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301

GEARCASE SERVICE, 40 – 65 HP MODELS

GEARCASE DISASSEMBLY

GEARCASE
DISASSEMBLY

Pre-Disassembly Inspection

IMPORTANT:

Clean and inspect all parts during

disassembly. Replace an y damaged parts, seals,

O-rings, and gaskets.

Remove the propeller and mounting hardware.

Drain a nd inspect o il as d escribed in

Gearcase

Lubricant

on p. 39.

Remove gearcase. Refe r to

GEARCASE

REMOVAL AND INSTALLATION

on p. 296.

Remove wa ter pump. Re fer to

WATER PUMP

SERVICE

on p. 298.

Before disassembling the gearcase, examin e the

following:

•

Gearcase Housing —

Check for visible da m-

age to skeg, strut, an ti-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 sp lines a nd d amaged

threads.

•

Shift Rod —

Check for misadjusted, bent, or

binding rod. A misadjusted shift rod height can

cause shift difficulty, loss o f boat an d outboard

control, and gearcase damage.

•

Hydrostatic Seal Grooves —

Must be in good

condition to help prevent propeller ventilation.

•

Gearcase Anodes —

If anodes have eroded to

two-thirds their origina l size, t hey must b e

replaced.

•

Drive Shaft —

Check splin es for visible dam-

age, twisting and wear. Severe spline wear indi-

cates th e exh aust h ousing or ge arcase has

been distorted, possibly by impact damage.

•

Water Intake Screens —

Ch eck f or damage

and blo ckage. If screens ca nnot b e cleane d,

they mu st be re placed. Dif ferent scre ens a re

available and should not be mixed. Refer to cor-

rect model parts manual for listing and descrip-

tion.

WARNING

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

Hydrostatic seal grooves

002217

Gearcase anode

002014

Содержание E-Tec 40 HP

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: ...185 11 MIDSECTION 233 12 GEARCASE 289 GEARCASE SERVICE 40 65 HP MODELS 296 GEARCASE SERVICE 75 90 HP MODELS 318 13 TRIM AND TILT 343 14 MANUAL STARTER 361 SAFETY S 1 INDEX I 1 TROUBLE CHECK CHART T 1...

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: ...p atch screws be requ ired a lways replace with a new one When repla cement p arts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and...

Страница 7: ...rd may 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 disc...

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

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

Страница 11: ...Power Tilt Remote Steering Electric Start E50DSLINM 86 L 52 7 ci 12 32 0 375 F 20 White Power Tilt Remote Steering Electric Start E60DTLINM 86 L 52 7 ci 12 32 0 375 F 20 Blue Power Tilt Tiller Steeri...

Страница 12: ...Bore 3 601 in 91 47 mm Stroke 2 588 in 65 74 mm Standard Bore 3 6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1...

Страница 13: ...rge Firing Order 1 2 Ignition Timing EMM Controlled RPM Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Cha...

Страница 14: ...6005 to 3 6015 in 91 45 to 91 48 mm To bore oversize add piston oversize dimension to standard bore Top Crankshaft Journal 2 1870 to 2 1875 in 55 55 to 55 56 mm Center Crankshaft Journals 2 1870 to 2...

Страница 15: ...Limit in Gear 6250 RPM Limit in Neutral 1800 Crankshaft Position Sensor Air Gap Fixed Spark Plug Refer to Emission Control Information Label Champion QC10WEP 0 028 003 in 0 71 mm GEARCASE Gear Ratio...

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

Страница 17: ...ENDING UNIT ADJUSTMENT 75 90 HP 30 TRIM TAB ADJUSTMENT 31 DUAL OUTBOARD ALIGNMENT 32 OPERATIONAL CHECKS 33 COOLING SYSTEM 34 ENGINE FLUSHING 35 RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER 3...

Страница 18: ...components Water intake screens check condition Cooling system check water pump indicator water pressure Anticorrosion anodes check condition Gearcase check condition Propeller check condition Fuel a...

Страница 19: ...ith the service manual set Common Practices All Models Control Cable Identification IMPORTANT Identify con trol ca ble fun ction before rigging outboard Identify each control cable Put the co ntrol ha...

Страница 20: ...d section behind the straight section Cable Hose and Wire Routing Refer to Control Cable Identification on p 17 Apply soapy water to the inside surfaces of grom met and install cables and fuel line as...

Страница 21: ...t o remove slack With outboard in NEUTRAL place the cable trun nion into the lower anchor pocket Adjust the trun nion nut so the casing fits onto the shift lever pin If there are not enough threads on...

Страница 22: ...m SystemCheck Harness Connections Place th e wirin g harne ss through notch in lower motor cover a nd ro ute t o the recess in th e fly wheel cover Secure the cable with a tie strap as shown Before in...

Страница 23: ...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 24: ...heck co nnector with 6 Pin Connector Seal P N 586076 If conne cting to an existing I Command Classic network connect the purple wires bet ween the I Command Ig nition and Trim Harn ess an d the I Comm...

Страница 25: ...s Water Pressure Gauge To display engine water pre ssure install a water pressure hose fitting in th e cylind er block as shown Use Pipe Sealant with Teflon on the threads of the hose fitting Refer to...

Страница 26: ...to the batte ry 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 27: ...the outside diameter of the hose when installed on the fitting Chose a clamp so that the outside diameter of the hose is approximately in the middle of the clamp ing range of the clamp A WARNING DO N...

Страница 28: ...stepless clamps Oetiker p incers a re 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 29: ...s are equ ipped with a thro ttle friction adjustment knob lo cated on the st eering handle Tighten the knob to reduce the effort required to hold a throttle setting Turn the knob clockwise to increase...

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

Страница 31: ...Loosen cam scre w a nd rot ate eccen tric cam to adjust full down gauge position If the needle was above the lowest mark move the thick part of the cam T OWARD the contact point Tighten the screw and...

Страница 32: ...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 wa ter cau sing the boa t to bow steer r...

Страница 33: ...d to the right move rear of the trim tab slightly to the right If the boat pulled to the left move rear of the trim tab slightly to the left Tighten the trim tab screw as follows 40 90 HP 35 to 40 ft...

Страница 34: ...ments Each app lica tion must be thoroughly tested until the idea l combination of performance steering and cooling is found A common practice is to set up the outboards par allel or with a small a mo...

Страница 35: ...rt In Gear Prevention Start outboard and shift to FORWARD Turn outboard OFF while control is in FORWARD Try to restart the o utboard Outboard should not start Shift back to NEUTRAL and restart outboar...

Страница 36: ...d Make sure the outboard idles within the specified idle RPM range If the outboard is run on a flush ing device the idle speed and quality may not be representative of actual in water use COOLING SYST...

Страница 37: ...ard 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 outb...

Страница 38: ...ents 1 GPM Gallons per minute 2 LPM Liters per minute Install flushing adapter onto gearcase water inlet screens A steady stre am o f water should flo w f rom t he overboard indicator while the engine...

Страница 39: ...it wit h gre ase Make sure wip er nu t is installed and not damaged Tiller Handle Lubricate the tiller ha ndle grease fitting s with Tri ple Guard grease A WARNING Failure to regrease as recommended c...

Страница 40: ...from throttle and shift lever pins Carefully remove casing g uides from pins IMPORTANT DO NOT disturb cab le trunnion adjustments Shift remote cont rol into FULL THROTTLE REVERSE position to fully ex...

