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67

OUTBOARD RIGGING

EVINRUDE E-TEC MODELS 40–90 HP

3

SystemCheck

 Harness 

Connections

Place the wiring harness through notch in lower
motor cover and route to the recess in the fly-
wheel cover. Secure the cable with a tie strap as
shown:

Before installing electrical connectors, check that
the seal is in place. Clean off any dirt from con-
nectors. Apply a light coat of 

Electrical Grease

 to

the seal only. DO NOT fill connectors with 

Electri-

cal Grease

.

Arrange connectors in flywheel cover.

Install electrical cover and secure with screws.

BE SURE all harnesses and wires

are not pinched, cannot contact flywheel, and
do not interfere with moving throttle or shift
linkages.

1.

Recess

2.

Tie strap

002011

1.

Seal

42079A

2

1

1

001999

002102

NOTICE

Содержание Evinrude

Страница 1: ......

Страница 2: ......

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: ...N 15 BATTERY RECOMMENDATIONS 15 BATTERY CONNECTIONS 15 BATTERY CABLE REQUIREMENTS 16 BATTERY SWITCHES AND MULTIPLE BATTERIES 16 AUXILIARY BATTERY CHARGING 17 BATTERY AND SWITCH WIRING DIAGRAMS 18 FUEL...

Страница 5: ...5 30 HP 71 FUEL AND OIL PRIMING FUEL REQUIREMENTS 75 FUEL SYSTEM PRIMING 76 OIL REQUIREMENTS 77 RECOMMENDED LUBRICANTS 77 OIL INJECTION RATE 77 BREAK IN OILING 78 OIL SUPPLY PRIMING 79 PREDELIVERY BEF...

Страница 6: ...ew one When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Use of substandard parts could result in inj...

Страница 7: ...drop unexpectedly 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...

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

Страница 9: ...d 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 certific...

Страница 10: ...ponents on the outboard These systems use a Modular Wiring System MWS harness to carry start stop and trim sig nals analog to the outboard Specific harness selection depends on the type of Information...

Страница 11: ...k clearance around remote control lever at full throttle in FORWARD and then at full throttle in REVERSE There must be at least 2 5 in 64 mm of clearance between the handle and any part of the boat th...

Страница 12: ...transferred between the outboard and an Evinrude ICON system through a single network cable For complete installation instructions refer to the Evinrude ICON Remote Control System Installation Guide...

Страница 13: ...onal displays and accessories can be added with the plug and play design I Command information displays can be used with either a mechanical remote control system or with an Evinrude ICON system For c...

Страница 14: ...Connector Connect to a pre wired remote control or to a dash mounted key switch 2 3 Pin Connector Connect to remote control trim switch or to a dash mounted trim switch 3 Black purple white tan wires...

Страница 15: ...0 5 0 20 25 30 35 40 Water MPH 15 2 MENU DO WN U P EX IT PA GE S EN TE R 30 20 10 0 40 50 60 70 x 100 RPM 3550 1 3 4 2 5 6 Typical I Command wiring with a binnacle mount mechanical remote control 0079...

Страница 16: ...DEVICE BUSS BUSS BUSS BUSS DEVICE DEVICE 10 20 30 40 50 60 70 0 x 100 RPM 3550 UP DOW N EX IT PAG ES ENT ER MENU 10 20 30 40 50 60 70 0 x 100 RPM 3550 UP DOW N EX IT PAG ES ENT ER MENU 10 20 30 40 50...

Страница 17: ...T Con nect the battery negative cable to the battery negative post LAST Install a starwasher on the threaded battery post Stack cables from the outboard then cables from accessories Finish this connec...

Страница 18: ...econdary bat tery for emergency starting only Secondary Used as back up starting battery under abnor mal operating conditions Red cable connected to battery switch Secondary battery is charged indepen...

Страница 19: ...d Kit P N 5006253 is routed from a connector on the outboard s electri cal harness to the accessory battery The accessory charging kit must never be connected to any battery of a 24 volt electrical sy...

Страница 20: ...Cable Negative Battery Cable Accessory charge wire V models 50 amp fuse 1 Single starting battery with ON OFF switch 2 Two starting batteries with isolator combiner 15 90 HP models 3 Voltage sensitiv...

Страница 21: ...ted accessory batteries ACCESSORY PRIMARY 1 PRIMARY 2 S S 1 2 OFF BOTH 1 2 OFF BOTH 1 2 Positive Battery Cable Negative Battery Cable Accessory charge wire V models 50 amp fuse 008053 ACCESSORY PRIMAR...

Страница 22: ...fuel hose between per manent fuel tanks and motor well fittings in inac cessible routings Compliant hoses are labeled with the applicable specification Permanently installed fuel hoses should be as s...

