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253

GEARCASE

GEARCASE DISASSEMBLY

12

GEARCASE 
DISASSEMBLY

Pre-Disassembly Inspection

IMPORTANT:

Clean and inspect all parts during

disassembly. Replace any damaged parts, seals,
O-rings, and gaskets.

Remove the propeller and mounting hardware.

Drain and inspect oil as described in 

Gearcase

Lubricant

 on p. 34.

Remove gearcase. Refer to

 GEARCASE

REMOVAL AND INSTALLATION

 on p. 248.

Remove water pump. Refer to 

WATER PUMP

SERVICE

 on p. 250.

Before disassembling the gearcase, examine the
following:

•

Gearcase Housing —

 Check for visible dam-

age to skeg, strut, anti-ventilation plate, bullet,
and mating surface. Check seal areas for visible
signs of lubricant leakage.

•

Propeller Shaft —

 Check for bent or damaged

shaft. Check for twisted splines and damaged
threads.

•

Shift Rod —

 Check for bent, or binding rod. 

•

Hydrostatic Seal Grooves —

 Must be in good

condition to help prevent propeller ventilation.

•

Gearcase Anodes —

 If anodes have eroded to

two-thirds their original size, they must be
replaced. 

•

Drive Shaft —

 Check splines for visible dam-

age, twisting and wear. Severe spline wear indi-
cates the exhaust housing or gearcase has
been distorted, possibly by impact damage.

Remove and discard exhaust seal assembly.

WARNING

Wear safety glasses to avoid personal
injury, and set compressed air pressure to
less than 25 psi (172 kPa).

1.

Hydrostatic seal grooves

007665

1.

Gearcase anode

007666

1.

Seal assembly

007667

1

1

1

Содержание Evinrude E-TEC Series

Страница 1: ...Main Menu...

Страница 2: ......

Страница 3: ...ered trademark of The General Motors Corporation Locquic and Loctite are registered trademarks of The Henkel Group Lubriplate is a registered trademark of Fiske Brothers Refining Company NMEA is a reg...

Страница 4: ...41 9 COOLING SYSTEM 157 10 POWERHEAD 167 11 MIDSECTION 197 12 GEARCASE 243 13 TRIM AND TILT 267 14 MANUAL STARTER 279 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1 DIAGRAMS IMPORTANT For complete outbo...

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: ...required always replace with a new one When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Use of subs...

Страница 7: ...edly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent accidental starting while servicing disconnect the battery 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: ...changes such as altitude adjustments for exam ple Owner s Responsibility The owner operator is required to have outboard maintenance performed to maintain emission lev els within prescribed certifica...

Страница 10: ...T 3 R 4 O 5 D 6 U 7 C 8 E 9 S 0 Ex II 2011 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: ..._ 57 L 35 1 ci 13 28 0 46 H 20 White Manual Tilt Tiller Steering Electric Start Touch Troll E25DELII_ 57 L 35 1 ci 13 28 0 46 H 20 Blue Manual Tilt Remote Steering Electric Start E25DPLII_ 57 L 35 1 c...

Страница 12: ...wo Cycle Displacement 35 1 cu in 575 cc Bore 2 992 in 76 mm Stroke 2 500 in 63 50 mm Standard Bore 2 9916 to 2 9931 in 75 989 to 76 026 mm To bore oversize add piston oversize dimension to standard bo...

Страница 13: ...gnition Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1100 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label...

Страница 14: ...nauti cal orientation This manual often identifies parts and procedures using these terms Size In Lbs Ft Lbs N m No 6 7 10 0 58 0 83 0 8 1 1 No 8 15 22 1 25 1 83 1 7 2 5 No 10 24 36 2 3 2 7 4 0 No 12...

Страница 15: ...T ADJUSTMENT 26 TRIM TAB ADJUSTMENT 27 OPERATIONAL CHECKS 28 COOLING SYSTEM 29 WATER INTAKE SCREENS 29 ENGINE FLUSHING 30 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 31 LUBRICATION 32 STEER...

Страница 16: ...n any loosened components Water intake screens check condition Cooling system check water pump indicator Anticorrosion anodes check condition Gearcase check condition Propeller check condition Fuel an...

Страница 17: ...f the hoist is at least twice the weight of the outboard DO NOT allow the lift hook or chain from the hoist to come in contact with any part of the engine during lifting Model Lifting Fixture 15 30 HP...

Страница 18: ...ock Carefully lift engine with hoist To avoid damage to the outboard lift the outboard in one smooth motion DO NOT allow the outboard to bounce CAUTION To avoid damage to the outboard DO NOT allow the...

Страница 19: ...ple Guard grease Cable Retainer Clip Installation When installing retainer clips on control arm link age pins clips should be locked and must not be bent or deformed For proper installation review the...

Страница 20: ...les to avoid binding or chafing through all engine steering and tilting angles Control Cable Installation Refer to Control Cable Identification on p 17 Make sure the remote control is in NEUTRAL and t...

Страница 21: ...and adjust the trunnion nut so the casing fits onto the throttle lever pin IMPORTANT Move control handle to FOR WARD and pull back slowly to NEUTRAL Make sure the engine throttle lever is against the...

Страница 22: ...tie straps as shown Route trim and tilt connector under air silencer Use tie strap to secure connector as shown Install battery cables and secure with tie strap Route battery cable through grommet of...

Страница 23: ...to the battery negative post LAST Install a starwasher on the threaded battery post Stack cables from the outboard then cables from accessories Finish this connection with a hex nut Do not use wing n...

Страница 24: ...The clamp identification numbers appear on the side of the clamp near the top of the ear Refer to Clamp Selection chart for dimensions Clamp Selection To select the correct size Oetiker clamp measure...

Страница 25: ...r stepless clamps Oetiker pincers are available in the Evinrude Johnson Genuine Parts and Accessories Catalog Position correct size clamp over hose Install hose on fitting Close clamp ear fully with O...

Страница 26: ...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 clockwise to increase friction...

Страница 27: ...tilting the tiller handle Neutral Switch Adjustment Adjust neutral switch as follows Make sure neutral switch is centered on shift lever detent Loosen two neutral switch bracket screws Center the neu...

Страница 28: ...st be adjusted so that the gauge needle is aligned with the lowest gauge mark with the outboard trimmed all the way DOWN Check if the gauge needle is above or below the lowest gauge mark Tilt engine U...

Страница 29: ...or right when its load is evenly distributed adjust the trim tab as follows With the remote control in NEUTRAL and the engine OFF loosen the trim tab screw If the boat pulled to the right move rear o...

Страница 30: ...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 SystemCheck Confirm accuracy of tach...

Страница 31: ...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 condition of cooling system...

Страница 32: ...in VERTICAL DOWN position in a well ventilated area Thread garden hose into flushing port Turn water supply on Run outboard at IDLE only until full operating tem perature is reached Leave the outboard...

Страница 33: ...oles on each side of the gearcase with water proof tape to make sure enough water travels to the powerhead Water can drain from auxil iary inlets resulting in engine overheat A steady stream of water...

Страница 34: ...t Lubricate the swivel bracket with Triple Guard grease Apply grease until the grease begins to flow from the upper or lower swivel bracket areas Coat the pivot points of the trailering bracket with T...

Страница 35: ...heck proper throttle and shift function Propeller Shaft Debris from the water can become lodged around propeller shaft Frequent inspection can minimize potential gearcase damage Remove propeller Refer...

Страница 36: ...of one hour to determine if there is an abnormal amount of water in the oil If water is present refer to GEARCASE LEAK TEST on p 247 Overheated lubricant will have a black color and burned odor Intern...