Страница 41: ...stall propeller hardware and propeller Gearcase Lubricant Draining IMPORTANT Always check the fill le vel of the gearcase lub ricant at the u pper plug befo re removing the lower drain fill plug A tie...

Страница 42: ...nspect ion is re commended when lubricant is contaminated or shows signs of failure Filling Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p 16 for service freque ncy and recommended lubricants S...

Страница 43: ...eads Install the filler cap and tighten to a torque of 45 to 55 in lbs 5 to 6 N m Disengage tilt support Cycle the un it at lea st five complet e cycles to purge all air from the system When cycling t...

Страница 44: ...e sp ark plug opposite the fuel injector nozzle Put an ink mark on the cera mic of the spark plug in line with the OPEN sid e of the ground ele c trode This mark will be used to orient the spark plug...

Страница 45: ...system leaks Make certain the oil t ank is filled a nd oil supply is not contaminated Air Silencer The air silencer maximizes air flow while minimiz ing noise Routine cleaning of the air silence r is...

Страница 46: ...based antifouling paint on the boat or outboard Testing Procedure Continuity Connect ohmmeter leads between engine ground and anode surface The meter should show little or no re sistance If resistanc...

Страница 47: ...nds the System Check lights will go off Move thro ttle to IDLE position SystemCheck lights will light again Wait ano ther 15 seconds SystemCheck lights will go of f At this poin t advance thrott le t...

Страница 48: ...storage make sure it is reinstalled with fa ctory specified hardware Refer to the Predelivery and Installation Guide Outboard Mounting Bolts Check and re tig hten outb oard moun ting bolts to a torque...

Страница 49: ...supp ly h ose and oil ret urn hose from outboard Drain and clean a ll oil hoses fil ters and oil tank assemblies Refill fuel tank with fresh fuel and oil tank with rec ommended oil Prime oil system an...

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

Страница 51: ...3 ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE 50 LATCH HOOK INSTALLATION 50 LOWER COVER SERVICE 50 LOWER COVER REMOVAL 50 LOWER COVER INSTALLATION 51 LATCH HANDLE INSTALLATION 52 TRIM...

Страница 52: ...sition with opening toward the front Tighten screws to a torque of 60 to 84 in lbs 7 to 9 5 N m LOWER COVER SERVICE Lower Cover Removal Remove lower engine cover screws Loosen port side cover slightly...

Страница 53: ...t side cover Connect trim tilt switch connector Place port side cover into position on outboard Start the screw above the exhaust relief grommet first Tighten just enoug h to hold the gro mmet in plac...

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

Страница 55: ...SWITCH 58 THROTTLE POSITION SENSOR 59 CRANKSHAFT POSITION SENSOR 59 NEUTRAL SWITCH 59 INTERNAL EMM FUNCTIONS 60 ENGINE MONITOR SYSTEM 61 S A F E WARNING SYSTEM 62 SHUTDOWN MODE 62 DIAGNOSTIC SOFTWARE...

Страница 56: ...ust water valve activation 60 65 HP EMM Connections IMPORTANT EMM connections an d wiring must be clean and tigh t Improper electrical con nections can damage the EMM DO NOT r un the outboard with loo...

Страница 57: ...e Sensor AT 9 Engine Temperature Sensor 10 Fuel Pump high pressure 11 Oil Injection Pump and Manifold 12 Ignition Coil 13 Fuel Injector 14 Tachometer SystemCheck Gauge 15 I Command CANbus Display 16 D...

Страница 58: ...or read s less than 71 F 57 4 C or greater than 313 F 156 C a senso r circuit fault is detected and the EMM 55 V Circuit Sensor Monitors the EMM s 55 V alternator circuit If system voltage exceeds 57...

Страница 59: ...or sensor cir cuits It monitors all sen sor volt age inpu ts and compares them to prede termined accept able ranges Inputs that fa ll outside of the acceptable range create service codes Air Temperatu...

Страница 60: ...e quarter t he EMM b egins counting oil pump pulse cycles When it reaches 40 65 HP 4800 pulses 75 90 HP 6000 pulses the EMM To recover from S A F E mode the oil pump must cycle for a minimum of th ree...

Страница 61: ...a tachometer signal and control fuel and ignition timing If the sensor is damaged or the signal is intermit tent 10 occurrences the EMM Approximate air g ap b etween CPS a nd flywhee l encoder ribs i...

Страница 62: ...resumes when engine RPM returns to the specified range Neutral RPM Limiter This featu re prevents engine damage due to excessive RPM if accelerated in NEUTRAL Neu tral engine speed is limited to 1800...

Страница 63: ...EMM Service Code Chart at the back of th is manual for a co mplete list of all fault codes System Self Test During engine start up pause with the key switch in the ON position The horn se lf tests by...

Страница 64: ...est on p 137 Check for external fuel leakage that could allow fuel and o r vapo r to enter th e engine throug h the air intake Check for internal fuel leakage from a le aking injector or vapor separat...

Страница 65: ...ple of the EMM J1 B connec tor The EMM is also turn ed ON when it begins to receive AC volt age from the stator while the out board is being cranked ROPE START MODELS Diagnostic co mmunications on non...

Страница 66: ...infor mation The outboard model and serial numbers displayed on the Identity screen must ma tch the identifica tion label on the outboard swivel bracket The serial number and cylinder location display...

Страница 67: ...ours of the last occurrence Historical faults cannot be erased Static Tests Static Tests allow dia gnostic testing o f system components while the outboard is NOT running Ignition Test Use the diagnos...

Страница 68: ...lity chang es can b e observed Refe r to DYNAMIC TESTS on p 76 Prime Oil This test is used to cycle the oil injection pump for priming the o iling syst em Per form th is test with outboard running to...

Страница 69: ...h an installed tiller conversion kit MUST be set to TILLER Ignition Timing Use the Ignition Timing scre en to check an d adjust EMM timing EMM timing must be synchro nized to crankshaft position Refer...

Страница 70: ...set an absolute fixed speed Af ter the offset is changed th e EMM continues to control engine operation normally Engine idle speed is not fixed Fuel Injector Servicing All E TEC fuel inje ctors use so...

Страница 71: ...available to enhance the opera tion of an outboard Select Engine Software Update from the Utilities menu and refer to the instructions pro vided with the program IMPORTANT If using Diagnostic Power S...

Страница 72: ...y and follow the instructions provided with the program IMPORTANT Whenever th e EMM is rep laced EMM timing must be synchronized to crankshaft position Refe r to TIMING ADJUSTMENTS on p 113 EMM SERVIC...

Страница 73: ...performing the following tasks Make sure isolator mounts are placed in slots in of EMM case Slide EMM into position Apply Nut Lock t o t hreads o f EMM ret aining screws Tighten to a torque of 30 to...

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

Страница 75: ...77 RUNNING 78 IGNITION OUTPUT TESTS 79 REQUIRED IGNITION SYSTEMS 79 WIRING INSPECTION 79 CRANKSHAFT POSITION SENSOR CPS TEST 80 SYSTEM VOLTAGE TEST 80 STATIC IGNITION TEST 81 RUNNING IGNITION TESTS 82...

Страница 76: ...spark plugs Check the fuse an d the emergency st op switch lanyard Operational Inspections Run the ou tboard to confirm actual symp toms before perfo rming any unne cessary procedures Inspection shou...

