re...

Страница 66: ...computer s serial port The EMM must turn ON before it will communicate with the computer Power is normally supplied to the EMM when the key switch is ON Switched B 12 V enters the EMM at pin 21 purpl...

Страница 67: ...operating hours of first and last occurrences Active Faults An active fault is a se rvice code th at cu rrently exists Active faults become occurred faults only if the outboard is running Historical F...

Страница 68: ...rcuit 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 ete...

Страница 69: ...ection rate This set ting REQUIRES th e use of Evinrude XD100 out board lub ricant and is not re commended for all applications Use the XD100 setting for Conventional use runabouts cruisers Moderate a...

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

Страница 71: ...ment Engine Management Software is loaded into th e EMM at the factory Periodically a new program may be available to enhance the opera tion of an outboard Select Engine Software Update from the Utili...

Страница 72: ...er th e EMM is rep laced EMM timing must be synchronized to crankshaft position Refe r to TIMING ADJUS TMENTS on p 112 EMM SERVICING IMPORTANT If a n ew EMM is being installed refer to EMM Transfer on...

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

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

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

Страница 76: ...lugs Check the fuse an d the emergency st op switch lanyard Diagnostic Software Inspections Before running the out board use Evinrude Diag nostics so ftware to review historical informatio n saved in...

Страница 77: ...tity Report provides a sn ap shot of current engine and sensor conditions From the Identity screen press the Print button Next press Printer to print or PDF File to save the report Operational Inspect...

Страница 78: ...fer to EMM LED INDICA TORS on p 78 Use the Evinrude Diagnostics software Monitor screen to chec k sy stem 55 V and TPS vo lt ages System volt age should b e steady a nd TPS voltage should be between 0...

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

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

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

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

Страница 83: ...tware Monitor screen to check system voltage Results EMM ON not running 30 V 2 system volt age is GOOD EMM ON not ru nning less tha n 30 V 2 check 12 V power to EMM Repair connection or wiring Possibl...

Страница 84: ...Connect timing ligh t pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test an d observe timing light strobe for consistent flash IMPORTANT You may need to remove...

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

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

Страница 87: ...er to che ck continuity bet ween pin 2 of fuel pump connector and ground Refer to Circulation Pump Resistance Test on p 141 If the pump runs Refer to Fuel System Pressure Test on p 139 Refer to Runnin...

Страница 88: ...ing switche d by the EMM The Dynamic Tests screen allows the contr ol signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always...

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

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

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

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

Страница 93: ...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...

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

Страница 95: ...and 22 of the EMM J1 B connector and the main harness ground Sensor circuit g rounds Check continuity between termina l pins 4 and 1 1 of the EMM J1 A co nnector and the appropriate sensor ground con...

Страница 96: ...sensor resis tance betwee n the yellow a nd white wires The complete circuit can b e tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mounted to throttle body housing and...

Страница 97: ...mperature 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 meas...

Страница 98: ...read 1 ohm or less To che ck for a g rounded winding conne ct on e meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no contin uity If meter rea d...

Страница 99: ...an d various o ther a mp meters should be available through local tool suppliers Reconnect the battery cables Following the manufa cturer s dire ctions conne ct the variable lo ad teste r carbon pile...

Страница 100: ...f there is no increase turn the key switch to OFF and test red black wire between the EMM an d auxiliary battery connection Continuity indicates fa ulty ou tput from EMM Check 12 V alternator output b...

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

Страница 102: ...ss 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 switc...

Страница 103: ...r 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...

Страница 104: ...ve lead to starter motor terminal Activate st arter motor a nd observe volt age reading No Load Current Draw Test Securely fasten starter in a vise or suitable fixture before proceeding with this chec...

Страница 105: ...l S Meter should indicate continuity IMPORTANT The cho ke function or ter minal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or con tinuity light to test the continuity o...

Страница 106: ...are incorrect Emergency Stop Switch Test This switc h can be part of the ke y switc h or installed as a separate swit ch Either st yle con nects the M terminals of the key switch The emergency stop sw...

Страница 107: ...B connec tion to TNT motor Terminals 87 and 30 are no rmally ope n B is applied to terminal 30 when relay is activat ed This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Dia...

Страница 108: ...urn on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the ke y switch ON T est for b attery volt age be tween instrument harne ss terminal 1 purple w...

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

Страница 110: ...low 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 t...

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

Страница 112: ...r This pr events Nut Lock from migrating into upper seal of crankshaft Align the flywheel keyway and install the flywheel Coat the threads of the flywheel nut with Gasket Sealing Compound Install the...

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

Страница 114: ...ly ag ainst the tool Mark the flywheel directly across from the pointer Label this mark A Rotate th e flywheel clockwise until the p iston contacts the tool Mark the flywheel directly across from the...

Страница 115: ...ke sure the timing poin ter is set and the outboard reaches operating tempera ture before making any timing adjustments TPS CALIBRATION Use Evinrude Diagnostics sof tware to te ll th e EMM what thrott...

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

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

Страница 118: ...ring under the spacer Remove t he ret aining ring sp acer an d spring from pinion shaft Remove pin ion and plastic weathe r cover from pinion shaft Remove the driven gear and thrust washer Using No 2...

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

Страница 120: ...ed windings Clean off any carbon deposits or foreign matter which could con tribute to fa ilure of win d ings Check permanen t magn ets Ma ke sure they strongly attract any steel or iron object held i...

Страница 121: ...s could damage the st arter or cause reverse rotation Apply Moly Lube to th e armature bushing Install the thrust washer and armature Align the st arter frame and make sure th e lon g alignment mark m...

Страница 122: ...etaining ring flat side up with No 2 e xternal retaining ring pliers Lightly coa t the gear housing bearing with Moly Lube Lightly coat th e d riven ge ar wit h Triple Guard grease Install the thrust...

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

Страница 124: ...and gently pull on wire Terminal Installation Push terminal through seal until it locks into place Fill conn ector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push we dge in un...

Страница 125: ...ck Tool P N 77 7077 to release locking tab of connector housing Release locking tab a nd pull on wire to remove fro m connector housing Terminal Installation Align terminal with co nnector housing Pus...

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

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

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

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

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

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

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

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

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

Страница 135: ...e NOTE A small a mount o f fuel m ay be released when the fuel connector is dison nected Store portable fuel tanks in well ve ntilated areas awa y from hea t sources a nd open flames Close th e ve nt...