Страница 37: ...Add Evinrude Johnson Biodegradable TNT Fluid as needed to bring level to the bottom of the 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...

Страница 38: ...ramic of the spark plug in line with the OPEN side of the ground elec trode This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector Apply Tr...

Страница 39: ...identify oiling system leaks Make certain the oil tank is filled and oil supply is not contaminated Air Silencer The air silencer maximizes air flow while minimiz ing noise Routine cleaning of the air...

Страница 40: ...e coatings to anodes or anode fasteners Avoid using metal based antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface Th...

Страница 41: ...n at idle speed After approximately 15 seconds move throttle to IDLE position Wait another 15 seconds At this point advance throttle to FULL in neutral EMM LEDs will flash indicating that outboard is...

Страница 42: ...orage make sure it is reinstalled with factory specified hardware Refer to the Predelivery and Installation Guide Outboard Mounting Bolts Check and re tighten outboard mounting bolts to a torque of 40...

Страница 43: ...supply hose and oil return hose from outboard Drain and clean all oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil system and fu...

Страница 44: ...42 ROUTINE SERVICE NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 45: ...VER SERVICE 43 3 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 44 LATCH HOOK INSTALLATION 44 LOWER COVER SERVICE 45 LOWER COVER REMOVAL 45 LOWER COVER INSTALLATION 45 LATCH HANDLE INSTALL...

Страница 46: ...pply Ultra Lock to screw threads Place latch into position with roller toward the front Tighten screws securely Front Insert bracket into pocket Apply Ultra Lock to screw threads Place hook into posit...

Страница 47: ...tall fuel hose on fuel connector fitting Secure with new Oetiker clamp Place port cover on outboard If equipped route battery and trim cables through grommet opening Place starboard side cover into po...

Страница 48: ...ining cover screws and tighten all screws to 24 to 36 in lbs 3 to 4 N m Install cable entry cover grommets cable entry cover and cable entry cover screws Tighten screws to 24 to 36 in lbs 3 to 4 N m I...

Страница 49: ...coat of Triple Guard grease to latch handle shaft Insert handle into lower cover Apply Ultra Lock to screw threads Place spring washer and hook into position and tighten screw to a torque of 180 in l...

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

Страница 51: ...54 LOW OIL SWITCH 54 THROTTLE POSITION SENSOR 55 CRANKSHAFT POSITION SENSOR 55 NEUTRAL SWITCH 55 INTERNAL EMM FUNCTIONS 56 ENGINE MONITOR SYSTEM 56 S A F E WARNING SYSTEM 57 SHUTDOWN MODE 58 DIAGNOST...

Страница 52: ...RPM profile and engine hours Oiling ratios 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 wit...

Страница 53: ...S 5 Throttle Position Sensor TPS 6 Neutral Switch 7 Air Temperature Sensor AT 8 Oil Level Switch 9 Engine Temperature Sensor 10 Ignition Coil 11 Fuel Injector 12 Diagnostic Connector 13 Oil Injection...

Страница 54: ...to SHUTDOWN MODE on p 58 If EMM temperature is less than 22 F 30 C or the circuit fails the EMM If sensor reads less than 71 F 57 4 C or greater than 313 F 156 C a sensor circuit fault is detected an...

Страница 55: ...Use Evinrude Diagnostics software to troubleshoot the sensors Refer to the EMM Service Code Chart at the back of this manual for a complete list of all engine fault codes The EMM provides a 5 V DC sig...

Страница 56: ...er LOW OIL is displayed the EMM counts oil pump pulse cycles again When it reaches 6700 pulses the EMM To recover from S A F E mode Oil level must be above one quarter The warning resets after three o...

Страница 57: ...his signal to identify crankshaft posi tion and speed generate a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 occurrences the EMM A...

Страница 58: ...engine speed is limited to 1100 RPM Engine Monitor and Warning Systems Refer to ENGINE MONITOR SYSTEM on p 56 Refer to S A F E WARNING SYSTEM on p 57 Refer to SHUTDOWN MODE on p 58 Fault Code Creation...

Страница 59: ...ht remains ON until the key is turned OFF or the failure is cor rected The warning will reoccur at the next start up if the problem is not corrected S A F E WARNING SYSTEM The S A F E Speed Adjusting...

Страница 60: ...tores valuable information about the outboard and its running history This information can be used for troubleshooting for checking parts information and for making adjustments to the system Use Evinr...

Страница 61: ...teries will produce false results Use Accessory Power Cable Kit P N 5008092 to connect an external 12 volt battery to the Power Supply Tool when performing these static tests Fuel pump Fuel injector I...

Страница 62: ...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...

Страница 63: ...p 78 Tachometer This test is used to check operation of the tachom eter circuit Dynamic Tests Dynamic tests are performed with the outboard running Ignition Test This test momentarily disables the ign...

Страница 64: ...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...

Страница 65: ...d replacement Crankshaft replacement Flywheel removal or replacement CPS replacement EMM replacement EMM software replacement IMPORTANT Make sure the outboard reaches operating temperature before maki...

Страница 66: ...ace button on the Injector Coefficients screen and select the file for the replacement injector Refer to Vapor Separator and Fuel Injector Service on p 132 Reports Engine reports provide service recor...

Страница 67: ...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...

Страница 68: ...hen performing the following tasks Make sure isolator mount is in place on recoil starter housing Slide pin at rear EMM into posi tion on isolator mount IMPORTANT Turn self tapping screws counter cloc...

Страница 69: ...AMP METER TEST 70 EMM LED INDICATORS 71 KEY ON 71 STARTING 71 RUNNING 72 IGNITION OUTPUT TESTS 73 REQUIRED IGNITION SYSTEMS 73 WIRING INSPECTION 73 CRANKSHAFT POSITION SENSOR CPS TEST 74 SYSTEM VOLTA...

Страница 70: ...ppearance of the spark plugs Check the fuse and the emergency stop switch lanyard Operational Inspections Run the outboard to confirm actual symptoms before performing any unnecessary procedures Inspe...

Страница 71: ...dicators for system sta tus information Refer to EMM LED INDICA TORS on p 71 Use the Evinrude Diagnostics software Monitor screen to check system 55 V and TPS volt ages System voltage should be steady...

Страница 72: ...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 function to tem porarily disabl...

Страница 73: ...to turn until the outboard 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 in...

Страница 74: ...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 circu...

Страница 75: ...ovides EMM with input Outboard cranking speed exceeds 300 RPM and a steady CPS signal is generated Alternator Output System Voltage System voltage from EMM white red provides 55 VDC to the high pressu...

Страница 76: ...e Results EMM ON not running approximately 1 V less than battery voltage system voltage is GOOD EMM ON not running no voltage check 12 V power to EMM Repair connection or wiring RUNNING 55 V 2 system...

Страница 77: ...gency stop switch lanyard must be installed 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 consis...

Страница 78: ...age and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 78 Inspect for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace s...

Страница 79: ...black meter lead to pin 1 and repeat test to confirm harness ground Harness resistance test If control signal is NOT present calibrate multime ter to low ohms scale Use appropriate adapters on meter...

Страница 80: ...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...

Страница 81: ...switched 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...

Страница 82: ...80 SYSTEM ANALYSIS NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 83: ...H TESTS 98 KEY SWITCH TEST 98 NEUTRAL START CIRCUIT TEST 98 NEUTRAL START SWITCH TEST 99 EMERGENCY STOP SWITCH TEST 99 TILT TRIM RELAY TEST 100 SYSTEMCHECK CIRCUIT TESTS 101 TACHOMETER CIRCUIT TESTS 1...