Страница 77: ...D Indicators for system sta tus information Refer to EMM LED INDICA TORS on p 77 Use the Evinrude Diagnostics software Monitor screen to check syste m 55 V and TPS vo lt ages System volt age should b...

Страница 78: ...MPORTANT DO NOT misinterpret tests run at IDLE The idle speed controller in the EMM com pensates to maintain a constant IDLE speed The Dynamic Tests screen includes a fun ction to tem porarily disable...

Страница 79: ...el begins to turn until the outboard is running for 2 seconds During st arting a ll four LEDs should light and then go off in sequence LED 1 CHARGING OKAY Stator signal 30 V or higher LED 2 CRANK POSI...

Страница 80: ...ircuit shorted Code 102 No 2 ignition timing circuit shorted Code 103 No 3 ignition timing circuit shorted LED 3 Sensor circuits 5 V SENSOR FAULT For LIGHT ON check for possible fault codes Code 12 TP...

Страница 81: ...rom EMM white red provides 55 VDC to the high pressure fu el pump the oil injection pump the fuel injectors and the igni tion coils Capacitor Connected to 55 V circuit white red to stabilize current o...

Страница 82: ...esults 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 vol...

Страница 83: ...gency stop switch lanyard must be installed Connect timing ligh t pickup to the secondary cir cuit spark plug lead of the cylinder being tested Activate test an d observe timing light strobe for cons...

Страница 84: ...oltage and strobe engine misfires Inspect or replace spark plugs Refer to FUEL DELIVERY TESTS on p 84 Check for internal engine damage Steady voltage erratic strobe engine misfires Inspect or replace...

Страница 85: ...d ig nition coil connector Refer to engine wiring diagram If circuits test good replace EMM Ignition Coil Tests There are no simple ignition coil test s available Before replacing an ignition coil be...

Страница 86: ...ntinuity between pin 2 of f uel pump co nnector a nd ground Use the fuel pump static test to activate the control function of the EMM Resi stance should drop as EMM connects the control circuit to gro...

Страница 87: ...che d by the EMM The Dynamic Tests screen allows the contr ol signal to be turned off to a particular injector IMPORTANT Some timing lights may not flash consistently at cranking speeds Always check t...

Страница 88: ...the voltage at pin 2 blue red wire of the the water valve connector V oltage shou ld d rop while the static test is active Exhaust Water Valve Dynamic Test Use the diagnostics program t o pe rform a...

Страница 89: ...ST 97 CHARGING SYSTEM TESTS 98 ELECTRIC START CIRCUIT 100 ELECTRIC START TESTS 102 REMOTE CONTROL SWITCH TESTS 104 TILT TRIM RELAY TEST 106 EXHAUST WATER VALVE TEST 106 SYSTEMCHECK CIRCUIT TESTS 107 T...

Страница 90: ...o 84 in lbs 7 to 9 5 N m 60 to 84 in lbs 7 to 9 5 N m 168 to 192 in lbs 19 to 21 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m 24 to 36 in lbs 2 7 to 4 N m N A T IMPORTANT DO NOT lubri...

Страница 91: ...s 2 7 to 4 N m 60 to 84 in lbs 7 to 9 5 N m F 30 to 42 in lbs 3 4 to 4 8 N m 24 to 36 in lbs 2 7 to 4 N m B 15 to 30 ft lbs 20 to 41 N m X J 002249 A Triple Guard Grease B Gasket Sealing Compound C Ad...

Страница 92: ...sition sensor Capacitor 7 8 Ignition coil Main harness ground 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34...

Страница 93: ...1 8 9 18 17 16 15 14 13 12 11 10 13 12 11 10 17 16 15 14 34 33 32 31 30 29 28 27 26 24 25 23 22 21 20 19 18 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B J1 A J2 4 1 2 3 1 2 3 1 2 3 4 5 6 2 3 4 5 6 1 2...

Страница 94: ...875 Pin No Description of Circuit Wire Color 1 vacant 2 Diagnostic connector Red 3 Diagnostic connector White 4 vacant 5 vacant 6 Crankshaft position sensor CPS Yellow 7 Ground CPS digital White 8 Boo...

Страница 95: ...tor ground Black 15 vacant 16 vacant 17 vacant 18 vacant 19 Ignition cylinder 2 75 90 HP Orange Purple 19 Ignition cylinder 2 40 65 HP Orange Green 20 Injector ground Black 21 Injector ground Black 22...

Страница 96: ...f the EMM J1 B conne ctor a nd the main h arness ground Sensor circuit g rounds Check continuity between terminal pin s 26 and 27 of the EMM J1 A co nnector and the appropriate sensor ground connectio...

Страница 97: ...sure sensor resis tance betwee n the yellow a nd white wires The complete circuit can b e tested by measuring between pins 6 and 7 of the EMM J1 A connector The CPS is mount ed to the throttle body ho...

Страница 98: ...ly as the sensor lever is moved Engine Temperature Sensor Test Remove the ele ctrical connector from the engine temperature sensor Use a digital multimeter to measure sensor resis tance Air Temperatur...

Страница 99: ...ed winding conne ct on e meter lead to ground and alternately connect the other meter lead to each stator wire Meter should read no contin uity If meter rea ds continuity replace stator Stator Voltage...

Страница 100: ...be able to run the outboard continuously at approximately 5000 RPM such as in a test tank or on a marine dynamometer The test consist s of mo nitoring the system s response to a partially discharged b...

Страница 101: ...ON che ck battery voltage at battery 12 V Then use Ele ctrical Test Probe Kit P N 342677 and a dig ital multimeter set to read 55 VDC to check voltage on white red wires a t J2 connector of EMM Volta...

Страница 102: ...9 18 FUSE J1 B J1 A J2 4 B A NEG A B 2 1 6 5 4 15 10 2 3 M A S C M B 1 2 3 4 5 6 2 1 7 8 9 9 11 12 13 14 1 1 Marine battery 9 PURPLE wire switched B 2 RED wire POS 10 Engine Management Module EMM 3 BL...

Страница 103: ...g 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 1...

Страница 104: ...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 105: ...arter cable of solenoid terminal Connect negative lead to starter motor terminal Activate st arter motor a nd observe volt age reading No Load Current Draw Test Securely fasten starter in a vise or su...

Страница 106: ...nal S Meter should indicate continuity IMPORTANT The cho ke function or terminal C of the key switch is NOT used Neutral Start Circuit Test Use an ohmmeter or con tinuity light to test the continuity...

Страница 107: ...are incorrect Emergency Stop Switch Test This switc h can be part of the ke y switc h or installed as a separate swit ch Either st yle con nects the M terminals of the key switch The emergency stop s...

Страница 108: ...ivated This supplies ground B connection to TNT motor Refer to Tilt and Trim Module Diagram Test Procedure Make sure r ed and black wire s are connected to 12 V battery power supply Set voltmeter to...

Страница 109: ...on turn the key switch OFF Disconnect the gauge 8 pin connec tor from the back of the gauge and turn the ke y switch ON T est for b attery volt age be tween instrument harne ss termi nal 1 purple wir...

Страница 110: ...f the Sys temCheck connector and pin 17 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits WATER TEMP HOT Circuit Test The tan wire of engine harness and the MW...

Страница 111: ...llow wire of the Sys temCheck connector and pin 24 of the EMM J1 A connector Turn the key switch OFF and reconnect all discon nected circuits TACHOMETER CIRCUIT TESTS Check voltage at the battery Use...