Страница 136: ...the out board Additives IMPORTANT The only fuel additives ap proved for use in Evinrude outboards are 2 4 fuel condi tioner a nd Evinrude Johnson Fue l System Cleaner Use of other fuel additives can r...

Страница 137: ...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 s...

Страница 138: ...a por sep arator decreases the fuel level begins to in crease An increase in the fuel level raises the float valve and the vent closes Pressure Regulator The fuel pressure regulator helps maintain con...

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

Страница 140: ...fuel primer until fuel flows from the fuel hose Once fue l flow is observed co nnect fuel supply hose from fuel tank to hose fitting on outboa rd Secure hose with Oetiker clamp Use the primer to fill...

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

Страница 142: ...por sep arator if the venting of fuel is continuous Fuel Injector Pressure Test This te st re quires Inj ector T est Fi tting ki t P N 5005844 Disconnect the battery cables at the battery Relieve fuel...

Страница 143: ...green Resistance should be the same as o r slightly higher than the injector alone Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter with app ropr...

Страница 144: ...o prevent fuel or air leaks Do not use fuel primer bulb manual fuel primer or ele ctric fuel pump primer to restart o utboard A posit ive pressu re in the fuel suppl y could dama ge som e vac uum gaug...

Страница 145: ...pump electrical connector If outb oard runs start and run at IDLE for 5 se conds a nd ST OP o ut board If o utboard doe s NOT run crank for 1 0 seconds Disconnect the battery cables at the battery 1 A...

Страница 146: ...lter s contents Inspect contents for any presence of wa ter If water is pre sent iden tify the source and correct the problem T ake ad ditional fu el samples a nd drain fuel tank s if necessary Instal...

Страница 147: ...assembly Installation Place fu el pu mp bracket with rubb er isola tor mounts in front of the throttle body Apply Nut Lock to screws and inst all screws in to throttle body Tighten screws to a torque...

Страница 148: ...unts Install forward iso lator o f vapor separator on mounting stud a nd secure with retainer clip Install all hoses and manifolds in original locations and secu re wit h ap propriate clamps Squeeze p...

Страница 149: ...in the correct cy linder lo cations Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioni ng The Injector Coefficients screen display s injector serial number...

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

Страница 151: ...es to EMM Use the Evinrude Diagnostics sof tware Settings screen to upload the coefficient file to the EMM Select the Injectors tab Select the cylinder tab for injector being replaced Select the Repla...

Страница 152: ...tall washers on e per screw on injec tor retaining screws I nstall screws and washers through mounting flange of injector and into cylin der head Tighten screws in st ages starting with the lower scre...

Страница 153: ...mbly All reed plat e assembly and reed valve assem blies must be cleaned before reassembly DO NOT use strong carb uretor cleaner or the hot soaking tank method for cleaning Remove th e re ed v alve re...

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

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

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

Страница 157: ...WARNING 166 CYLINDER AND CRANKCASE 167 OIL RECIRCULATION SYSTEM 167 OIL CONTROL SETTINGS 168 OIL INJECTION RATE 168 BREAK IN OILING 169 OIL SUPPLY PRIMING 170 OIL HOSE PRIMING 170 OIL PUMP PRIMING 17...

Страница 158: ...as 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 This outboard has been...

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

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

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

Страница 162: ...der 4 5 Cylinder 5 6 Cylinder 6 6 5 4 7 2 1 8 6 6 2 3 4 5 6 1 1 Cylinder 2 2 Cylinder 4 3 Cylinder 6 4 Cylinder 1 5 Cylinder 3 6 Cylinder 5 Rear oil pump delivers oil to cylinder sleeves 1 2 3 4 5 6 0...

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

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

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

Страница 166: ...o at least one quar ter capacity The LOW OIL warning should not display Failure to follow these recom men dations could void the outboard warranty if a lubrication related failure occurs COMPONENTS Th...

Страница 167: ...the specified range open circuit the EMM Oil Pressure Sensor The oil pressure sensor react s to chang es in oil manifold pressure The EMM supplies and moni tors electrical current to the sensor The se...

Страница 168: ...rs the o il injection pump electr i cal circuit If the circuit is open the EMM LOW OIL Warning A sen ding unit in the oil t ank p ick up assembly monitors the oil level in the oil tank If the oil leve...

Страница 169: ...irculate any accumulation of oil from various locations in the po werhead The movement of oil is controlled by check valves Cylinder Recirculation Internal po werhead oil drain passages connect the lo...

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

Страница 171: ...bel an d boat decals match EMM programming Break In Oiling IMPORTANT DO NOT add oil in the fuel tank on Evinrude E TEC models The EMM automatically supp lies extra oil to the engine as follows 90 V6 F...

Страница 172: ...the type of oil being used 250 300 HP 3 4 L MODELS Start the outboard Use the oil priming functions in the sof tware to m ake sure t he sy stem is com pletely primed IMPORTANT The outbo ard sho uld be...

Страница 173: ...l flow through all oil distribution hoses Air must be purged during the priming procedure Small bubbles are a cceptable Larg e bu bbles must be eliminated through continued priming Repair any fuel or...

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

Страница 175: ...ir med Listen for an audible click from the oil injection pump when it is activated Use an ind uctive timing lig ht to monitor cu rrent flow through the ground circuit blue wire at the oil pump connec...

Страница 176: ...n p 81 Oil Injection Pump Circuit Resistance Test IMPORTANT The complete oil injection pump electrical circu it includes EMM alternator outp ut the engine wire harness the injection pump wind ing and...

Страница 177: ...ltimeter to the Hertz Hz scale Meter should read approximately 2 Hz Results If volt age and con trol signal readings Hz at pin A are within range the EMM and wiring are not at fault If voltage at pin...

Страница 178: ...y remove the pickup filter and flush with a mild solvent to re move any cont amination Rein stall filter Carefully remove the oil hose from the oil pickup and remove the oil supply hose from the oil i...

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

Страница 180: ...o rear manifo ld hose does not use a hose support IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is full y in serted into man ifold Insertion depth is...

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

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

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

Страница 184: ...is primed Check oil flow through o il d istribution ho ses Check oil syste m operation and rou ting o f oil h oses Refer to OIL SUPPLY PRIMING on p 170 Run the outboard and check for leaks Repair any...