Страница 84: ...6 in lbs 9 5 to 12 N m F 60 to 84 in lbs 7 to 9 5 N m IMPORTANT DO NOT lubricate TPS to throttle shaft surface 31 to 48 in lbs 3 5 to 5 5 N m F 60 to 84 in lbs 7 to 9 5 N m A Triple Guard Grease B Gas...

Страница 85: ...head is seated F 31 to 49 in lbs 3 5 to 5 5 N m F 31 to 48 in lbs 3 5 to 5 5 N m F 10 to 12 ft lbs 14 5 to 16 5 N m 60 to 84 in lbs 7 to 9 5 N m N A Triple Guard Grease B Gasket Sealing Compound C Ad...

Страница 86: ...2 1 3 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 34 33 32 31 30 29 28 27 26 9 8 7 6 5 4 3 2 1 1 2 3 1 2 3 8 1 2 5 1 2 3 4 4 3 4 1 7 2 7 1 6 NEG 2 3 1 2 3 Key switch stop circuit Tiller handle sto...

Страница 87: ...il solenoid Blue 3 Switched B to EMM Purple 4 Crankshaft position sensor CPS Yellow 5 Injector cylinder 2 Green 6 Injector cylinder 1 Blue 7 System Ground Black 8 System Ground Black 9 Stator winding...

Страница 88: ...terminal pins 7 and 8 of the EMM con nector and the main harness ground Sensor circuit grounds Check continuity between terminal pin 29 of the EMM connector and the appropriate sensor ground connecti...

Страница 89: ...on sensor Use a digital multimeter to measure sensor resis tance between the yellow and white wires The complete circuit can be tested by measuring between pins 4 and 12 of the EMM connector The CPS i...

Страница 90: ...as the sensor lever is moved Engine Temperature Sensor Test Remove the electrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperature S...

Страница 91: ...calibrated to read 1 ohm or less To check for a grounded winding connect one meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no continuity If m...

Страница 92: ...n connector from the engine harness 6 pin connector Connect Stator Test Adaptor tool P N 354719 to stator connector Connect meter leads to terminals of adaptor tool Rotate the flywheel with the starte...

Страница 93: ...y 6 Key switch connector 2 RED wire POS 7 Fuse 10 amp 3 BLACK wire NEG 8 Stator 4 Starter solenoid 9 EMM 5 Main harness ground 10 Battery charge module 007351 17 16 15 14 13 12 11 10 25 24 23 22 21 20...

Страница 94: ...odule and the positive B battery cable terminal of starter solenoid Fluke model 334 or 336 Snap On model MT110 or EETA501 and various other amp meters should be available through local tool suppliers...

Страница 95: ...heck stator and alternator circuit BEFORE replacing the battery charge module Refer to STATOR TESTS on p 89 and 55 V Alternator Circuit on p 93 55 V Alternator Circuit Check battery ground cable for c...

Страница 96: ...A S C M B 1 2 3 4 5 6 8 9 13 1 2 3 1 Marine battery 10 Battery charge module connector 2 RED wire POS 11 Engine Management Module EMM 3 BLACK wire NEG 12 YELLOW RED wire start 4 Starter solenoid 13 Y...

Страница 97: ...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...

Страница 98: ...terminal Meter must not show continuity high reading If meter shows continuity low reading replace the solenoid Apply B to terminal A of solenoid and ground NEG to terminal B of solenoid Measure resi...

Страница 99: ...rter cable of solenoid terminal Connect negative lead to starter motor terminal Activate starter motor and observe voltage reading No Load Current Draw Test Securely fasten starter in a vise or suitab...

Страница 100: ...d 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 contin...

Страница 101: ...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...

Страница 102: ...B connec tion to TNT motor Terminals 87 and 30 are normally open B is applied to terminal 30 when relay is activated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagr...

Страница 103: ...OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the key switch ON Test for battery voltage between instrument harness terminal 1 purple wire and terminal 2 black wire If...

Страница 104: ...key switch 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 no...

Страница 105: ...Hz replace tachome ter If meter reads low or no signal confirm output on gray wire at pin 24 of EMM J1 A connector Reading OK Check condition of tachometer circuit gray wire Repair as needed Reading n...

Страница 106: ...Hold puller body with han dle and tighten pressing screw until flywheel releases Turn the center screw and lift the fly wheel off of the crankshaft Stator Service Disconnect stator harness connector...

Страница 107: ...y wheel removal or replacement Refer to TIMING ADJUSTMENTS on p 106 IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis connect ignition coil electrical con...

Страница 108: ...ming IMPORTANT Make sure the 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 EM...

Страница 109: ...r bearings and commutator Disconnect the battery cables at the battery Remove lower motor covers Refer to Lower Cover Removal on p 45 Remove the starter positive cable from post on starter Remove thre...

Страница 110: ...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...

Страница 111: ...ew 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 orienta...

Страница 112: ...f starter pinion shaft with Starter Bendix Lube DO NOT use liquid or aerosol spray lubricants Install pinion spacer and spring Install spacer and retaining nut Tighten nut to a torque of 20 to 24 ft l...

Страница 113: ...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 connectors apart To connect the...

Страница 114: ...in 14 16 gauge notch of crimping pliers AMP Connectors IMPORTANT Always use the appropriate meter test probes and adapters when testing compo nents fitted with these terminals Electrical grease is NOT...

Страница 115: ...N 777281 SUPER SEAL The J1 A connector of the EMM is an AMP Super Seal connectors Disconnect Depress BOTH latches and pull connector from plug Connect Push connector into plug until latches engage Te...

Страница 116: ...erminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gasket on wires and feed wires through the correc...

Страница 117: ...UEL INJECTORS 124 FUEL SYSTEM PRIMING 125 VENT LINE CLAMP 125 PRIMING THE FUEL SYSTEM 125 FUEL SYSTEM TESTS 126 FUEL SYSTEM PRESSURE TEST 126 VAPOR SEPARATOR VENT CHECK 127 FUEL INJECTOR PRESSURE TEST...

Страница 118: ...lbs 12 2 N m 14 ft lbs 19 N m 22 to 23 5 ft lbs 30 to 32 N m A F 31 to 48 in lbs 3 5 to 5 5 N m F 84 to 106 in lbs 9 5 to 12 N m S 007406 Tighten in 4 stages A Triple Guard Grease B Gasket Sealing Co...

Страница 119: ...s 1 8 to 2 N m F 84 to 106 in lbs 9 5 to 12 N m Tighten until screw head is seated C E 35 to 60 in lbs 4 0 to 6 8 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red U...

Страница 120: ...vapor separator Fuel filter Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply to injectors internal passage Fuel injector s Fuel return to vapor separator internal passage Pressu...

Страница 121: ...2 3 Stator EMM Fuel injector 4 5 6 Fuel circulation pump WHITE RED 55 V BLACK ground wires 7 8 9 BLUE GREEN BROWN 008046 2 1 1 2 1 2 17 16 15 14 13 12 11 10 25 24 23 22 21 20 19 18 34 33 32 31 30 29...

Страница 122: ...ge NOTE A small amount of fuel may be released when the fuel connector is dison nected Store portable fuel tanks in well ventilated areas away from heat sources and open flames Close the vent screw of...

Страница 123: ...damage the out board Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other fuel additives c...

Страница 124: ...pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressure components of the fuel system from contaminants Refer to INSPEC...

Страница 125: ...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 system...