Страница 112: ...lternat or o utput can he lp determine the flywh eel s co ndition Refer to CHARGING SYSTEM TESTS on p 98 Flywheel Removal Remove the recoil st arter asse mbly rope st art models Refer to RECOIL STARTE...

Страница 113: ...nd washers Hold puller body with han dle and tighten pressing scre w u ntil flywheel releases T urn the center scre w a nd lif t the fly wheel off of the crankshaft Stator Service Disconnect stator ha...

Страница 114: ...to TIMING ADJUSTMENTS on p 113 IGNITION COIL SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis connect ignition coil electrical connector Remove two ignition coil reta...

Страница 115: ...ol Mark the flywheel directly across from the pointer Label this mark A Rotate th e flywheel clockwise until the p iston contacts the tool Mark the flywheel directly across from the pointer Label this...

Страница 116: ...gramming IMPORTANT Make sur e the timing pointer is set and the outboard reaches operating tempera ture before making any timing adjustments TPS Calibration Use Evinrude Diagnostics sof tware to te ll...

Страница 117: ...tarter positive cable from post on starter Remove the bat tery neg ative cable from the double ended stud Remove two starter mounting screws and double ended stud Remove the starter Starter Installati...

Страница 118: ...and gently pull on wire Terminal Installation Push terminal through seal until it locks into place Fill conn ector with Electrical Grease to 1 32 in 0 8 mm below ledge or end of plug Push we dge in u...

Страница 119: ...ck Tool P N 77 7077 to release locking tab of connector housing Release locking tab a nd pull on wire to remove fro m connector housing Terminal Installation Align terminal with co nnector housing Pus...

Страница 120: ...eated in con nector housing Close lock mechanism POWER TIMER SERIES The J2 conne ctor of the EMM is an AMP Power Timer Series connector Disconnect Use a screw driver to open latch Pull co nnector from...

Страница 121: ...releas ing the tab and then pushing the terminal and wire through connector housing Insert a thin tool into the connector above the ter minal to release tab Terminal Installation Install wire gasket o...

Страница 122: ...120 ELECTRICAL AND IGNITION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 123: ...PRIMING 136 VENT LINE CLAMP 136 PRIMING THE FUEL SYSTEM 136 FUEL SYSTEM TESTS 137 FUEL SYSTEM PRESSURE TEST 137 PRESSURE REGULATOR TEST 138 VAPOR SEPARATOR VENT CHECK 138 FUEL INJECTOR PRESSURE TEST 1...

Страница 124: ...lbs 2 7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F 002154a Tighten in 3 stages A Triple Guar...

Страница 125: ...n lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease B Gasket Sealing Compound C Ad...

Страница 126: ...7 4 N m 60 84 in lbs 7 9 5 N m 60 84 in lbs 7 9 5 N m H S H 60 84 in lbs 7 9 5 N m F A A 5 ft lbs 7 N m 24 26 Ft lbs 33 35 N m 10 ft lbs 14 N m 1 2 3 F A Triple Guard Grease B Gasket Sealing Compound...

Страница 127: ...20 in lbs 7 14 n m 10 14 in lbs 1 1 1 6 n m 10 14 in lbs 1 1 1 6 n m 60 120 in lbs 7 14 n m 10 18 in lbs 1 1 2 0 n m F F IMPORTANT DO NOT lubricate TPS to throttle shaft surface A Triple Guard Grease...

Страница 128: ...system Fuel lift pump 2 to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel in...

Страница 129: ...to 8 psi Pulse hose from cylinder crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump 20 to 30 psi Fuel supply manifold Fuel injector s Fuel return mani...

Страница 130: ...EMM Fuel injector Fuel circulation pump 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 GREEN BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15...

Страница 131: ...mp 5 6 7 8 Capacitor WHITE RED 55 V BLACK ground wires BLUE 9 10 11 PURPLE GREEN 2 BROWN 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 7 6 5 4 3 2 1 13 12 11 10 9 8 26 24 25 23 22 21 20 19 17 16 15 14 18 J1 B...

Страница 132: ...rage 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...

Страница 133: ...damage the out board Additives IMPORTANT The only fuel additives ap proved for use in Evinrude outboards are 2 4 fuel condi tioner a nd Evinrude Johnson Fue l System Cleaner Use of other fuel additiv...

Страница 134: ...aches the pump interna l pump pressure force s the fuel from the pump through the fuel filter and into the vapor separator Fuel Filter The fuel filter protects the vapor separator and the high pressur...

Страница 135: ...he fuel level in the fu el chamb er Hot fuel causes an increase in vapor pressure This results in a lower fuel level in th e vapor separator The float valve drops and the vent opens This allows fuel v...

Страница 136: ...manifo lds route fue l through the high pressure side of the fuel system Fuel Supply Manifold The fuel supply manifold supplies pressurized fuel to the inlet port of each fuel injector Fuel Return Ma...

Страница 137: ...or s unique fuel flow characteristics Fuel injectors MUST NOT be moved from one cylinder to another EMM program ming is associated with the cylinder location of each injector Installing an injector on...

Страница 138: ...hose Once fue l flow is observed co nnect fuel supply hose from fuel tank to hose fitting on outboa rd Secure hose with Oetiker clamp TILLER MODELS Connect the fuel hose connector to the quick con nec...

Страница 139: ...t on p 140 Higher vacuum readings indicate restrictions in the fuel supply Repair or replace as needed Restricted fuel filter water separator assembly Lift pump not supp lying enou gh fuel to vap or s...

Страница 140: ...us Fuel Injector Pressure Test This te st re quires Inj ector T est Fi tting ki t P N 5005844 Disconnect the battery cables at the battery Loosen oil tank assembly to provide access to fuel manifolds...

Страница 141: ...urple or green Resistance should be the same as o r slightly higher than the injector alone Circulation Pump Resistance Test Disconnect the battery cables at the battery Use a digital multimeter with...

Страница 142: ...lift pump Temporarily install a vacuum gauge T fitting and 8 in 20 3 cm of clear vinyl hose between the fuel supply hose and fuel lift pump inlet Secure con nections with tie straps to prevent fuel o...

Страница 143: ...ti siphon valve fro m f uel tank Install adapter fitt ings and a 36 in 91 4 cm leng th of clear hose to the inlet side tank end of valve Fill clear hose with water to a height of 20 in 500 mm W ater m...

Страница 144: ...into a suit able con tainer Slowly open gauge s venting valve Clean up any spilled fuel with shop towels A WARNING Gasoline is extremely flammable and highly explosive under certain conditions Use ca...

Страница 145: ...ld pressure on bulb and check for fuel leaks Connect battery cables Run outboard and check for fuel leaks Fuel Lift Pump Service The fuel lif t pump is serviceab le as a comple te assembly or can be...

Страница 146: ...lation pump Remo ve clamp and va por vent hose from separator cover Remove clamp s and vap or separator cooling water hoses Remove clamps and fuel return manifold and fuel supply hose from bottom of v...

Страница 147: ...remove the manifold assemblies Installation Check condition of sealing O rings on fuel man i fold fittings Lubricate O rings with outboard lubri cant and insert fuel manifo ld fittings into injector B...

Страница 148: ...ry Relieve fuel system pressure Refer to Relieving Fuel System Pressure on p 142 Remove fuel manifold s Refer to Fuel Manifold Service on p 145 Remove the ignition coil assemblies Disconnect the fuel...