Страница 185: ...MOSTATS 187 BLOCK VENTING 187 OPERATION 188 CYLINDER BLOCK CYLINDER HEAD COOLING 188 EMM AND VAPOR SEPARATOR COOLING 189 ENGINE TEMPERATURE CHECK 189 SOFTWARE METHOD 190 PYROMETER METHOD 190 IDLE OPER...

Страница 186: ...er housing Water supply adapter to cylinder block port and starboard Water supply to EMM cylinder block vent Water supply EMM to vapor separator Vapor separator water outlet to adapter Port thermostat...

Страница 187: ...er housing Water supply adapter to cylinder block port and starboard Water supply to EMM cylinder block vent Water supply EMM to vapor separator Vapor separator water outlet to adapter Port thermostat...

Страница 188: ...GHER speeds Refer to WATER PUMP SER VICE on p 292 for water pump servicing Water Supply Tube The wa ter pump outlet co nnects with the wa ter supply tube located in th e outboard s midsection Grommets...

Страница 189: ...vent the valve from closing completely Thermostats Thermostats control water flow and operating tem perature at lower speeds below 1200 RPM Overheating A restricted or faulty thermostat typ ically res...

Страница 190: ...hrou gh the block to the exhaust housing and then out of the outboard At higher sp eeds wate r pressure op ens th e pressure relief valve at approximately 1200 RPM Water flows through the valve and by...

Страница 191: ...TEMPERATURE CHECK IMPORTANT The e ngine te mperatures liste d below are based o n an intake water temperature of 70 10 F 21 3 C Install correct test propeller and place outboard in a test tank or in t...

Страница 192: ...eck temperature on both sides of powerhead Typical pyrometer readings at IDLE speed should be 143 F 15 F 62 C 8 C IMPORTANT If you get low or inaccurate read ings with a digital pyrometer coat the pro...

Страница 193: ...e liminating water flow to th e cylinder he ads pressure relief valve is lea king Replace pressure relief valve If IDLE temperature is still below operating range with hoses pinche d off inspect therm...

Страница 194: ...to bleed from cav ity Th ermal compo und may seep past threads Retighten sensor THERMOSTAT SERVICING Disassembly Remove the thermostat cover and O ring from cyl inder head Remove spring thermostat an...

Страница 195: ...from the hou s ing Remove the pressure valve assembly Inspection Inspect all parts for cracks heat damage or signs of corrosion Rep lace d amaged p arts Clea n debris from housing and parts Assembly A...

Страница 196: ...194 COOLING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 197: ...SHIFT ACTUATOR 197 THROTTLE ACTUATOR 198 ICON SYSTEM FAILSAFE MODE 198 ICON COMPONENT SERVICING 199 ELECTRONIC SERVO MODULE ESM 199 SHIFT ACTUATOR 202 THROTTLE ACTUATOR 204 ICON SYSTEM SETTINGS 207 S...

Страница 198: ...4 in lbs 7 to 9 5 N m F 18 to 20 ft lbs 24 5 to 27 N m F 60 to 84 in lbs 7 to 9 5 N m ICON buss cable connector ESM to EMM connector ESM to trim tilt connector ESM power supply harness ESM to throttle...

Страница 199: ...t Actuator The shift actuator converts electronic signals from the ESM into the mechanical motion required to shift the outboard into and out of gear If the shift actuator sensor cannot determine gear...

Страница 200: ...g on gear p osition whe n fault occurred If the throttle cannot move toward closed position all L ED indicators flash until control levers a nd shift actuators are in NEUTRAL Then the NEUTRAL indicato...

Страница 201: ...harness from solenoid and ground stud Remove the ESM from studs Installation Install grommets on ESM Apply soapy water to grommets and push assembly on to studs Route the CANbus harness from the ESM t...

Страница 202: ...e as shown Connect to harness from ESM and attach to clip on mount ing plate Make sure the oil recirculation hose is not pinched during assembly Secure ESM to throttle actuator harness with tie strap...

Страница 203: ...0 to 84 in lbs 7 to 9 5 N m Install cop per crush washer over ESM positive ring termina l T hen install star washer battery cable and nut Tighten nut to a torque of 60 to 84 in lbs 7 to 9 5 N m Connec...

Страница 204: ...t cover IMPORTANT Calibrate shift and throttle actua tors Refer to Calibrate Actuator Stroke on p 207 Shift Actuator Removal Disconnect the battery cables at the battery Remove electrical bracket cove...

Страница 205: ...and shift actuator retaining screws Apply Nut Lock to the threads of the screws Install shift actuator o n mounting plate with thre e long screws and one short screw Tighten screws to a torque of 60...

Страница 206: ...ration procedure has been completed Refer to Calibrate Actuator Stroke on p 207 Throttle Actuator Removal Disconnect the battery cables at the battery Remove the flywheel cover Remove the electrical b...

Страница 207: ...t actuator retaining screws Apply Nut Lock on the threads of the screws Install thro ttle actuator on mounting plat e with three long screws and one short screw Tighten screws to a to rque of 60 t o 8...

Страница 208: ...rque of 60 to 84 in lbs 7 to 9 5 N m Route the thrott le actua tor harness behin d and over the oil recirculation hose as shown Connect the throttle actu ator harness Att ach to clip on mounting plate...

Страница 209: ...s use the ICON tab of the Evinrude Diagnostics Settings screen In a multi engine application all outboards can be calibrated through one con nection Use the Engine Instance menu to sele ct the engin e...

Страница 210: ...ard Select FORWARD under Shift Position on t he ICON screen The actu ator arm will move for ward Use the Nudge butt ons to move the actuator arm forward or backward until the shif t link aligns with t...

Страница 211: ...l move to the neutral position After forward and reverse strokes have been cali brated the ESM calculates neutral position Install the shift link and secure with retainer clips and washers Lock the re...

Страница 212: ...outboard EMM The EMM then sends a Check Engine message to the NMEA 2000 gauges Stops shift or throttle actuator movement at the point where the fault occurred Will NOT activate S A F E When all contro...

Страница 213: ...EUTRAL gear LED s Flashes the NEUTRAL LED of the faulty engine five times per second if the condition is ESM or actu ator related Turns OFF all gear LED s of the failed remote control lever if the fau...