Страница 126: ...ch injector and its location on the outboard is identified by the EMM DO NOT install an injector without updating the compensa tion software Each service injector includes its fuel flow infor mation o...

Страница 127: ...hose connector to the quick con nect fitting on the outboard Use the primer to fill the vapor separator The high pressure fuel circuits and injectors will prime as the outboard is cranked with the sta...

Страница 128: ...upply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supplying enough fuel to vapor separator Refer to Lift Pump Pressure Test on p 128 If the above tests ar...

Страница 129: ...ting Secure with tie strap Pressurize the injector to 30 psi 207 kPa Pres sure must hold for at least five minutes Refer to FUEL DELIVERY TESTS on p 78 for additional test procedures Fuel Injector Res...

Страница 130: ...mal pressure Perform the Lift Pump Vacuum Test on p 129 Make sure no air leaks or restrictions exist in the fuel supply hose or boat fuel system Low pressure Check pulse hoses and fittings for restric...

Страница 131: ...ceeding There should be no air or vapor bubbles visible in the clear hose The maximum inlet fuel vacuum should not exceed 4 in Hg 13 5 kPa at the inlet to the fuel lift pump under any operating condi...

Страница 132: ...ical connector If outboard runs start and run at IDLE for 5 sec onds and STOP outboard If outboard does NOT run crank for 10 seconds Disconnect the battery cables at the battery 1 Anti siphon valve 2...

Страница 133: ...the battery Remove filter carefully to prevent spilling contents Inspect contents for any presence of water If water is present identify the source and correct the problem Take additional fuel samples...

Страница 134: ...t the fuel hoses to the fuel pump Secure with Oetiker clamps Place fuel pump in position on the oil tank Secure the fuel pump with new pushnuts P N 354365 Be sure fuel hoses are routed in channels on...

Страница 135: ...in the correct cylinder locations Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning The Injector Coefficients screen displays injector serial numbers fo...

Страница 136: ...read 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 and O rings from injecto...

Страница 137: ...icient Files to EMM Use the Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM Select the Injectors tab Select the cylinder tab for injector being replaced Select...

Страница 138: ...during assembly Place injector and insulator in the proper cylinder location Temporarily install injector screws finger tight Position fuel injector wiring vapor separator wiring and electrical connec...

Страница 139: ...e is 14 ft lbs 19 N m Final torque is 22 to 23 5 ft lbs 30 to 32 N m Tighten vapor separator to powerhead mounting screw to 29 to 48 in lbs 3 3 to 5 5 N m I Install fuel supply hose Secure with Oetike...

Страница 140: ...nostics software to run fuel pump Observe for fuel leaks Run outboard and check for fuel leaks IMPORTANT Pay close attention to fuel vapor separator fuel injector connection for leaks Repair any leaks...

Страница 141: ...mbly Inspection Inspect the leaf plate assemblies for damage or contamination Leaf plates must not be distorted Leaf valve must not be cracked or chipped Leaf plate stops must not be distorted or loos...

Страница 142: ...Install throttle body on reed plate and install new screws IMPORTANT If old screws must be re used make sure all previous thread locking material is removed and apply Nut Lock to threads Tighten the...

Страница 143: ...V 147 LOW OIL WARNING 147 NO OIL WARNING 147 CYLINDER AND CRANKCASE 148 OIL RECIRCULATION SYSTEM 148 OIL CONTROL SETTINGS 149 OIL INJECTION RATE 149 BREAK IN OILING 150 OIL SUPPLY PRIMING 150 OILING S...

Страница 144: ...g F 31 to 48 in lbs 3 5 to 5 5 N m X Tighten until screw head is seated A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubricant X Se...

Страница 145: ...oard 7 9 4 5 Oil supply to crankcase Oil supply to cylinder block Cylinder 1 oil lines Cylinder 2 oil lines Oil supply to crankcase Oil supply to cylinder block Rope Start Models ONLY J Clamp crankcas...

Страница 146: ...144 OILING SYSTEM OIL RECIRCULATION DIAGRAM OIL RECIRCULATION DIAGRAM 007316...

Страница 147: ...LACK WHITE RED wires 55 V EMM injector control BLUE Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK MWS Connector EMM 008047 A B 17 16 1...

Страница 148: ...r capacity The LOW OIL warning should not display Failure to follow these recommen dations could void the outboard warranty if a lubrication related failure occurs COMPONENTS The oiling system include...

Страница 149: ...proximate oil reserve at Low Oil activation 0 375 qt 0 35 l NO OIL Warning After LOW OIL is displayed the EMM counts oil pump pulse cycles again When it reaches 6700 pulses the EMM To recover from S A...

Страница 150: ...trolled by check valves Crankcase Main Bearing Recirculation The movement of oil through the main bearings is controlled by internal passages external fittings and hoses and check valves Lower to uppe...

Страница 151: ...an option to run the outboard at a reduced oil injection rate This set ting REQUIRES the use of Evinrude XD100 out board lubricant and is not recommended for all applications IMPORTANT The XD100 sett...

Страница 152: ...et up Use Evinrude Diagnostics software to make sure the break in program has been started on a new outboard Use the diagnostics software to start break in oiling after a powerhead rebuild The operato...

Страница 153: ...ly This will produce false results Refer to Communication on p 58 The EMM controls the pump by providing ground through pin 2 blue wire of the J1 A connector and pin A blue wire of the oil pump connec...

Страница 154: ...ve meter lead to pin B white red wire of oil injection pump electrical connector Observe voltage at pin B Voltage at pin B should be approximately 12 V Set digital multimeter to a scale that reads 55...

Страница 155: ...ly inserted into manifold Refer to Oil Distribution Hoses on p 154 Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remo...

Страница 156: ...8 in 16 mm Visually inspect for hose supports Oil distribution hoses have specific locations and routing DO NOT alter the location of any hoses The oil distribution manifold includes a built in hose...

Страница 157: ...ct the electrical connector to the low oil switch IMPORTANT Note oil distribution hose rout ings before proceeding with disassembly Remove oil distribution hoses from the manifold Remove oil tank reta...

Страница 158: ...oil distribution hoses Check oil system operation and routing of oil sys tem hoses Repair any oil leaks and kinked or misrouted hoses Install engine covers Oil Injection Pump Removal Remove oil distr...

Страница 159: ...OPERATION 161 CYLINDER BLOCK CYLINDER HEAD COOLING 161 VAPOR SEPARATOR EMM AND BATTERY CHARGE MODULE COOLING 161 ENGINE TEMPERATURE CHECK 162 SOFTWARE METHOD 162 PYROMETER METHOD 162 IDLE OPERATING TE...

Страница 160: ...6 7 8 10 9 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Exhaust housing Cylinder block Pressure relief valve Thermostat Water supply to...

Страница 161: ...housing with liner must seal against a separate water pump plate The bottom plate MUST seal to gearcase Refer to WATER PUMP SERVICE on p 250 for servicing IMPORTANT The water pump housing includes a...

Страница 162: ...stricted or faulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing completely Thermostat The thermostat controls water flow and operating temper...

Страница 163: ...ng and then out of the outboard At higher speeds water pressure opens the pressure relief valve at approximately 2800 RPM Water flows through the valve to the cylinder head and bypasses the thermostat...

Страница 164: ...shoot cooling system Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperature sensor readings at IDLE speed should be 167 F 5 F 73 C 3 C Typical temperature...

Страница 165: ...ssure 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...

Страница 166: ...LOWLY tighten temperature sensor to a torque of 50 to 70 in lbs 5 6 to 8 0 N m Wait 10 minutes for trapped air to bleed from cav ity Thermal compound may seep past threads Retighten sensor THERMOSTAT...