Страница 149: ...r coefficient dat a ca n be downloade d from th e Evinrude Johnson dealer website Ref er to th e instructions provided with the injector kit Upload Coefficient Files to EMM IMPORTANT If using Diagnost...

Страница 150: ...eaned prior to reassembly Injector Cylinder head Adapter Screws Threaded areas Place injector and insulator in the proper cylinder location IMPORTANT Be careful not to pinch any wiring or hoses during...

Страница 151: ...N m Install fuel manifolds Refer to Fuel Manifold Ser vice on p 145 Intake Manifold Service Removal Disconnect vapor separator vent hose main bear ing vent hose air temperature sensor crankshaft posi...

Страница 152: ...an assembly Inspection Inspect the leaf plate a ssemblies for da mage or contamination Leaf plates must not be distorted Leaf valve must not be cracked or chipped Leaf plate stops must not be distorte...

Страница 153: ...rottle body on reed plate and install new screws IMPORTANT If old screws mu st be re used make sure all previous thread locking mate rial is removed and apply Nut Lock to threads Tighten the center sc...

Страница 154: ...152 FUEL SYSTEM NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 155: ...V 161 LOW OIL WARNING 162 NO OIL WARNING 162 CYLINDER AND CRANKCASE 162 OIL RECIRCULATION SYSTEM 163 OIL CONTROL SETTINGS 164 OIL INJECTION RATE 164 BREAK IN OILING 165 OIL SUPPLY PRIMING 165 OILING S...

Страница 156: ...P F F 30 to 42 in lbs 3 5 to 5 N m X 30 tp 42 in lbs 3 5 5 N m 30 to 42 in lbs 3 5 5 N m 008058 A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboa...

Страница 157: ...n lbs 3 5 to 5 N m X 30 to 42 in lbs 3 5 to 5 N m 30 to 42 in lbs 3 5 to 5 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Lock H Outboard Engine Lubrica...

Страница 158: ...M OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 40 65 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1...

Страница 159: ...OILING SYSTEM 157 8 75 90 HP 1 2 3 Oil tank Oil pick up filter Oil injection pump 4 5 6 Oil distribution manifold Crankcase oil inlet port Cylinder oil inlet starboard 1 3 4 2 1 5 4 6 6 5 6 5 008061...

Страница 160: ...158 OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 40 65 HP 75 90 HP 002483a Starboard view Port view 002223 Starboard view Port view...

Страница 161: ...RED Oil injection pump Low oil switch Low oil switch to EMM TAN BLACK Low oil signal to SystemCheck gauge TAN BLACK No oil signal to SystemCheck gauge TAN YELLOW 1 2 3 5 6 7 8 12 13 14 15 16 9 10 11 1...

Страница 162: ...itor warn ing display should show LOW OIL Add enough oil to raise level to at least one quar ter capacity The LOW OIL warning should not display Failure to follow these recommen dations could void th...

Страница 163: ...ls activation of the pump The oil manifold distributes the oil supplied by the pump Electrical Circuit 55 V The oil injector is powered by t he 55 V electrical circuit The EMM controls pump operation...

Страница 164: ...ing re sets after thre e oil p ump pulse cycles when th e out board has been stopped and restarted If outboard has be en run fo r more th an 3 hou rs with NO OIL faults codes 34 117 the EMM Cylinder a...

Страница 165: ...e upper cylin der port Crankcase Main Bearing Recirculation The movement of oil through the main bearings is controlled by int ernal p assages e xternal fittings and hoses and check valves Lower to up...

Страница 166: ...XD100 out board lub ricant and is not re commended for all applications IMPORTANT The XD100 setting is not avail able on all models Use the XD100 setting for Conventional use runabouts cruisers Moder...

Страница 167: ...up Use Evinrude Diagnostics sof tware to m ake sure the break in program has been started on a new outboard Use the diag nostics sof tware to st art break in oiling after a powerhead rebuild The oper...

Страница 168: ...ly This will p roduce false results Refer to Communication on p 63 The EMM controls the pump by providin g ground through pin 23 blue wire of th e J1 B co nnector and pin B blue wire of the oil pump c...

Страница 169: ...eter lead to pin A white red wire of oil injection pu mp electrical connector Observe voltage at pin A Voltage at pin A should be approximately 12 V Set digital multimeter to a scale that re ads 55 V...

Страница 170: ...in serted int o ma nifold Refer to Oil Distribution Hoses on p 169 Oil Injection Fittings Flow Test Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move Remo...

Страница 171: ...a cement Oil Hose P N 778708 to the correct length Insert hose support in manifold end of hose IMPORTANT DO NOT insert distribution hoses into manifold without a hose support Be sure the hose is full...

Страница 172: ...a torq ue of 30 to 42 in lbs 3 5 to 5 N m Install protective sleeves and route oil distribution hoses from the oil distribu tion ma nifold to the crankcase oil delivery fittings Refer to OIL SUP PLY...

Страница 173: ...s from oil pump assembly Twist and pull up on oil pump to remove from tank DO NOT pull up on oil manifold Installation Apply a dro p of out board lubricant to a new oil pump o ring Install o ring on...

Страница 174: ...n front of oil t ank ba ffle to prevent interference with the LOW OIL switch ALL MODELS Install oil pump ret ainer screw s T ighten securely IMPORTANT Turn self tapping screws cou nter clock wise to s...

Страница 175: ...7 THERMOSTAT 177 BLOCK VENTING 178 WATER PRESSURE CONNECTION 178 OPERATION 179 CYLINDER BLOCK CYLINDER HEAD COOLING 179 EMM AND VAPOR SEPARATOR COOLING 179 ENGINE TEMPERATURE CHECK 180 SOFTWARE METHOD...

Страница 176: ...5 6 8 7 10 60 65 HP 004971 Incoming water cool Outgoing water warm hot 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Exhaust housing Cylinder block Pressure relief valve Thermostat Water suppl...

Страница 177: ...01818 1 2 3 4 5 6 7 8 9 10 Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply EMM to vapor separator Overboard...

Страница 178: ...IMPORTANT The water pump hou sing on 2 cylinder models includes a small hole to the rear of the wa ter outlet This hole provides cooling water for the tip of the exhaust passage Be sure to use the co...

Страница 179: ...incre ases Spring tension sets the opening pressure Overheating A restricted or fa ulty valve typically results in HIGH SPEED overheating Overcooling Debris may prevent the valve from closing complet...

Страница 180: ...ck Circulated water flows t hrough the EMM and vapo r separator before exiting through the overboard indicator Water Pressure Connection A fitting and hose for an accessory water pressure gauge can be...

Страница 181: ...down through the cylinder head to a passage in the cyl inder block W ater flows through the block to the exhaust housing and then out of the outboard At higher speeds wate r pressure op ens th e pres...

Страница 182: ...mon itor d isplay ind icates a W ATER TEMP warning refer to WATER TEMP HOT Cir cuit Test on p 108 Software Method Use Evinrude Diagnostics software to read tem perature displays Typical temperatur e...

Страница 183: ...ief Valve Inspection The pressu re re lief va lve should b e closed at IDLE speed W ater should no t flo w past th e plunger and seal Start the outboard and check IDLE operating tem perature If IDLE t...

Страница 184: ...gasket sealing com pound SLOWLY 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 Th ermal compo und may seep past threads...