Страница 214: ...ON 6 port hub connection port is damaged Remote Control Power Check Chart 5 108 RPM Reduction S A F E Code 108 always appears with fault codes 107 109 111 149 and 151 The fault message is sent from th...

Страница 215: ...engine continues to flash five times per second 30A fuse for the ESM has failed The ESM buss cable is damaged or not connected to the 6 port hub The ESM buss cable extension is damaged or not connect...

Страница 216: ...ve times per second With the remote control lever in NEUTRAL the NEUTRAL LED of the affected engine continues to flash five times per second RFI due to excessive spark plug gap damaged or worn spark p...

Страница 217: ...LY 230 CRANKSHAFT ASSEMBLY 230 PISTONS AND CONNECTING RODS 233 CYLINDER HEAD INSTALLATION 234 CRANKSHAFT AND CONNECTING RODS 235 CRANKCASE ASSEMBLY 238 SHIFT LINKAGE INSTALLATION 239 THROTTLE LINKAGE...

Страница 218: ...In lbs 7 9 5 N m L 30 42 In lbs 3 5 5 N m L H H 84 108 In lbs 9 5 12 N m P X Q B X 120 144 In lbs 13 5 16 5 N m 120 144 In lbs 13 5 16 5 N m 144 168 In lbs 16 5 19 N m E 60 84 In lbs 7 9 5 N m F 7 10...

Страница 219: ...3 5 N m 96 120 In lbs 11 13 5 N m F A A B F B D 96 120 In lbs 11 13 5 N m F B B X A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle B...

Страница 220: ...tachment into spark plug hole 14 mm threads While cranking outbo ard with st arter note maxi mum pressure reading on gauge Repeat proce dure for each cylinder If engine sh ows a variation greater than...

Страница 221: ...s fue l spray Before st arting any fuel syst em service carefully relieve fuel system pressu re Refer to Relie ving Fue l System Press ure on p 143 To preve nt accid ental s tarting while s er vicing...

Страница 222: ...hreads Fasten appropriate chain hook to eye of tool a nd support weight of powerhead with hoist Remove all powerhead retaining screws and nuts Remove the rear powerhead nut Use a suitable tool to care...

Страница 223: ...TANT Mark in jectors for cylinder loca tion before removal All injectors must be installed in their original location Improper injector installa tion can result in powerhead failure Remove throttle li...

Страница 224: ...or any oth er tool that could jam in or da mage the taper bore when removing the pin Remove crankcase flange screws Remove the upper crankcase head screws Remove the lower crankcase head screws IMPORT...

Страница 225: ...crankshaft seal rings Cylinder Head Removal Loosen in st ages and remove cylinde r he ad retaining screws Remove the cylinder head Connecting Rods and Pistons Use a permanent marker to identify each c...

Страница 226: ...o mponents so that if reu sed they can be reinst alled in their original positions Repeat steps for each remain ing piston and con necting rod Use an approp riate ring exp ander to remove all piston r...

Страница 227: ...emove the lower crankshaft seal Remove and discard two crankcase head O rings Remove the O ring from cr ankshaft sleeve an d inspect it Repla ce the O ring if it is not in goo d condition Inspect the...

Страница 228: ...NOT reuse it Use a b earing separator to suppo rt t he bearing and press off the crankshaft Remove and inspect crankcase seal rings Iden tify each ring for installation in original location Remove ce...

Страница 229: ...ver to remove all traces of ga skets adhesives and Gel Seal II sealant from the cylinder block and crankcase Carefully rem ove an y carbon ac cumulation from the tops and ring groo ves of the piston u...

Страница 230: ...arpage using a piece of bar stock or machinist s straightedge and a feeler gauge set Cylinder head warpage must not exceed 0 003 in 0 08 mm per inch of me asurement Replace head if warpage exceeds thi...

Страница 231: ...TIONS on p 10 The cylinder must not be oversized by more than 0 003 in 0 08 mm Pistons Visually inspect pisto ns for signs o f abn ormal wear scuffing cracks or burning Piston Rings For new ring sets...

Страница 232: ...an and lightly coated with outboard lubricant IMPORTANT Use new wrist pin retaining rings gaskets seals and O rings during assembly Crankshaft Assembly Place be aring ret ainer plate flat sid e down o...

Страница 233: ...be used if surface is damaged Use retaining ring pliers to install bearing retaining ring with sharp edge facing away from bearing Lubricate a new driveshaft O ring and lightly lubri cate crankshaf t...

Страница 234: ...75 to align retainer plate with crankcase hea d Slide crankcase head onto crankshaft u ntil sea ted around lower main bearing Install new seals on th e fo ur be aring ret ainer screws Appl y Nut Lock...

Страница 235: ...ston will b e loca ted toward the flywheel and opposite the exhaust port It is als o very im portant tha t the connecting rods are installed with the align ment dots and the diagonal oil hole facing u...

Страница 236: ...ould be misaligned Refer to CYLIN DER BLOCK CLEANING on p 227 Coat pistons rings cylinder walls and ring com pressor with outboard lubricant Center connecting rod in piston and locate piston rings on...

Страница 237: ...are seated in the block Push all pistons to the to p of cylinders Remove the numbered connecting rod caps and hold the connecting rods to the outside with rubber bands Gently lower crankshaft into pla...

Страница 238: ...ews without Alignment Fixture P N 396749 o r us ing an incorrect procedure c ould ca use perma nent damage to the connecting rod and crankshaft To maint ain accurate torque values keep torque wrench e...

Страница 239: ...23 in lbs 2 5 N m IMPORTANT Make sure th at frame is squarely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Torquing Socket P N 346187 to tighten rod ca...

Страница 240: ...el Seal II h as a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the tube cannot be determined Using old Gel Seal II could cause crank...

Страница 241: ...w threads and tighten to a torque of 7 to 10 in lbs 0 8 to 1 1 N m If removed install cam on shif t arm Apply Ultra Lock to screw threa ds and tighten to a torqu e of 60 to 84 in lbs 7 to 9 5 N m Lubr...

Страница 242: ...fer to PRES SURE RELIEF VALVE SERVICING on p 193 Install shift linkage Refer to Shift Linkage Instal lation on p 239 Install throttle linkage Refer to Throttle Linkage Installation on p 240 Install fu...

Страница 243: ...mpound to the threads of all powerhead screws Loosely install all fasteners before tightening Tighten the 3 8 in diameter powerhead screws to a torque of 20 to 22 ft lbs 27 to 30 N m in the sequence s...