Страница 167: ...orming the following additional tasks Install a new plunger seal on plunger Apply a light coat of Gasket Sealing Compound to a new o ring and place in groove in plate Install thermostat gasket thermos...

Страница 168: ...166 COOLING SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 169: ...LINDER BORE 178 PISTONS 179 PISTON RINGS 179 POWERHEAD ASSEMBLY 179 CRANKSHAFT ASSEMBLY 179 PISTONS AND CONNECTING RODS 181 CRANKSHAFT ASSEMBLY INSTALLATION 182 CRANKCASE ASSEMBLY 183 CYLINDER HEAD IN...

Страница 170: ...al Grease M RTV Sealant P Permatex No 2 Q Gel Seal II Y Extreme Pressure Grease F 84 to 106 in lbs 9 5 to 12 N m E H 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft l...

Страница 171: ...10 H H B D B H D D H H A 007739 A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H Outboard Lubricant P Permatex No 2 Q Gel Seal II...

Страница 172: ...linder head damaged pistons broken or stuck piston rings scored cylinder walls Return throttle to idle position and reconnect CPS connector Replace spark plugs Refer to Spark Plug Indexing on p 36 POW...

Страница 173: ...th hoist Remove the two exhaust housing to powerhead nuts and six exhaust housing to powerhead screws Use a suitable tool to carefully separate the pow erhead from exhaust housing IMPORTANT Do not dam...

Страница 174: ...must be installed in their original location Improper injector installa tion can result in powerhead failure Remove ignition coils Remove the electric starter Refer to Starter Removal on p 107 Remove...

Страница 175: ...y from the crankcase Cylinder Head Removal Loosen in stages and remove cylinder head retaining screws Remove the cylinder head Dis card cylinder head gasket Crankcase Disassembly Remove screws and exh...

Страница 176: ...val Carefully lift crankshaft straight up and remove from crankcase Connecting Rods and Pistons Use an appropriate ring expander to remove all piston rings from pistons Discard the rings Remove wrist...

Страница 177: ...Remove upper seal from crankshaft Discard the seal A new upper seal must be installed on assembly Remove the upper main bearing Remove the lower bearing seal housing Remove the housing O ring Discard...

Страница 178: ...essary To remove the sleeve use Slide Hammer P N 432128 and Puller Jaws P N 432130 Remove the lower main bearing only if it needs to be replaced Use external retaining ring pliers to remove the lower...

Страница 179: ...Gel Seal and Gasket Remover to remove all traces of gaskets adhesives and Gel Seal II sealant from the cylinder block crankcase cylin der head and water cover Carefully remove any carbon accumulation...

Страница 180: ...age Bearings Inspect upper and lower main bearings for excess wear nicks or scratches Replace if necessary Cylinder Bore Use a Cylinder Bore Gauge to inspect each cylin der bore for an out of round ov...

Страница 181: ...edge against the side of the piston Rings must be even or just below the surface of piston Rings must move freely in piston ring groove POWERHEAD ASSEMBLY IMPORTANT Proceed slowly Make no forced assem...

Страница 182: ...lower hous ing seal with Gasket Sealing Compound Press against outer case of the seal to install seal in the lower housing with extended lip facing down Lubricate seal lip with Moly Lube Install a new...

Страница 183: ...Apply outboard lubricant to the wrist pin bearings wrist pin and wrist pin bore Install the bearings in the small end of the connecting rod Place the piston over the connecting rod and bearings Insta...

Страница 184: ...that all Gel Seal II has been removed from the cylinder block and crankcase mating flanges If traces of hardened Gel Seal II are left main bearings could be misaligned Refer to CYLINDER BLOCK CLEANING...

Страница 185: ...PORTANT Gel Seal II has a shelf life of at least one year when stored at room temperature Test the Gel Seal II or replace it if the age of the tube cannot be determined Using old Gel Seal II could cau...

Страница 186: ...block Apply Nut Lock to cover screws Tighten all screws in sequence to a torque of 84 to 106 in lbs 9 5 to 12 N m Cylinder Head Installation Apply soapy water to water dam and insert into block Place...

Страница 187: ...k as shown Place a new gasket on the powerhead Apply Nut Lock to screws Install exhaust megaphone and secure with three screws Tighten screws to a torque of 84 to 106 in lbs 9 5 to 12 N m Apply Nut Lo...

Страница 188: ...ever and shaft assembly Guide shaft through bushings in crankcase IMPORTANT Shift lever and shaft must be positioned with pin toward the rear of the cylinder block Install shift lever and detent on sh...

Страница 189: ...and pressure valve assembly Refer to THERMOSTAT AND PRESSURE RELIEF VALVE SERVICING on p 164 Install electrical harness Install fuel injectors and ignition coils Refer to Fuel Injector Vapor Separato...

Страница 190: ...wise direction to align crankshaft and driveshaft splines Apply Triple Guard grease to the threads of the powerhead screws Loosely install all powerhead screws before tight ening Tighten the eight pow...

Страница 191: ...ower Cover Installation on p 45 Shift Linkage Adjustment Adjust shift linkage as follows STEP 1 Move shift lever into neutral position Make sure shift lever detent is in neutral posi tion Make sure ge...

Страница 192: ...before returning outboard to service Index all spark plugs Refer to Spark Plug Indexing on p 36 Use Evinrude Diagnostics software to start pow erhead break in oiling Refer to Powerhead Break In on p 6...

Страница 193: ...191 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS Port Electric Start Models Starboard Electric Start Models 008359 008278...

Страница 194: ...192 POWERHEAD POWERHEAD VIEWS Port Rope Start Models Starboard Rope Start Models 008430 008431...

Страница 195: ...193 POWERHEAD POWERHEAD VIEWS 10 Front 007809...

Страница 196: ...194 POWERHEAD POWERHEAD VIEWS Rear 007810...

Страница 197: ...195 POWERHEAD POWERHEAD VIEWS 10 Top 008280...

Страница 198: ...196 POWERHEAD NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 199: ...207 STERN BRACKET POWER TILT MODELS 208 STERN BRACKET DISASSEMBLY POWER TILT 208 STERN BRACKET ASSEMBLY POWER TILT 210 TRIM SENDING UNIT REMOVAL 214 TRIM SENDING UNIT INSTALLATION 215 STERN BRACKET MA...

Страница 200: ...0 to 84 in lbs 7 to 9 5 N m A A A A A A 35 to 61 in lbs 4 to 7 N m E 144 to 168 in lbs 16 to 19 N m 10 to 16 in lbs 1 to 2 N m A A X 40 to 45 ft lbs 54 to 61 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36...

Страница 201: ...19 N m 60 to 84 in lbs 7 to 9 5 N m A X 40 to 45 ft lbs 54 to 61 N m A 10 to 16 in lbs 1 to 2 N m 60 to 84 in lbs 7 to 9 5 N m 35 to 61 in lbs 4 to 7 N m A A A A A A A A Use Triple Guard grease on al...

Страница 202: ...N m E 60 to 84 in lbs 7 5 to 9 N m A A 18 to 20 ft lbs 24 5 to 27 N m 18 to 20 ft lbs 24 5 to 27 N m 24 to 36 in lbs 2 7 to 4 1 N m 35 to 61 in lbs 4 to 7 N m 35 to 61 in lbs 4 to 7 N m A A A 84 to 1...