Страница 185: ...y close attent ion when pe rforming the following additional tasks Coat t hreads of thermost at cover with Gasket Sealing Compound and install new O ring Install and tighten cover to a torque of 120...

Страница 186: ...sassemb ly Pa y close attent ion when pe rforming the following additional tasks Install a new plunger seal squarely over ridge in housing Apply a light coat of Triple Guard grease to a new cover o ri...

Страница 187: ...K CLEANING 200 POWERHEAD INSPECTION 201 POWERHEAD ASSEMBLY 203 CRANKSHAFT ASSEMBLY 203 PISTONS AND CONNECTING RODS 205 CYLINDER HEAD INSTALLATION 207 CRANKSHAFT AND CONNECTING ROD INSTALLATION 208 CRA...

Страница 188: ...cedure Q Apply to crankcase mating flange M Apply to water passages F 60 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m F 60 84 In lbs 7 9 5 N m B J 18 20 ft lbs 24 5 27 N m B 002283 A Triple Guard Grea...

Страница 189: ...iple 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 Y Extreme Pressure Grease H 30 32 Ft...

Страница 190: ...Q Apply to crankcase mating flange M Apply to water passages F 60 84 In lbs 7 9 5 N m H 26 30 Ft lbs 35 41 N m B 60 84 In lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B J 002281 A Triple Guard Grease B Gas...

Страница 191: ...gnment tool H G D H H H H B A D D D 15 20 Ft lbs 20 27 N m 110 130 Ft lbs 149 176 N m A Triple Guard Grease B Gasket Sealing Compound D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grea...

Страница 192: ...ed pistons broken or stuck piston rings scored cylinder walls Return throttle to idle position and reconnect CPS connector Replace sp ark plugs Refer t o S park Plug Indexing on p 42 POWERHEAD REMOVAL...

Страница 193: ...ectronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool an d support weight of powerhead with hoist Loosen the screws holding the exhaust wa ter valve to the exhaust housi...

Страница 194: ...o use only the 1 1 8 in short screws P N 398067 included with the tool to avoid damage to electronic compo nents under the flywheel Fasten appropriate chain hook to eye of tool a nd support weight of...

Страница 195: ...sembly Label connectors for reassembly locations Re fer to EMM SERVICING on p 70 Remove flywheel and stator Refer to FLYWHEEL AND STATOR SERVICING on p 110 Remove ignition coils and fuel injectors Ref...

Страница 196: ...ld ing t he shift shaft 2 cylinder models Slide ent ire shif t linkag e assembly from crank case Remove t he ball g uide and spring of the shif t detent assembly from the crankcase 2 Cylinder Models 1...

Страница 197: ...ANT Do not use a t apered pun ch or any othe r tool th at co uld jam in or damage th e taper bore when removing the pin Remove crankcase flange screws Loosen in stages and remove the main bearin g nut...

Страница 198: ...N 331638 t o loo sen in stages the ro d cap ret aining screws DO NOT remove the screws Use one hand to sup port the piston an d remove the rod cap screws with your other hand Remove each piston and r...

Страница 199: ...sin g Tool P N 326356 to remove the wrist pin bearing Be careful not to lose any of the 28 needle bear ings or the two wrist pin washers Do not mix bear ings with those from another cylinder If any of...

Страница 200: ...using O ring Discard O ring Use a punch to remove the housing seal Discard seal Inspect housing and replace if necessary Remove the O ring from cr ankshaft sleeve a nd inspect it Repla ce the O ring i...

Страница 201: ...be replaced Use e xternal retaining ring pliers to remove the lower bearing retaining ring IMPORTANT If the lower main bearing is removed fro m the cranksha ft it must be dis carded DO NOT reuse it U...

Страница 202: ...al and Gasket Remover to remove all traces o f g askets adhesives and Gel Seal II sealant from th e cylinder block crankcase cylin der head and water cover Carefully rem ove an y carbon ac cumulation...

Страница 203: ...ge must not exceed 0 006 in 0 15 mm per inch of me asurement Re place head if warpage exceeds this dimension Check fuel deflector pins for damage Crankshaft Measure the diameter of each crankp in and...

Страница 204: ...uge to measu re the ring end gap Ring end gap should be 0 011 to 0 023 in 0 28 to 0 58 mm IMPORTANT Ring end g ap increases ap proxi mately 0 003 in 0 076 mm for e ach 0 001 in 0 025 mm incre ase in c...

Страница 205: ...e lower main bearing If the inst aller sticks on the sleeve after installa tion thread Slide Hamme r P N 391008 in to installer and pull it off IMPORTANT Inspect sleeve af ter inst allation Sleeve mus...

Страница 206: ...et Sealing Compound to outer edge of O ring Place lower seal housing on crankshaft Lubricate upper main bearing with outboard lubri cant and install on crankshaft Pack lip of upper oil seal with Moly...

Страница 207: ...the flywheel Apply Needle Bearing Grease to the wrist pin bearings Install the bearings in the small end of the connecting rod Align be arings with Wrist Pin Bearing Tool P N 336660 Place the two wri...

Страница 208: ...all Gel Seal II has been removed from the cyl inder block and crankcase mating flanges If traces of hardened Gel Seal II are left main bearings could be misaligned Refer to CYLIN DER BLOCK CLEANING on...

Страница 209: ...nd install in cylinder head Apply soa py water to water dam and insert into block Apply a 1 16 in 2 mm be ad of RTV Adhesive around each water passage on the block and cyl inder head as shown Install...

Страница 210: ...cylin ders Remove numbered connecting rod caps Gently lower crankshaft into place Align t ab o n lower bearing seal housing with hole in crankcase Align upper oil seal in groove Locate each main bear...

Страница 211: ...dot on rod and that both dot s face fly wheel Tightening rod cap screws without Alignment Fixture P N 396749 or using an incorrect procedure could cause permanent damage to the connecting rod and cra...

Страница 212: ...forcing screw to a torque of 14 to 16 in lbs 1 6 to 1 8 N m IMPORTANT Make sure that frame is squ arely in position and that rod and cap are aligned Loosen both rod cap screws one quarter turn Use Tor...

Страница 213: ...mating fla nge Th e sea ler must no t come within 1 4 in 6 4 mm of bearings IMPORTANT Gel Seal II ha s a shelf life o f at least one year when stored at room temperatu re Test the Gel Seal II or repla...

Страница 214: ...ing Compound to both sides of a new water cover gasket Place gasket and cover on cylinder block Apply Nut Lock to cover screws Position J clamps as shown Tighten all screws to a torque of 60 to 84 in...

Страница 215: ...k to threads Install arm screw and washer and tighten screw to a torque of 120 to 144 in lbs 13 5 to 16 N m Throttle Linkage Installation Apply Nut Lock to threads of throttle lever screw Insert sprin...

Страница 216: ...nition coils Ref er to Fuel Injector Installation on p 147 and IGNITION COIL SERVICING on p 112 IMPORTANT All inj ectors mu st be installed i n their original location Improper injector installation c...

Страница 217: ...assemblies and remove Inspect mounts and replace if necessary IMPORTANT The motor mount washer and screw are serviced as an assembly Do not disas semble Installation Place mount assemblies in position...

Страница 218: ...st housing If necessary rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines Apply Triple Guard g rease to th e t hreads a nd Gasket Sealing Compound to the shan k of th...

Страница 219: ...Nut Lock to threads of exhaust water valve screws and tighten to a torque of 60 to 84 in lb s 7 to 9 5 N m Connect cooling water hoses to exhaust housing Connect the power trim connectors and exhaust...