Страница 23: ...lectric primer pumps offer the convenience of outboard priming from a dash mounted momentary switch Fuel Filters Boat mounted fuel filters and water separating fuel filter assemblies must meet the req...

Страница 24: ...1 4 in 6 4 mm min ID 3 8 in 9 5 mm min ID 3 8 in 9 5 mm min ID ALL MODELS Fuel tank pickup screen 100 mesh 304 grade stainless steel wire 0 0045 in wire diameter 1 in 25 mm long Antisiphon valve 2 5 i...

Страница 25: ...ft 7 6 m Do not add hose to an existing oil supply hose If the oil tank requires a longer oil supply hose Oil supply hose between the primer bulb and outboard must be replaced with one continuous len...

Страница 26: ...or bracket Assemble cross bar onto hook rods install flat washers and lock nuts Tighten locknuts to securely hold tank 1 8 GALLON TANK Place rods into floor bracket and secure floor bracket with lag b...

Страница 27: ...the required length of 1 in I D fill hose to route as directly and as vertically as possible Avoid inappropriate hose routings that could distort the fill tube or tank tube Refer to installation instr...

Страница 28: ...nsor kit Boat Cable and Harness Routing Remote control cables wiring and hoses must follow a similar path into the lower motor covers Select the best routing for the specific application All cables wi...

Страница 29: ...this consideration Route fuel hoses with enough slack to allow the primer bulb arrow to point up during use Install the primer bulb with the arrow pointing in the direction of fuel flow to the outboar...

Страница 30: ...e 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 NOT...

Страница 31: ...er 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...

Страница 32: ...30 BOAT RIGGING NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 33: ...ould be wide enough to allow full steering travel The ABYC standard for most single outboard installations is 33 in 84 cm Check cable and hose routing clearances Make sure there is clearance for mount...

Страница 34: ...be or steering cable nuts Elongated mounting holes Bent or deformed washers Replace any hardware that fails to maintain torque specifications Mounting Hardware Outboard mounting hardware must meet min...

Страница 35: ...boat manufacturer for recommendations If the standard spacing does not allow full steering travel in a particular installation it may be neces sary to increase the spacing IMPORTANT Some steering syst...

Страница 36: ...with the bottom of the hull The anti ventilation plate should NOT extend more than 2 in 5 cm BELOW the bottom of the hull Transom Drilling Locations 75 300 HP ALL MODELS 40 60 HP POWER TRIM MODELS 25...

Страница 37: ...T Be sure to drill the required holes perpendicular to transom surface 40 65 HP MANUAL TILT MODELS 25 30 HP MANUAL TILT MODELS 15 HP POWER TILT MODELS Center the outboard on the transom or mounting br...

Страница 38: ...f Transom 6 318272 Plate 2 327053 3 in 76 mm 3 1 2 Bolt Hole Locations 7 318273 Retainer 2 318573 3 1 2 in 89 mm 4 Outside of Transom 8 319886 Screw 4 336676 4 1 2 in 114 mm 9 307238 Washer 2 331578 5...

Страница 39: ...OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 37 2 IMPORTANT This is not a template 5 10 11 12 9 6 7 8 90...

Страница 40: ...ANUAL TILT MODELS IMPORTANT This is not a template 1 Center of Transom 2 Top of Transom 3 5 16 Bolt Hole Locations 3 3 3 3 2 2 1 2 09 in 53 08 mm 5 16 in 131 01 mm 4 031 in 4 1 32 102 4 mm 4 031 in 4...

Страница 41: ...OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 39 2 IMPORTANT This is not a template 90 8 99 in 228 34 mm 2 09 in 53 08 mm...

Страница 42: ...MEASURING AND DRILLING 25 30 HP MANUAL TILT MODELS IMPORTANT This is not a template 1 Center of Transom 2 Top of Transom 3 5 16 Bolt Hole Locations 3 3 2 1 4 3 4 in 121 2 mm 4 3 4 in 121 2 mm 5 in 126...

Страница 43: ...OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 41 2 IMPORTANT This is not a template 2 3 2 in 50 2 mm 3 4 in 19 mm 3 1 2 in 91 mm 3 3 4 in 95 25 mm...

Страница 44: ...TION TRANSOM MEASURING AND DRILLING 15 HP POWER TILT MODELS IMPORTANT This is not a template 1 Center of Transom 2 Top of Transom 3 5 16 Bolt Hole Locations 7 39 in 187 6 mm 2 1 in 53 1 mm 10 25 in 26...

Страница 45: ...OUTBOARD INSTALLATION TRANSOM MEASURING AND DRILLING 43 2 IMPORTANT This is not a template 9 38 in 238 25 mm 2 1 in 53 1 mm...