Страница 244: ...ins freely in neutral Install wa ter hoses and exha ust back pressure hose Route power trim harness through clamp and con nect to engine harness 1 Rear powerhead nut 004252 1 Shift rod pin 004241 1 1...

Страница 245: ...on p 40 Use Evinrude Diagnostics software to start pow erhead b reak in o iling Ref er to Powerhead Break In on p 67 Use Evinrude Diagnostics software to set TPS calibration Refe r to TPS CALIBRA TION...

Страница 246: ...244 POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port Hose Routings 3 3 L models 007153...

Страница 247: ...POWERHEAD POWERHEAD VIEWS 245 11 Starboard Hose Routings 3 3 L models 007154...

Страница 248: ...246 POWERHEAD POWERHEAD VIEWS Port Hose Routings 3 4 L models 008503...

Страница 249: ...POWERHEAD POWERHEAD VIEWS 247 11 Starboard Hose Routings 3 4 L models 008502...

Страница 250: ...248 POWERHEAD POWERHEAD VIEWS Port 3 3 L models 008448...

Страница 251: ...POWERHEAD POWERHEAD VIEWS 249 11 Starboard 3 3 L models 008449...

Страница 252: ...250 POWERHEAD POWERHEAD VIEWS Port 3 4 L models 008441...

Страница 253: ...POWERHEAD POWERHEAD VIEWS 251 11 Starboard 3 4 L models 008442...

Страница 254: ...252 POWERHEAD POWERHEAD VIEWS Front 3 3 L models 008450...

Страница 255: ...POWERHEAD POWERHEAD VIEWS 253 11 Front 3 4 L models 008439...

Страница 256: ...254 POWERHEAD POWERHEAD VIEWS Rear 3 3 L models 007142...

Страница 257: ...POWERHEAD POWERHEAD VIEWS 255 11 Rear 3 4 L models 008440...

Страница 258: ...256 POWERHEAD POWERHEAD VIEWS Top 008438...

Страница 259: ...POWERHEAD POWERHEAD VIEWS 257 11 Starboard ICON models 008504...

Страница 260: ...258 POWERHEAD NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 261: ...SING SERVICE 266 EXHAUST HOUSING REMOVAL 266 LOWER MOUNT SERVICE 266 EXHAUST HOUSING INSTALLATION 267 EXHAUST HOUSING DISASSEMBLY 3 3 L MODELS 268 EXHAUST HOUSING DISASSEMBLY 3 4 L MODELS 269 CLEANING...

Страница 262: ...N m 216 240 In lbs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m...

Страница 263: ...7 9 5 N m 60 84 In lbs 7 9 5 N m B F F F 144 168 In lbs 16 19 N m B B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P B C See Assembly Instructions B C C C See Assembly Instructions A C C 60 84...

Страница 264: ...19 N m 20 22 Ft lbs 27 30 N m 60 84 In lbs 7 9 5 N m B F F 144 168 In lbs 16 5 19 N m B 9 12 Ft lbs 12 16 N m 40 42 Ft lbs 54 57 N m A C A P C A C C B L 60 84 In lbs 7 9 5 N m Q E A Triple Guard Grea...

Страница 265: ...MIDSECTION SERVICE CHART 263 12 Muffler 007117...

Страница 266: ...ve the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer f rom Tilt T ube Service Kit P N 434523 on to the st arboard end of th e tilt tube Remove steerin g ca...

Страница 267: ...a wood or leather mallet to t ap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft lbs...

Страница 268: ...owerhead Refer to POWER HEAD REMOVAL on p 219 Remove and discard four lower mount screws Remove the steering arm ground lead and screw Remove two upper mount screws Remove the exhaust housing Lower Mo...

Страница 269: ...washers and screws and tighten to a torque of 156 to 180 in lbs 18 to 20 N m Exhaust Housing Installation Bring the exhaust housing into position with th e stern bracket Install four new lower mount...

Страница 270: ...TION on p 289 Install powerhead Refe r to POWERHEAD INSTALLATION on p 241 Exhaust Housing Disassembly 3 3 L models Remove two front adapter to outer exhaust hous ing screws Remo ve thre e nut s at rea...

Страница 271: ...ube and grommet from the inner exhaust housing Discard the grommet Loosen ret aining screws an d remove the cover from water plate Loosen retaining screws a nd remove water plate from the adapter Exha...

Страница 272: ...e if deteriorated or damaged Before checking the ex haust housing fo r distor tion thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion Check the e xhaust hou sing f...

Страница 273: ...Gasket Sealing Compound to thread s of cover retaining sc rews Ins tall with washers and tighten to a torque of 60 to 84 in lbs 7 to 9 5 N m Coat the outside diameter o f a n ew water tub e grommet wi...

Страница 274: ...n uts and washers Lubricate the upp er mount with so apy water a nd push into place in the adapter housing The mount radius must face aft with the T OP mark facing up Apply Locquic Primer and Nut Loc...

Страница 275: ...Apply Triple Guard grease to outer seal surface Install gro mmet and wate r tube in the inn er exhaust housing Clean an d d egrease t he a dapter hou sing an d outer exhaust ho using matin g surface...

Страница 276: ...e scre ws and inst all the p late a nd screws loosely Inst all the ground le ad and st ar washer under the forward starboard screw Align the out er exhaust housing and adapte r by placing two powerh e...

Страница 277: ...trim tilt unit must be removed Refer to TRIM AND TILT SERVICE on p 349 Remove and discard steering shaft locknut Remove the lower mount bracket and keeper Remove the steering shaf t an d thru st wash...

Страница 278: ...e braid ed tube Remove the tilt limit swi tch and retainer from t he swivel bracket Disconnect the trail lock spring and remove it from the swivel bracket Remove trail arm retainer Remove the trail lo...

Страница 279: ...roceeding make sure all components ha ve be en thoro ughly cleane d Replace any seals th at h ave been remove d Inspect all thrust washe rs and bushin gs for evi dence of deterioration Install the det...

Страница 280: ...e 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 braid ed tube and install the send er unit i...

Страница 281: ...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 it s u nstaked side f acing the mount bracket Align...

Страница 282: ...y connects to th e e xhaust relief hoses from the adaptor housing assembly The overboard indicato r and flush port in the exhaust re lief gro mmet conne ct to the adaptor housing assembly with a hose...