Страница 220: ...slowly lower powerhead ont o exhaust hou sing Guide into positio n over alignment pin at rear of exhaust housing If necessary rotate flywheel in a clockwise direction to align crankshaft and drive sh...

Страница 221: ...s to a to rque of 60 to 84 in lbs 7 to 9 5 N m Place the shift rod in the shift rod lever Install the retaining pin and washer Tighten pin to a torque of 60 to 84 in lbs 7 to 9 5 N m Check shif t lin...

Страница 222: ...NT on p 323 Tighten adjustment screws to 60 to 84 in lbs 7 to 9 5 N m Final Adjustments After installing a new or rebuilt powerhead perform the following procedures before returning outboard to servic...

Страница 223: ...221 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS 2 Cylinder Port Hose Routings 2 Cylinder Starboard Hose Routings 006490 006491...

Страница 224: ...222 POWERHEAD POWERHEAD VIEWS 2 Cylinder Port Dressed Powerhead 2 Cylinder Starboard Dressed Powerhead 008428 008159...

Страница 225: ...223 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Port Rope Start Models 2 Cylinder Starboard Rope Start Models 008370 008185...

Страница 226: ...224 POWERHEAD POWERHEAD VIEWS 2 Cylinder Front 008160...

Страница 227: ...225 POWERHEAD POWERHEAD VIEWS 10 2 Cylinder Rear 008161...

Страница 228: ...226 POWERHEAD POWERHEAD VIEWS 2 Cylinder Top 008162...

Страница 229: ...POWERHEAD POWERHEAD VIEWS 227 10 2 Cylinder Top Rope Start Models 008186...

Страница 230: ...228 POWERHEAD POWERHEAD VIEWS 3 Cylinder Port Hose Routings 3 Cylinder Starboard Hose Routings 006760 006761...

Страница 231: ...229 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Port Dressed Powerhead 3 Cylinder Starboard Dressed Powerhead 008163 008164...

Страница 232: ...230 POWERHEAD POWERHEAD VIEWS 3 Cylinder Front 008166...

Страница 233: ...231 POWERHEAD POWERHEAD VIEWS 10 3 Cylinder Rear 008167...

Страница 234: ...232 POWERHEAD POWERHEAD VIEWS 3 Cylinder Top 008165...

Страница 235: ...251 STERN BRACKET DISASSEMBLY 251 STERN BRACKET ASSEMBLY 252 STERN BRACKET 75 90 HP POWER TILT 253 STERN BRACKET DISASSEMBLY 253 STERN BRACKET ASSEMBLY 256 STERN BRACKET 40 60 HP MANUAL TILT 258 CLAM...

Страница 236: ...t Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease P Permatex No 2 Q Gel Seal II 004304 60 84 in lbs 7 9 5 N m F 60 84 In lbs 7 9 5 N m B F 16 18 ft...

Страница 237: ...9 5 N m E 60 84 In lbs 7 9 5 N m C C A B B 60 84 In lbs 7 9 5 N m F 150 180 In lbs 17 20 N m A A C B 18 20 Ft lbs 24 5 27 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lub...

Страница 238: ...BRACKET 40 60 HP POWER TILT 144 168 In lbs 16 19 N m F 10 16 In lbs 1 2 N m 45 50 Ft lbs 61 68 N m A A A 45 50 Ft lbs 61 68 N m A Triple Guard Grease B Gasket Sealing Compound 002220 IMPORTANT Use Tri...

Страница 239: ...16 240 In lbs 25 27 N m 40 50 In lbs 4 5 5 5 N m 40 50 In lbs 4 5 5 5 N m 60 84 In lbs 7 9 5 N m 28 30 Ft lbs 38 41 N m 30 50 In lbs 3 3 5 5 N m 10 16 In lbs 1 1 1 8 N m 8 12 In lbs 0 9 1 4 N m A A A...

Страница 240: ...6 19 N m 144 168 In lbs 16 19 N m F 40 45 Ft lbs 54 61 N m See Text A 144 168 In lbs 16 19 N m A Triple Guard Grease B Gasket Sealing Compound C Adhesive 847 D Moly Lube E Red Ultra Lock F Blue Nut Lo...

Страница 241: ...60 84 In lbs 7 9 5 N m A F 60 84 In lbs 7 9 5 N m 40 Ft lbs 54 N m Marine Sealant 18 20 Ft lbs 24 27 N m 18 20 Ft lbs 24 27 N m 18 20 Ft lbs 24 27 N m 60 84 In lbs 7 9 5 N m A 110 130 Ft lbs 149 176 N...

Страница 242: ...2 3 3 4 N m 36 48 In lbs 4 5 4 N m 36 40 Ft lbs 49 54 N m 18 20 Ft lbs 24 5 27 N m 24 36 In lbs 2 7 4 N m A F F F A A D D 18 20 Ft lbs 24 5 27 N m Switched 12V For CANbus To Engine Key Switch Connecto...

Страница 243: ...ollar Remove the cam and collar from the tilt tube Remove the nut from the starboard side Thread the spacer f rom Tilt T ube Service Kit P N 434523 on to the st arboard end of th e tilt tube Remove st...

Страница 244: ...se a wood or leather mallet to t ap the tilt tube into position Make sure the lock tab is in correct position Install the starboard locknut Tighten starboard tilt tube nut to a torque of 45 to 50 ft l...

Страница 245: ...e Re fer to Ge arcase GEARCASE REMOVAL AND INSTALLATION on p 296 Remove th e powerhea d Refer to Powerhe ad POWERHEAD REMOVAL on p 190 Remove the three lower mount cover screws Separate lower mount co...

Страница 246: ...valve and bracket in position Apply Nut Lock to screws install and tighten 60 to 84 in lbs 7 to 9 5 N m Exhaust Relief Muffler Remove exhaust relief muffler cover to inspect fil ter element Clean or r...

Страница 247: ...Place lo wer thrust washer on th e stee ring shaf t and place the lower front mount into position Install lower side mount covers Install and tighten the screws in stages to a torque of 16 to 18 ft l...

Страница 248: ...NSTALLATION on p 296 Remove the p owerhead Refer to POWER HEAD REMOVAL on p 190 Remove and discard four lower mount screws Remove the exhaust housing Lower Mount Service Remove lower mount covers and...

Страница 249: ...crews and tighten to a torque of 150 to 180 in lbs 17 to 20 N m Exhaust Housing Installation Bring the exhaust housing into position with th e stern bracket Install four new lower mount screws with lo...

Страница 250: ...r exhaust housing to the adapter housing Remove the wa ter tube from the inne r exhaust housing Discard water tube grommet Remove the se al from the bott om flan ge of the inner exhaust housing Remove...

Страница 251: ...mum allowable run out is 0 009 in 0 228 mm If you do not have access to a dial indicator and surface plate seek the services of a machine shop DO NOT attempt to straighten a distorted housing replace...

Страница 252: ...Adhesive 847 to the bottom flange of the inner exhaust hou sing Install a new seal Apply Triple Guard grease to outer seal surface Clean an d d egrease t he a dapter hou sing a nd outer exhaust ho usi...

Страница 253: ...0 to 84 in lbs 7 to 9 5 N m STERN BRACKET 40 60 HP Power Tilt Stern Bracket Disassembly Remove th e bumpers from th e uppe r mou nt retaining screws Remove the screws upp er mount and ground lead from...