Страница 46: ...ool on flywheel and seat the three screws completely Refer to RECOIL STARTER REMOVAL in the correct Service Manual Use only the 1 1 8 in short screws P N 398067 included with the tool to avoid damage...

Страница 47: ...e Remove chain from lifting tool Remove lifting tool from outboard 1 Lifting tool P N 354717 007122 A WARNING To avoid personal injury or outboard dam age be sure the lifting tool is fully threaded on...

Страница 48: ...al outboard installations if an ABYC approved steering link is used Dual cable mechanical steering helps provide firm steering control at high speeds Extend the steering cable and lubricate the inner...

Страница 49: ...oard Centerlines on p 33 Drag Links Use the correct drag link to allow full steering travel Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm For s...

Страница 50: ...ANT Use a marine sealant rated for above or below waterline use RTV silicone is not approved for below waterline use Polyurethane sealants are not easily removed and may damage outboard or boat mounti...

Страница 51: ...d stern brackets Install the mounting bolts through the stern brack ets and transom Install round backing plates and locknuts onto bolts and tighten securely 25 30 HP MANUAL TILT MODELS 15 HP POWER TI...

Страница 52: ...50 OUTBOARD INSTALLATION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 53: ...link age pins clips should be locked and must not be bent or deformed For proper installation review the following steps Place washer on pin Position retainer clip with straight section on the bottom...

Страница 54: ...t in the grommet Refer to the following diagram to ensure proper positioning of rigging components in grommet The main wiring harness battery cables oil tank sending unit harness and any ICON or I Com...

Страница 55: ...the remote control gearcase shift link age and shift cable are in NEUTRAL Hold the shift linkage in NEUTRAL Push and pull on the shift cable and observe the cable slack Hold the casing guide in the c...

Страница 56: ...n Install trunnion cover and screw Tighten screw to a torque of 60 to 80 in lbs 7 to 9 N m Battery Cable Connections Install battery cables on starter solenoid and main ground stud SystemCheck Harness...

Страница 57: ...ICON I Command Harness Connec tions on p 14 If using a mechanical control system connect the I Command Engine Interface Cable to the EMM CANbus connector Use an I Command Ignition and Trim Harness to...

Страница 58: ...nectors Carefully align pins and sockets of connectors Do NOT force connectors together Tighten locking rings of buss connectors finger tight Do NOT use locking rings to force connec tors together Do...

Страница 59: ...of the powerhead along the same path as the battery cables For an I Command water pressure display sev eral water pressure sensor kits are available Refer to the Evinrude Johnson Genuine Parts and Ac...

Страница 60: ...et Refer to the following diagram to ensure proper positioning of rigging components in grommet The main wiring harness battery cables oil tank sending unit harness and any ICON or I Com mand network...

Страница 61: ...te control gearcase shift link age and shift cable are in NEUTRAL Hold the shift linkage in NEUTRAL Push and pull on the shift cable and observe the cable slack Hold the casing guide in the center of...

Страница 62: ...tall trunnion cover and screw Tighten screw to a torque of 60 to 80 in lbs 7 to 9 N m Battery Cable Connections Install battery cables on starter solenoid and main ground stud SystemCheck Harness Conn...

Страница 63: ...If the outboard will be used with I Command or other NMEA 2000 compliant CANbus instruments use the following connections to supply informa tion to the network If using an Evinrude ICON control system...

Страница 64: ...nterface Cable This connec tion supplies power to the network when the key switch is on Newer quick connect style networks do not use this connection Route the harnesses around the starboard side of t...

Страница 65: ...tors together Do not rotate connectors until they align This could result in a mismatched connection It is pos sible for each pin to enter a socket even if the tabs are misaligned Look at the tabs to...

Страница 66: ...er pressure display sev eral water pressure sensor kits are available Refer to the Evinrude Johnson Genuine Parts and Accessories catalog To send water pressure data to the EMM along with an I Command...

Страница 67: ...ing angles Control Cable Installation Refer to Control Cable Identification on p 51 Remove cable retainer from anchor block Apply Triple Guard grease to both anchor block pockets IMPORTANT DO NOT secu...

Страница 68: ...ocket 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 agains...

Страница 69: ...nnectors check that the seal is in place Clean off any dirt from con nectors Apply a light coat of Electrical Grease to the seal only DO NOT fill connectors with Electri cal Grease Arrange connectors...

Страница 70: ...l tie straps as shown To prevent wire chafing harness must be routed below the flywheel cover Connect the I Command Engine Interface Cable to the EMM CANbus connector 2 CYLINDER MODELS To prevent inte...

Страница 71: ...ct the purple wires between the I Command Ignition and Trim Harness and the I Command Engine Interface Cable This connec tion supplies power to the network when the key switch is on Newer quick connec...