Страница 283: ...GEAR AND PROPELLER SHAFT INSTALLATION 312 PINION GEAR AND DRIVESHAFT INSTALLATION 313 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION L2 TYPE 315 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTAL...

Страница 284: ...bs 6 8 9 5 N m B A 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m A A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m A 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 18 20 Ft lbs 24 27 N m A G A B B 108...

Страница 285: ...40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m A 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 108 132 In lbs 12 15 N m A A E 18 20 Ft lbs 24 27 N m A G J 30 34 Ft lbs 41 46 N m...

Страница 286: ...bs 61 68 N m A A 35 40 Ft lbs 47 54 N m 60 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m B 60 84 In lbs 7 9 5 N m A 60 84 in lbs 6 8 9 5 N m A 30 34 Ft lbs 41 46 N m C 70 80 Ft lbs...

Страница 287: ...in propeller bearing housing performance gearset V6 14 26 538 90 V6 20 in 90 V6 25 in 90 V6 30 in M2 front water inlets and straight leading edge pressed in propeller shaft bearing housing with retain...

Страница 288: ...cond i tions will allow the engine to run near the mid point of the RPM oper ating range at full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blade s have too much pitch th e engi...

Страница 289: ...Propeller Hardware Installation IMPORTANT Depending on propeller style dif ferent thrust bushings sp acers and cotter pin keepers are used See the Evinrude Johnson Genuine Parts and Accessories Catal...

Страница 290: ...source of leak If the gauge does not in dicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leaks Make necessary repairs and repeat test Install Gearca se V acuum T ester P N 507...

Страница 291: ...e 7 16 14 x 3 5 in screw and washer Remove the four 3 8 16 x 1 75 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being careful not to bend the shift ro...

Страница 292: ...ome outboard models include hollow alignme nt pins between the exhaust housing and gearcase If o utboard is not equipped with alignment pins use Gea rcase Alig nment Kit P N 5 007231 to accurately ali...

Страница 293: ...ith the index marks noted prior to disassemb ly Tighten the trim tab screw to a torque of 35 to 40 ft lbs 47 to 54 N m For adjustme nt refer to Trim Tab Adjustment on p 30 Standard rotation and counte...

Страница 294: ...elting Make sure gasket surface is clean and smooth Assembly Apply a drop o f 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...

Страница 295: ...e r tube from exhaust ho using and replace o rin gs Apply a lig ht coat of Triple Guard grease to the o rings and install water tube in exhaust housing Apply Triple Guard grease to screw threads and i...

Страница 296: ...th e impeller key Rot ate t he driveshaft to engage the key with the impeller and slide water pump down over key Be sure impeller key does not fall out of position Make sure the impeller engages the i...

Страница 297: ...on p 295 SHIFT ROD ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gea rcase using Universa l Shift Rod Height Gauge P N 389997 With the gea rcase in NEUTRAL rot a...

Страница 298: ...ed sp lines a nd d amaged threads Shift Rod Check fo r misad justed bent or binding rod A misadju sted shift rod height can cause shift difficulty loss o f boat an d outboard control and gearcase dama...

Страница 299: ...ler shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using Propeller Shaf t Bearing Housing Puller Kit P N 354060 DO NOT use tools designed to push on the pro peller...

Страница 300: ...e clutch dog as far forward as possible This will help ease removal of the pinion nut Use Driveshaft Holding Socket P N 311875 Pin ion Nut Holde r P N 334455 and W rench Retainer P N 341438 to loo sen...

Страница 301: ...break the lock Install the too ls as shown by clamp ing them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between th e p uller an d th e g earc...

Страница 302: ...in the d riveshaft retainer and the lower driveshaft Install the roll pin to the specified dimension Shift Housing Gear and Propeller Shaft Removal Push d own o n t he shift rod This will move t he d...

Страница 303: ...ng to remove all dirt and deb ris prior to inspe ction Inspect pinion bearing an d forward thrust surfa ce of gea rcase housing Use Gearcase Alignment Gauge Kit P N 5006349 to check the condition o f...

Страница 304: ...g head If shaft does not slide into hole gearcase housing is damaged and must be replaced SHIFTER BEARING AND SEAL SERVICING Pinion Bearing Removal Remove pinion bearing retaining screw Assemble Pinio...

Страница 305: ...g up Insert the tool with the be aring into the gearcase Drive the bearing into the gearcase until the washer on the tool contacts the spacer Remove the tool Position new O ring on the pinion bearing...

Страница 306: ...g with a shop cloth to ca tch ball and spring Rotate the shifter detent 90 in either direction then pull the detent out of the housing Remove the detent ball and spring Remove needle bearings from bea...

Страница 307: ...e depressing t he ba ll and spring with a suitable tool Once the shifter detent is past the ball remove th e too l an d po sition d etent to engage NEUTRAL position Thoroughly grease 25 needle bearing...

Страница 308: ...in the correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing rear of the shaft The clutch dog is not symmetrical If ins...

Страница 309: ...and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage Do not insta...

Страница 310: ...127 and Large Puller Jaws P N 432129 Rest the puller plate on top of the housing to sup port the bridge and tighten t he ja ws securely behind the bearing Inspect th e b earing h ousing anode Replace...

Страница 311: ...l seat s When in stalled the lettered end of the bearing should be visible STANDARD ROTATION HOUSING Bearing Installation Tool P N 354139 front and rear bearings COUNTER ROTATION HOUSING Bearing Insta...

Страница 312: ...sh im th e assembly to restore factory clearance Use Driveshaft Shimming Tool P N 5005925 Shim gauge bars are precision made and should be han dled carefully The leng th of each bar is stamped near th...

Страница 313: ...g a nd rep eat check if var iance is greater than 0 004 in 0 101 mm Check squareness of the pinion to the driveshaft Hold the shim ga uge b ar aga inst the bearing housing between the screw holes wh i...

Страница 314: ...e while alig ning shift housing pin with hole in forward end of ge arcase housing Shift Rod Housing Installation Lubricate a new shift rod cover O ring with Triple Guard grease Install the O ring into...

Страница 315: ...proper alignment of the bearing housing locator pin into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 t...

Страница 316: ...Place the pinion gear into the gearcase Insert the driveshaft into the gearcase and thro ugh the pin ion gear Lightly coat the thre ads of a new pinion nut with outboard lubricant Use Pinion Nut Star...