Страница 203: ...lbs 14 5 to 16 5 N m A 22 to 23 ft lbs 30 to 32 N m A 10 to 12 ft lbs 14 5 to 16 5 N m E 10 to 12 ft lbs 14 5 to 16 5 N m 10 to 12 ft lbs 14 5 to 16 5 N m A 10 to 12 ft lbs 14 5 to 16 5 N m 10 to 12 f...

Страница 204: ...in lbs 2 2 to 3 4 N m V X 11 to 18 in lbs 1 2 to 1 9 N m X 9 to 15 in lbs 1 to 1 7 N m X X 26 to 28 ft lbs 35 to 38 N m A 36 to 60 in lbs 4 1 to 6 8 N m A X 18 to 24 in lbs 2 to 2 7 N m 10 to 20 ft lb...

Страница 205: ...pper mounts Remove washers from lower mounts Remove the exhaust housing Remove lower mount bracket rubber mount Check condition of the lower front mount Replace if deteriorated or damaged Exhaust Hous...

Страница 206: ...exhaust housing screws Remove mount Check condition of the mounts Replace if deterio rated or damaged Installation Apply Triple Guard grease to threads of the two mount to exhaust housing screws Inst...

Страница 207: ...ays aligned with pin as screw is tight ened Lower mount Apply Triple Guard grease to threads of the lower mount screws Install rubber bumper and washer Install screw through lower mount Tighten screw...

Страница 208: ...move overboard indicator grommet from muf fler Remove Oetiker clamp Install muffler drain hose on new muffler with tie strap Install muffler drain hose through hole Secure muffler with new Oetiker cla...

Страница 209: ...aust housing only if studs are loose Installation If studs are removed clean threads with cleaning solvent Apply Ultra Lock to upper threads of studs Install studs and tighten to a torque of 10 to 12...

Страница 210: ...ing screws Use a soft mallet to remove lower mount bracket and thrust washer If equipped with a steering friction device remove the steering friction nut Slide the steering arm out of the swivel brack...

Страница 211: ...se the outboard and engage the tilt support Remove the electrical connector from the trim sending unit Refer to CONNECTOR SERVICING on p 111 Remove the trim tilt cable connector Refer to TRIM AND TILT...

Страница 212: ...ion of the anode Replace the anode if it has been reduced to two thirds its origi nal size Stern Bracket Assembly Power Tilt Assemble stern and swivel brackets with tilt tube nuts tilt tube bushings t...

Страница 213: ...l bushings in hydraulic unit Position hydrau lic unit between stern brackets and install the angle adjustment rod Place the ground lead between the port stern bracket and tie bar as shown Assemble the...

Страница 214: ...iple Guard grease to the outside of the upper and lower bushings Install the upper and lower bushings in the swivel bracket Use Seal Installation tool P N 350958 to install new upper and lower seals i...

Страница 215: ...wn Install locking nut Temporarily tighten locking nut three to four full turns Final adjustment will be performed later Apply Triple Guard grease to both sides of thrust washer Install thrust washer...

Страница 216: ...CE on p 203 Install tiller handle Refer to TILLER HANDLE SERVICE on p 227 Adjust tiller steering friction Refer to Steering Friction Adjustment on p 24 Trim Sending Unit Removal Remove two screws Remo...

Страница 217: ...ender electrical connector on harness Refer to CONNECTOR SERVICING on p 111 Install tie straps on cable clamp and harness IMPORTANT Operate trim unit and make sure the wiring harness will not be damag...

Страница 218: ...crew and allow it to dry four to five minutes Then apply Ultra Lock to threads Install shoulder screw and swivel plate onto clamp screw and handle assembly Tighten screw to a torque of 60 to 84 in lbs...

Страница 219: ...ut of the swivel bracket and remove the thrust washer Remove the steering friction lever washers and plate Use an appropriate tool to pry the upper and lower seals from the swivel bracket 1 Mallet 2 L...

Страница 220: ...move the tilt pin two tie bar screws and tie bar Remove nuts washers and pins from stern brack ets Remove tilt tube nuts tilt tube bushings thrust washers handle and stern brackets 1 Friction plate 2...

Страница 221: ...n lever in the RUN position Loosen the bellcrank setscrew Push down on link Unhook reverse lock release rod from pin and remove rod from bellcrank Remove the bellcrank tilt lock lever and port stop li...

Страница 222: ...move the shallow water drive link and reverse lock assembly from the swivel bracket Remove cotter pins and disassemble shallow water drive and reverse lock assembly as needed If tilt lock assembly req...

Страница 223: ...el bracket when pressing in bushings Assemble reverse lock link and reverse lock lever as shown Install pin and secure with new cotter pin Place pin through the shallow water drive link as shown Secur...

Страница 224: ...RTANT Make sure the rounded end of the spring is installed as shown Use an appropriate tool to hook the straight end over the pin as shown Install the tilt lock lever and port stop link in the swivel...

Страница 225: ...e two reverse lock springs to the reverse lock lever Use an appropriate tool to connect the reverse lock springs to the top of the swivel bracket Install tilt tube bushings thrust washers handle and s...

Страница 226: ...tilt pin Tighten the tilt tube nuts to a torque of 40 to 45 ft lbs 54 to 61 N m then back off 1 8 to 1 4 turn Install friction screw and spring in swivel bracket Apply a light coat of Triple Guard gr...

Страница 227: ...he steering friction plate washers and lever Apply Triple Guard grease to both sides of thrust washer Install thrust washer on steering arm Slide the steering arm through the swivel bracket Align slot...

Страница 228: ...sides of thrust washer Install thrust washer on steering arm Install lower mount bracket on steering arm Install lower mount retaining screws Tighten screws to a torque of 10 to 12 ft lbs 14 5 to 16 5...

Страница 229: ...sher from shift lever pin and remove shift cable connector from shift lever pin Remove cable anchor screw and washer from shift cable retainer Remove locknuts from screws on bottom of steering arm Rem...

Страница 230: ...ORTANT Do not back screw out com pletely Nut is under spring tension Remove eight screws and bottom cover of tiller handle Remove shift handle screw and shift handle Remove stop switch screws Loosen s...

Страница 231: ...Remove shift cable retainer Remove screw and washer from shift link Remove shift cable and shift link Remove cotter pin from shift link and remove shift cable Remove four shift lever bracket retaining...

Страница 232: ...l switch and bracket Use Twist Grip Remover P N 390767 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 ou...

Страница 233: ...ully pry the trim switch out of the twist grip Remove the throttle friction control Remove nut washer and bushing from port side of tiller handle Remove steering handle screw Remove base from tiller h...

Страница 234: ...omponents for wear cracks or damage Replace parts if necessary Refer to Emergency Stop Switch Test on p 99 to test stop switch Assembly Install bracket on handle Install four screws Tighten screws sec...

Страница 235: ...wo bushings in base Hook spring to roll pin and recess in base as shown Turn tilt release lever one turn to apply tension to the spring Hold lever in position and install base in bracket Make sure spr...

Страница 236: ...ion control Press the trim switch into the twist grip Be sure trim switch UP position aligns with the twist grip indicator line as shown Install trim switch wiring through inner steering handle IMPORT...

Страница 237: ...ng for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Make sure trim switch wiring is NOT twisted before proceeding Install the throttle cable Install the throttle pin...

Страница 238: ...switch wires through inner tiller handle as twist grip assembly is installed Be sure the twist grip s speed indicator line is positioned with the speed range symbol on the handle Snap the grip into pl...

Страница 239: ...rely Install shift lever assembly Install four shift lever bracket retaining screws Tighten screws securely Install shift link and cable on shift lever Apply Ultra Lock to threads of screw and install...