Страница 72: ...water pressure install a water pressure hose fitting in the cylinder block as shown Use Pipe Sealant with Teflon on the threads of the hose fitting Refer to installation instructions sup plied with ga...

Страница 73: ...earance for all cables to avoid binding or chafing through all engine steering and tilting angles Control Cable Installation Refer to Control Cable Identification on p 51 Make sure the remote control...

Страница 74: ...nd 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 s...

Страница 75: ...cover with two 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 thro...

Страница 76: ...74 OUTBOARD RIGGING NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 77: ...which can damage the out board Additives IMPORTANT The only fuel additives approved for use in Evinrude outboards are 2 4 fuel condi tioner and Evinrude Johnson Fuel System Cleaner Use of other fuel a...

Страница 78: ...fuel hose Once fuel flow is observed connect fuel supply hose from fuel tank to hose fitting on outboard Secure hose with Oetiker clamp 15 65 HP MODELS Connect the fuel hose connector to the quick con...

Страница 79: ...gement 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 powerhead break in Use Evinrude Diagnostics software to acce...

Страница 80: ...dels The Engine Management Module EMM will auto matically supply extra oil to the engine as follows 90 V6 First two hours above 2000 RPM 60 V4 V6 First five hours above 2000 RPM 40 90 HP First two hou...

Страница 81: ...d Start the outboard Use the oil priming functions in the software to make sure the system is com pletely primed IMPORTANT The outboard should be running during the priming procedure to avoid pumping...

Страница 82: ...n outboard and secure with Oetiker clamp Oil Pump Priming Squeeze the oil primer bulb until oil flows from the oil supply hose through the oil filter and into the oil pump assembly IMPORTANT Inspect o...

Страница 83: ...bubbles are acceptable Large bubbles must be eliminated through continued priming Repair any fuel or oil leaks The oiling system on these models can also be primed using the Self Winterizing feature...

Страница 84: ...hould turn OFF during oil system priming Observe oil flow through all oil distribution hoses Air must be purged during the priming procedure Small bubbles are acceptable Large bubbles must be eliminat...

Страница 85: ...that the LOW OIL warning has been tested Refer to Rec ommended Lubricants on p 77 When starting the outboard for the first time refer to OIL SUPPLY PRIMING on p 79 Trim and Tilt Fluid Make sure trim a...

Страница 86: ...fuel primer bulb until hard or activate electric primer Observe all fuel hoses and con nections Repair any leaks Start outboard Inspect all hoses and connec tions Repair any leaks or misrouted hoses i...

Страница 87: ...gine and fuel tank set fuel tank capacity etc Refer to I Command User s Guide Water Pump Overboard Indicator A steady stream of water should flow from the overboard indicator Operating Temperature An...

Страница 88: ...e boat has a normal load Occasionally one propeller will not cover a wide range of boat applications water skiing to high speed performance boating In such cases it might be necessary to have a propel...

Страница 89: ...th Keeper 70 to 80 ft lbs 95 to 109 N m Without Keeper 120 to 144 in lbs 13 6 to 16 3 N m If cotter pin holes in the nut without keeper and shaft do not align tighten further Do not loosen Install kee...

Страница 90: ...Height and Jack Plate Adjustment Goals include Engine RPM within the full throttle operating range Best acceleration and top speed No excessive ventilation while boat is coming onto plane Start with t...

Страница 91: ...17 103 117 16 18 110 124 19 21 131 144 20 22 137 151 115 130 HP 60 V4 5 6 34 41 9 10 62 68 12 14 82 96 15 17 103 117 18 20 124 137 20 21 137 144 20 22 137 151 21 23 144 158 21 23 144 158 21 23 144 158...

Страница 92: ...position Check the adjustment by tilting the outboard fully Repeat this procedure until the tilt limit switch stops the outboard s upward travel before it con tacts the motor well To prevent damage t...

Страница 93: ...m down As the 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 water causing the boat to bow s...

Страница 94: ...point Loosen cam screw and rotate eccentric cam to adjust full down gauge position If the needle was above the lowest mark move the thick part of the cam TOWARD the contact point Tighten the screw an...

Страница 95: ...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 40 300 HP 35 to 40 ft lbs 47 to 54 N m 15 30 HP 60 to 80 in l...

Страница 96: ...oard alignments Each applica tion must be thoroughly tested until the ideal combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a sm...

Страница 97: ...n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Diagnostic Software Break In Programming 78 I Comma...

Страница 98: ...ing System Engine Lubricant 77 New Engine Set Up 23 77 Oil Tank 23 Priming 79 P n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n...

Страница 99: ...ng Batteries Wiring and Switches Batteries Qty ______ CCA Rating _______ Cable size ____ ga Length _____ ft m Connections tight NO wing nuts Battery switch operation optional Auxiliary Battery Chargin...

Страница 100: ......

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