Страница 317: ...es the pinion gear Lightly apply Triple Guard Grease to a new be ar ing housing O ring Install O ring in groove in the housing G rease t he m achined s ide s urfaces o f bearing housing Install hou si...

Страница 318: ...ft lbs 24 to 27 N m Propeller Shaft Bearing Housing and Gear Installation M2 Type IMPORTANT The propeller shaft bearing hous ing on the M2 type gearcases is PRESSED into the gearcase housing Oil and...

Страница 319: ...rcase Fixture P N 354059 an d an approp riate floor press 10 ton or gre ater t o inst all hou sing into gearcase Align and level gearcase assembly in fixture as shown Secure fixture to floor press Hou...

Страница 320: ...mplete gearcase assembly refer to GEARCASE LEAK TEST on p 288 WATER PUMP SERVICE on p 292 SHIFT ROD ADJUSTMENT on p 295 GEARCASE REMOVAL AND INSTALLATION on p 289 Gearcase Lubricant on p 37 Propeller...

Страница 321: ...n M2 type ge arcases is PRESSED into gearcase housing Remove the two retaining screws holding the pro peller shaft bearing housing Remove the propeller shaft bearing housing from the gearcase using Pr...

Страница 322: ...pulled o ut Unscrew the shif t rod from the dete nt lever Remove scre ws cover an d shif t rod from the gearcase Discard the cover gasket Remove the shift rod O ring from inside of cover and discard U...

Страница 323: ...o ut of the clutch dog Remove all parts Remove the ge ar thrust bearing and thrust washer from the shift housing IMPORTANT The shif t h ousing support s th e reverse gear on counter rotation gearcase...

Страница 324: ...coat the detent ball and spring with Needle Bearing grease Insert the spring in th e housing then the ball Insert shif ter de tent into the housing a s shown while depressing the ball and spring with...

Страница 325: ...ng grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the ge ar bearing and washer into th e bearing housing Bearing and washer must be installed in t...

Страница 326: ...303 Propeller Shaft Bearing Housing and Forward Gear Disassembly Remove and discard the bearing housing O ring Remove the anode and discard if more than two thirds deteriorated Clamp the propeller sh...

Страница 327: ...easure distance from flange of housing to flat surface as shown Add the appropriate shims to create a d imension of 0 140 in 3 556 mm To determine thickness of shims use the following example 1 389 in...

Страница 328: ...ds of the for ward gear bearing housing Install forward gear assembly with correct shims in bearing housing IMPORTANT To prevent da mage to thread s install forward gear bearing housing assembly by ha...

Страница 329: ...nto the drive shaft Use Driveshaft Seal Protector P N 318674 when installing or removing the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque...

Страница 330: ...Mea sure clea rance between the gauge bar and the pinion at se veral locations If varia nce is gre ater than 0 002 in 0 050 mm replace the pinion or driveshaft as necessary and repeat check Subtract...

Страница 331: ...fully into the ge arcase while alig ning shift housing pin with hole in forward end of ge arcase housing Shift Rod Cover Refer to Shift Rod Housi ng I nstallation on p 312 Pinion Gear and Driveshaft...

Страница 332: ...to inst all ret ainer 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...

Страница 333: ...OOTING 340 SYMPTOMS CHART 341 SERVICE PROCEDURES 341 PRESSURE LEAKDOWN TEST 341 ELECTRICAL CIRCUIT TESTS 344 RELAY TESTING 344 TRIM AND TILT MOTOR CURRENT DRAW TESTS 344 TRIM AND TILT MOTOR NO LOAD TE...

Страница 334: ...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...

Страница 335: ...ilt down to the top of the trim range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be ma nually raised or lo wered through the...

Страница 336: ...he pu mp through the open DOWN check valve In the trim ran ge fluid is pushed from th e top of the trim cylinders by the pistons and returns to the reservoir Only f luid f rom the top o f t he tilt cy...

Страница 337: ...linders Fluid from the bottom of the cylin ders return s through the open UP check valve to the pump In the tilt range all of th e fluid from the b ottom of the tilt cylinder returns through the UP ch...

Страница 338: ...xtends The fluid abo ve the piston is co m pressed producing high pressure This h igh pressure f luid p asses th rough the impact relie f valves in t he tilt piston dissipating much of the energy of t...

Страница 339: ...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...

Страница 340: ...Trimming Outboard OUT Pull gearcase out farth er than the desired fin al position up into the tilt range if necessary Close the manual release valve Manually push the gearcase in or down until it is...

Страница 341: ...e Fluid flows from the bot tom of th e 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 ra...

Страница 342: ...rmined th e Symp toms Chart on p 341 should help locate the problem Keep a manual release valve and a valve body in stock for troublesho oting Use these p arts whe n the Service Proce dures on p 341 c...

Страница 343: ...p ump mani fold assembly was faulty Remove temporary assembly and replace it with correct one STEP 6 Install replacement pump manifold assembly and retest If all symp toms are not corrected reco n si...

Страница 344: ...e 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 manu al release valve re...

Страница 345: ...d up several times to p urge a ir With all ro ds f ully extended run the un it down mome ntarily to reduce pressure Check fluid level again and add fluid if necessary Remember that all rods must be co...

Страница 346: ...ctric motor a nd certain mechanical components Use a battery rated at 360 CCA 50 Ah or higher that is in good condition and fully charged to per form this test IMPORTANT Specifications are for st atic...

Страница 347: ...ct a 0 to 50 A ammeter in series with the battery p ositive terminal ammete r red le ad toward battery Attach or hold a vibration or mechanical tachome ter to the motor while performing this test Moni...

Страница 348: ...m UP position If results are different replace the trim gauge If results agree refer to Trim Sender Test Trim Sender Test IMPORTANT To avoid immedia te me ter dam age never apply a multimeter to an el...

Страница 349: ...e co nnector by using a suitable tool to depress the tab While the tab is depressed pull on the wire from the rear of the connector to release it from the connector Separate the trim tilt unit wires i...

Страница 350: ...allation Place trim tilt unit into position Apply Triple Guard grease to the lower pin and install the pin Install external snap rings on lower pin with sharp edge of ring facing out Loosen the manual...