Страница 240: ...nut securely Install stop switch housing spring but ton and stop switch Secure with two screws Tighten screws securely Route shift and throttle cables and wiring harness as shown Install bottom cover...

Страница 241: ...set to center or angled to port or starboard 20 Install rear washer and screw in appropriate loca tion Tighten both screws to a torque of 18 to 20 ft lbs 25 to 27 N m Install locknuts on screws Hold...

Страница 242: ...eaded cable ends to make cable adjustments Shift Cable Adjustment Secure shift cable to the shift lever pin For proper installation review the following steps Place washer on pin Position retainer cli...

Страница 243: ...ign Install washer between anchor and trunnion bracket Install screw Tighten screw to a torque of 84 to 106 in lbs 9 5 to 12 N m Throttle Cable Adjustment Install throttle cable connector with Ball So...

Страница 244: ...toward the end of the cable Install washer between anchor and boss Install screw Tighten screw to a torque of 84 to 106 in lbs 9 5 to 12 N m IMPORTANT Rotate twist grip Make sure throt tle cam goes t...

Страница 245: ...SHAFT BEARING HOUSING REMOVAL 254 SHIFTER GEAR AND PROPELLER SHAFT REMOVAL 255 BEARING AND SEAL REMOVAL 256 DRIVESHAFT SEALS 256 DRIVESHAFT BEARING 256 PINION BEARINGS 257 FORWARD BEARING 257 SHIFT R...

Страница 246: ...lbs 1 1 to 1 6 N m 60 to 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m C 60 to 84 in lbs 7 to 9 5 N m D 60 to 84 in lbs 7 to 9 5 N m A B A B C A 120 to 144 in lbs 13 5 to 16 N m 007679 A Triple...

Страница 247: ...load condi tions will allow the engine to run near the mid point of the RPM operating range at full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blades have too much pitch the eng...

Страница 248: ...rts and Accessories Catalog for cor rect propeller hardware Apply Triple Guard grease to the entire propeller shaft before installing the propeller Install thrust bushing onto propeller shaft with tap...

Страница 249: ...7 mm Hg with pump If vacuum gauge indicates leakage apply oil around suspected seal If leak stops or oil is drawn in seal is defective Repeat test gearcase must hold minimum of 15 in vacuum 381 mm Hg...

Страница 250: ...because lubricant may prevent seating of the driveshaft in the crankshaft WARNING To prevent accidental starting while ser vicing twist and remove all spark plug leads During service the outboard may...

Страница 251: ...6 5 N m Align the groove in the upper shift rod with the screw hole in the connector Apply Gasket Sealing Compound to threads of the shift rod connector screw Tighten screw with washer to a torque of...

Страница 252: ...eller for overheating hub separation and other wear or damage Check liner and wear plate for scoring distortion and impeller material transfer Inspect the housing for cracks or melting Make sure gaske...

Страница 253: ...IMPORTANT The sharp edge of key slot in the impeller is the leading edge during rotation Apply Adhesive 847 to the outer seal groove of the impeller housing Install a new seal into the groove Lightly...

Страница 254: ...ound Place gasket on the gearcase Place the impeller plate over the gasket Slide the driveshaft down into the gearcase and engage the pinion Turn the driveshaft until holes of the impeller housing are...

Страница 255: ...Check seal areas for visible signs of lubricant leakage Propeller Shaft Check for bent or damaged shaft Check for twisted splines and damaged threads Shift Rod Check for bent or binding rod Hydrostat...

Страница 256: ...ining Ring Pliers P N 331045 Remove the retainer plate from the gearcase 1 Screws 007668 1 Body 2 Handle 3 Pressing screw 4 Washers 5 Screws obtain locally 007669 1 1 4 5 1 2 3 CAUTION Retaining ring...

Страница 257: ...the pivot pin O ring Remove the propeller shaft and reverse gear components from the gearcase IMPORTANT Shifter detent balls and spring will pop out of the clutch when the propeller shaft is removed U...

Страница 258: ...MOVAL IMPORTANT Inspect bearings for damage while in place If bearing is damaged remove and discard If the bearing is removed for any reason it must be replaced Driveshaft Seals Use Puller Bridge P N...

Страница 259: ...Rod Bushing Remover P N 327693 under the shift rod bushing Thread the adapter of the Slide Hammer P N 391008 in the slide hammer Place the adapter through the shift rod bushing and thread into the re...

Страница 260: ...blies Lubri cate all bearings shafts and gears with gearcase lubricant Press the bearings into the housings until the tools are seated on the housing Propeller Shaft Bearing Housing Bearings Use Beari...

Страница 261: ...oat the shift rod O ring with Triple Guard grease and install in shift rod bushing Place a new washer and bushing on Shift Rod Bushing Installer P N 304515 Apply Gasket Sealing Compound to the outside...

Страница 262: ...g Assemble tool using long spacer P N 330068 Driveshaft Bearing Oil and install a new driveshaft bearing in the bearing sleeve using Bearing Installer P N 322923 Press against the lettered side of the...

Страница 263: ...fter Installation IMPORTANT Make no dry assemblies Lubri cate all bearings shafts and gears with gearcase lubricant Oil and place the forward bearing cone and roller assembly in the forward bearing cu...

Страница 264: ...o hold in place while assembling Install the shifter cradle and clutch dog in the gearcase using long nose pliers Apply Triple Guard grease to a new pivot pin O ring Install O ring on the pivot pin Ap...

Страница 265: ...tool in gear case Make sure the following occurs Propeller shaft must engage forward bearing Tool ramps must engage clutch dog ramps Hold tool firmly against clutch dog Gently tap propeller shaft wit...

Страница 266: ...age the shifter yoke Thread the shift rod into the shifter yoke until the rod bottoms in the yoke Propeller Shaft Bearing Housing Installation Slide the retainer plate down the propeller shaft and int...

Страница 267: ...ghtly apply Gasket Sealing Compound to the aft support flange of the bearing housing Align the propeller shaft bearing housing on the guide pin with the word UP toward the top Using a brass punch and...

Страница 268: ...seal assembly and install it into the slot in the gearcase To complete gearcase assembly refer to WATER PUMP SERVICE on p 250 GEARCASE LEAK TEST on p 247 GEARCASE REMOVAL AND INSTALLATION on p 248 Gea...

Страница 269: ...GENERAL 270 RESERVOIR FLUID 270 MANUAL RELEASE VALVE 270 STERN BRACKETS 270 TROUBLESHOOTING 270 ELECTRICAL CIRCUIT TESTS 271 RELAY TESTING 271 TRIM AND TILT MOTOR CURRENT DRAW TESTS 271 TRIM AND TILT...

Страница 270: ...268 TRIM AND TILT SERVICE CHART SERVICE CHART 007632 A Triple Guard Grease W Biodegradable TNT Fluid W W 45 to 55 in lbs 5 to 6 N m 45 to 55 in lbs 5 to 6 N m 30 to 50 in lbs 4 to 5 6 N m A A...

Страница 271: ...torage The tilt cylinder moves the outboard through the tilt range IMPORTANT When in tilt range make sure water is available to gearcase water pickups Manual Adjustment The outboard can be manually ra...

Страница 272: ...ase valve with a torque wrench IMPORTANT Tighten valve to a torque of 45 to 55 in lbs 5 to 6 N m Stern Brackets Inspect the stern brackets for binding Tighten starboard tilt tube nut to a torque of 45...

Страница 273: ...motor and 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 static hydraul...

Страница 274: ...to green lead The motor shaft must rotate counterclockwise as viewed from the pump end when positive is applied to the green lead and negative is applied to the blue lead If test results vary replace...