Страница 351: ...cloth when handling power trim tilt components If p ainting the unit is required p aint it af ter it is completely assembled Painting of individual com ponents may ca use flakes of paint to en ter th...

Страница 352: ...damaged replace the manual release valve Remove reservoir ca p an d dra in th e fluid into a container Inspect the O ring in the cap Remove the three Pozidriv sc rews securing the reservoir to cylind...

Страница 353: ...chined surfaces on the manifo ld for nicks and scratches The pump manifold is not se rviceable Do no t remove the pump or any contro l va lves from the manifo ld Clea n the screen with a mild solvent...

Страница 354: ...the tilt rod end cap Drain the fluid from above the piston Slowly pull the piston out with a rag wrapped around the ro d and th e top of the cylinder Drain the remaining fluid from the cylinder Inspe...

Страница 355: ...s are identical Lubricate and install a new outer O ring on the tilt piston Place one ball on e plunge r an d on e spring in each hole in the piston as indicated The two five coil springs go in the la...

Страница 356: ...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 an d in stall T ilt Cylinder Seal Protector P N...

Страница 357: ...Trim 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...

Страница 358: ...p the rod tigh tly in a vise Remove the thrust p ad 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 Disc...

Страница 359: ...the rod and install thrust pad Tighten thrust pad to a torque of 84 to 108 in lbs 9 5 to 12 N m Manifold and Reservoir Installation Lubricate five new manifo ld b ody O rings Place them in the cylind...

Страница 360: ...three Pozidriv screws Tighten the screws to a torque of 35 to 52 in lbs 4 0 to 5 9 N m Trim Rod Installation Lubricate th e trim rod pistons Place the r od assemblies into the bo dy Push the m in unt...

Страница 361: ...ailure to fill the cylinde r co uld cause difficulty purging air from the unit Screw tilt cylinder end cap into cylinder body Use Tilt Cylinde r End Cap Remo ver Installer P N 326485 o r Universa l S...

Страница 362: ...servoir to the bottom of the fill hole with Power Trim Tilt Steering Fluid Inst all a nd tighten the reservoir cap Turn the manual release valve in until it sea ts Cycle the unit up and down several t...

Страница 363: ...CE 14 Check the tilt ro d bushings Replace them if the y are worn excessively Check the bushings on the bottom of the manifold body Replace them if they are worn excessively Check system operation in...

Страница 364: ...362 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 365: ...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...

Страница 366: ...S 2...

Страница 367: ...t also to protect the people around you It is impo ssible for this m anual to cover e very pote ntially hazardous situa tion you may encounter However your understanding and adherence to the re commen...

Страница 368: ...RWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of...

Страница 369: ...OP propeller What could happen If Operat or ca nnot slow do wn the ou tboard o r shift into NEUTRAL gea r stop prope ller Ope rator could panic and lose control of boat How can loss of speed control b...

Страница 370: ...l and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams operato...

Страница 371: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom ca n change a set up which was OK earlier If moved up or down eve...

Страница 372: ...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...

Страница 373: ...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...

Страница 374: ...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...

Страница 375: ...t s transom Outboard may S L I D E on transom Boat may turnand be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Страница 376: ...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...

Страница 377: ...suddenly Boat may SINK At high speeds suddentrimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test y...

Страница 378: ...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...

Страница 379: ...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...

Страница 380: ...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...

Страница 381: ...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...

Страница 382: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils c...

Страница 383: ...ust fumes from the engine o r other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In hig h c...

Страница 384: ...oat 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 af ter the engine is off Always shut off the engine when near peopl...

Страница 385: ...r leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Bat...

Страница 386: ...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...

Страница 387: ...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...

Страница 388: ...al as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to co...

Страница 389: ...Gear 302 303 Break In EMM Programming 169 243 Gearcase 291 318 330 Oiling 169 Procedure 67 C Cable Hose and Wire Routing 18 Capacitor Test 84 Connecting Rods Installation on Crankshaft 235 233 Orient...

Страница 390: ...ons 91 Fuse 93 Ground Circuits 93 Key Switch 101 Start Circuit 99 105 106 Electrical Connectors 122 AMP Connectors 123 Deutsch Connectors 122 Packard Connectors 125 Electrical Harness Connections 21 2...

Страница 391: ...ettings 23 Water Pressure Gauge 24 I Command Network Outboard connections 22 ICON Component Servicing Electronic Servo Module ESM 199 Shift Actuator 202 Throttle Actuator 204 ICON Network Outboard con...

Страница 392: ...9 181 Removal 179 180 Oil Pressure Sensor Description 165 Oil Pump Rear 166 Description 166 Electrical Circuit 166 175 Installation 180 Removal 180 Oil Tank 164 Oiling Rate 67 168 Oiling System Compon...

Страница 393: ...System 196 Midsection 260 Oiling System 156 Powerhead 216 Trim and Tilt 332 Shift Actuator Removal 202 Shift Housing Assembly 305 322 Installation 312 329 Removal 300 Shift Housing Counter Rotation Di...

Страница 394: ...Backing Plate P N 325867299 151 309 69 Collar P N 341440 311 327 122 230 123 122 Diagnostic Interface Cable P N 437955 64 298 314 299 310 311 314 327 328 310 327 Electrical Test Probe Kit P N 342677 9...

Страница 395: ...0 Installation 291 Removal 289 Troubleshooting Charging System Tests 97 77 Diagnostic Procedures 74 Fuel Control Adjustment 77 139 Ignition 80 83 77 Oiling System 173 5 3 4 5 6 1 4 Strategy 76 Timing...

Страница 396: ...I 8 INDEX...

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

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

Страница 399: ...nti 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...

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

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

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

Страница 403: ...A B C 5 1 2 3 6 4 5 1 2 3 6 4 5 1 2 3 6 4 DRC6165R MWS Instrument Wiring Harness 1 2 5 1 2 3 6 7 4 8 A B C...

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

Страница 405: ...Dual Outboards B M M C A S 3 4 2 5 1 6 5 2 3 4 6 1 Lanyard Switch Emergency Stop Circuits B M M C A S 5 2 3 4 6 1 Single Outboard 000705 B M M C A S...

Страница 406: ......

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

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

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

Страница 410: ......

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

Страница 412: ......

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

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

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Содержание DE250CXINR

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BRP DE250CXINR, Руководство по обслуживанию, Страница: 4 / 416

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Содержание DE250CXINR

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