Страница 275: ...s With the outboard fully UP meter must show a reading below 10 ohms If results agree refer to Trim Gauge Test on p 272 If results are different replace trim sender TRIM AND TILT REPLACEMENT Removal R...

Страница 276: ...ust ment rod Remove the rod from the stern brack ets Remove the unit from the stern brackets far enough to remove the ground lead from the pump motor mounting screw Installation Lubricate the cylinder...

Страница 277: ...mbly Thoroughly clean the unit before disassembling Scrub all outside surfaces with a stiff brush and hot soapy water to prevent surface dirt from con taminating internal parts Always use a lint free...

Страница 278: ...gs on the housing Remove the four large motor flange retaining screws Remove the motor and discard O ring screws and washers Remove drive coupler from either the motor or the pump assembly Assembly IM...

Страница 279: ...to a torque of 45 to 55 in lbs 5 to 6 N m Install retaining ring in groove Fill the oil reservoir up to the fill plug with Evinrude Johnson Biodegradable TNT Fluid Install the fill plug Run the motor...

Страница 280: ...278 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 281: ...9 14 MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 280 RECOIL STARTER REMOVAL 281 RECOIL STARTER INSTALLATION 282 RECOIL STARTER DISASSEMBLY 283 RECOIL STARTER CLEANING AND INSPECTION 285 RECOIL STAR...

Страница 282: ...NUAL STARTER SERVICE CHART SERVICE CHART F 84 to 106 in lbs 9 5 to 12 N m 124 to 141 in lbs 14 to 16 N m V V X Tighten securely E Red Ultra Lock F Blue Nut Lock V Lubriplate 777 X See Service Manual 0...

Страница 283: ...to the side Remove the vapor separator vent hose and wiring from the retainers on the recoil starter housing Remove three recoil starter mounting screws Remove recoil starter assembly WARNING To prev...

Страница 284: ...n lbs 3 5 to 5 5 N m Install stator connector in retainer groove of starter housing To prevent damage to wiring from rotating flywheel make sure stator connector is securely fastened to the starter ho...

Страница 285: ...ure can dam age the threads of the housing Connect the cooling hose to the EMM Secure with tie strap RECOIL STARTER DISASSEMBLY Use Starter Spring Winder and Installer P N 342682 to service the recoil...

Страница 286: ...tension is released from spring Remove retaining ring pawl and linkage Remove starter spindle screw and lock nut IMPORTANT Hold pulley down in housing and lift out spindle Carefully lift out pulley l...

Страница 287: ...Replace as necessary Inspect starter rope Replace rope if frayed Cut new rope 80 in 203 cm in length Fuse ends of rope to a length of 1 2 in 12 mm Examine the pulley and the starter housing Look for...

Страница 288: ...ce spring around base as shown Place starter housing over base Route the hook end of spring through the starter housing opening as shown To keep spring in position hold up on portion of spring that is...

Страница 289: ...pletely pulled into housing Allow pulley to slowly unwind until tension is relieved Turn pulley counterclockwise 3 5 turns until the pulley rope channel aligns with the rope guide Secure pulley by pl...

Страница 290: ...l Allow rope to slowly wind into starter Remove left hand threaded nut and retainer from tool base Remove starter assembly Install spindle screw and lock nut Tighten nut to a torque of 124 to 141 in l...

Страница 291: ...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 292: ...S 2...

Страница 293: ...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...

Страница 294: ...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...

Страница 295: ...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...

Страница 296: ...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...

Страница 297: ...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...

Страница 298: ...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...

Страница 299: ...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 300: ...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 301: ...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...

Страница 302: ...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 303: ...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...

Страница 304: ...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...

Страница 305: ...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 306: ...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 307: ...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 308: ...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...

Страница 309: ...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...

Страница 310: ...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...

Страница 311: ...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...

Страница 312: ...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 313: ...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 314: ...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...

Страница 315: ...veshaft 256 260 Forward Gear 257 259 Pinion Gear 257 260 Propeller Shaft 258 Break In EMM Programming 150 190 Gearcase 249 266 Oiling 150 Procedure 62 C Cable Hose and Wire Routing 18 Clamp Screw Serv...

Страница 316: ...Timing Verification 63 106 TPS Calibration 63 106 Driveshaft Bearing Installation 260 Removal 256 Driveshaft Seals Installation 261 Removal 256 E Electrical Circuits EMM Pin Locations 85 Fuse 86 Groun...

Страница 317: ...Fuse 86 G Gearcase Assembly 261 Bearings Installation 258 Removal 256 Disassembly 253 Inspection 253 Installation 248 Leak Test 247 Lubricant 11 34 Removal 248 Seal Installation 258 Removal 256 Water...

Страница 318: ...Circuits 145 Engine Lubricant 10 146 Low Oil Switch 54 New Engine Set Up 146 Oil Distribution 143 Oil Distribution Hoses 143 154 155 Oil Filters 37 Oil Recirculation 148 Oil Tank 146 155 Oiling Rate 6...

Страница 319: ...ctrical and Ignition 82 Fuel System 116 Gearcase 244 Midsection 198 Oiling System 142 Powerhead 168 Shift Cable Adjustment Tiller 240 Shift Linkage Adjustment 189 Installation 186 Lubrication 33 Remov...

Страница 320: ...justments Timing Pointer 106 Timing Verification 106 TPS Calibration 106 Tools Accessory Power Cable Kit P N 5008092 59 Ball Socket Installer tool P N 342225 241 Ball Socket Remover Tool P N 342226 13...

Страница 321: ...ver and In staller P N 5005927 257 260 Universal Puller Set P N 378103 104 171 254 Wrench P N 334359 257 Wrist Pin Pressing Tool P N 326356 175 Wrist Pin Retainer Installation Tool P N 354720 181 Torq...

Страница 322: ...I 8 INDEX...

Страница 323: ...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 324: ...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...

Страница 325: ...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...

Страница 326: ...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 327: ...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...

Страница 328: ...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...

Страница 329: ...tube 4 Exhaust housing 5 Cylinder block 6 Pressure relief valve 7 Thermostat 8 Water supply to vapor separator 9 Water supply vapor separator to EMM 10 Overboard indicator outgoing water from EMM Hos...

Страница 330: ...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 331: ...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 332: ...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...

Страница 333: ...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 334: ...1 2 1 2 A B 6 4 1 5 7 1 Tiller to Engine Harness Connector 2 Trim Switch Connector 3 Trim Switch 4 Power Connector Trim Switch 5 Start Switch 6 Stop Switch 7 Touch Troll Switch Tiller Harness 15 30 H...

Страница 335: ...ection Ignition Fault Sensors 5V Circuits Stop Circuit No Oil Overheat KEY ON LED s illuminate to indicate circuit function STARTING LED s illuminate to indicate circuit function RUNNING LED s illumin...

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Страница 337: ...eck Connector 9 Neutral Switch 10 Diagnostic Connector 11 Cylinder Head Temperature Sensor 12 Ignition Coil 13 Fuel Injector 14 EMM 15 High Pressure Fuel Pump 16 Low Oil Switch 17 Oil Injector 18 Main...

Страница 338: ......

Страница 339: ...range 3 3 LED 4 ON Running 8 seconds EMM Temperature 194 F 90 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running 5 minutes Battery voltage 12 5 V Perform stator ch...

Страница 340: ...ED 2 ON Running 10 instances EMM counts failed ignition events Check wiring Test with known good ignition coil 82 Ignition timing circuit 2 OPEN LED 2 ON Running 10 instances 91 Fuel pump circuit OPEN...

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