Страница 254: ...d to two thirds its origi nal size Stern Bracket Assembly Assemble the tie bar to the stern brackets Place the ground lead and starwasher between the port stern bracket and tie bar Lubricate the swive...

Страница 255: ...dhesive 847 to head s of the upper mount screws Place the bumpers on the upper mount screws STERN BRACKET 75 90 HP Power Tilt Stern Bracket Disassembly Before servicing the stern bracket Remove gearca...

Страница 256: ...scard Remove the upper and lower steering shaft bushings Remove the tilt tube Refer to TILT TUBE 75 90 HP on p 241 Remove the two tilt tube washers Remove the anode Remove the swivel bracket Inspect a...

Страница 257: ...etainer Remove the trail lock arm and b ushings from the swivel bracket Remove the two trim rod rollers from the swivel bracket Remove the tilt support and bushing from the swivel bracket and inspect...

Страница 258: ...ng in the swivel bracket T ighten bushing to a torque of 28 to 30 f t lbs 38 to 41 N m Install the two trim rod rollers on the swivel bracket Tighten to a torque of 216 to 240 in lbs 25 to 27 N m Inst...

Страница 259: ...w seals in the swivel bracket Both seal lips face out Coat the outside surfaces of seals with Gasket Sealing Compound Coat the bushing s and sea l lip s with Triple Guard grease Coat tilt tu be bushin...

Страница 260: ...d stern brackets through the two forward grease fit tings Install the e xhaust housing Refe r to Exhaust Housing Installation on p 247 STERN BRACKET 40 60 HP Manual Tilt Clamp Screw Service Inspect cl...

Страница 261: ...teering friction pin When the pin is flush with the inside surface of the ca sting remove the steering friction thrust ring Tighten the ste ering friction screw until the ste er ing friction pin can b...

Страница 262: ...p link screws and nuts from the stern brackets Remove the two stern bracket flange screws and separate the stern bracket s from the swive l bracket Place the tilt ru n lever in the RUN positio n Loose...

Страница 263: ...e l bracket Insert the reverse lock pins in the swivel bracket and p art wa y throu gh the reverse lock springs Place the reverse lock assembly between the springs Push the pins through the springs an...

Страница 264: ...tilt tube nuts loosely Starboard stern bracket Thrust washer Bushing Swivel bracket Bushing Thrust washer Port stern bracket Apply Nut Lock to threads of the two flange screws Inst all the two screws...

Страница 265: ...rin g friction bu shing in the swivel bracket with groove in line with the setscrews Apply Triple Guard grease to the steering frictio n pin Install the pin in the swivel bracket flush with inside sur...

Страница 266: ...rd side and the steering arm Install and tighten the mount retaining scr ews to a torque of 24 to 26 f t lb s 32 5 to 35 N m Place the mount screw bumpers on the up per mount screws Tilt Assist Cylind...

Страница 267: ...isassembly Install new cotter p ins in upper pivot pin Install a new set screw in st arboard stern bra cket lower pivot pin access hole and tighten securely STERN BRACKET 90 HP Manual Tilt Stern Brack...

Страница 268: ...Remove starboard reverse lock link Remove port reverse lock link Loosen bellcrank set screw remove bellcrank and handle link rod 1 Pins 2 Locking lever 006699 1 Starboard reverse lock link 006696 1 2...

Страница 269: ...e trail lock lever and reverse lock pivot shaft from swivel bracket Remove port trail lock lever and trail lock shaft as an assembly Remove port and starboard trail lock shaf t bush ings from swivel b...

Страница 270: ...l in swivel bracket from port side DO NOT tighten screw at this time Refer to Reverse Lock and Trail Lock Refer ence on p 268 for correct orientation of re verse lock and trail lock components Assembl...

Страница 271: ...shaft spacer on reverse lock pivot shaft then install retaining ring Install the handle link rod to reverse lock lever and bellcrank Install b ellcrank on reverse lock pivot shaft Tighten the setscre...

Страница 272: ...and screw Tighten screw to a torqu e of 60 to 84 in lbs 7 to 9 5 N m Install reverse lock release collar a nd tighten set screw Install locking lever pins and new cotter pins Install reverse l ock sp...

Страница 273: ...c trical harness Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove throttle cable and wires from grommet in lower engine cover Remove the scre w attach...

Страница 274: ...to depress the grip de tents Tighten screw and remove the grip by pulling grip Remove the helix halves rollers and guides Pull the throttle pin out of the cable Remove stop switch cover screws and co...

Страница 275: ...andle by driving the outer handle off with a mallet and a punch Inner handle is bonded to the outer handle After removing chip away remnants of inner handle Remove throttle cable seal from the inner h...

Страница 276: ...retainer clip Install the throttle control plate on outer handle Push the throttle cable pin throug h the end of the throttle cable Lubricate e nd of t he pin guides rollers h elix grooves an d inner...

Страница 277: ...he bushin gs into the steering bracket Attach the steering handle to the bracket Tighten screw to a torqu e of 36 t o 40 f t lbs 49 to 54 N m Route t hrottle cab le and electrical ha rness through gro...

Страница 278: ...hrottle cam is against idle stop when anchor screw aligns with throttle bod y boss Th en rotate a nchor fo ur turns to ward the end of the cable Install washer cable a nchor and cable anchor screw on...

Страница 279: ...clip from shift cable Remove the electrical cover Disconnect the electrical harness coming from the tiller handle Remove shift and throttle cables and wire harness from grommet in lower engine cover...

Страница 280: ...Loosen th rottle frict ion control so the re is no restriction on grip IMPORTANT Do not back screw out com pletely Nut is under spring tension Remove seven screws and bottom cover of tiller handle Rem...

Страница 281: ...d guides Pull the throttle pin out of the cable Remove the throttle friction control Remove the thro ttle cable ret aining clip Pry the cable trunnion ou t of th e st eering hand le an d remove cable...

Страница 282: ...shift cable retainer from shift cable trun nion Remove cotter pin from shift handle pin Remove shift cable Remove shift handle screw and washer Remove shift handle bushing and washer Remove shift hand...

Страница 283: ...ft pin into shift handle Tighten to a torque of 18 to 22 ft lbs 24 5 to 29 N m Coat de tent ball spring a nd guide with Triple Guard grease and install into shif t handle Place one washer on shift han...

Страница 284: ...of tab must be flush with top of flange Apply Nut Lock on the screw threads install the washer and screw IMPORTANT Turn se lf tapping screw counter clock wise until th reads of screw en gage threads...

Страница 285: ...er steering handle Wire guide sho uld slide easily into place If any binding is felt inspect trim switch wirin g for twist ing If wire guide is forced into place it WILL dam age trim switch wiring Mak...

Страница 286: ...Lube Place the guides over the roller p in and into t he slots of the inner handle Place the rollers on t he ends of the roller pin Assemble the helix halves on the handle and slide the grip over the...

Страница 287: ...ioned straight or angled 15 port or starboard by moving the adjust ment plate Place tiller bracket on steering arm from the bot tom Thread steering arm screws with washers into steering arm and tighte...

Страница 288: ...the lower anchor pocket Adjust the trunnion nut so the cas ing fits onto the shift lever pin Secure shift cable to the shift lever pin For proper installation review the following steps Place washer o...

Страница 289: ...Adjust cable anchor so throttle cam is against idle stop when anchor screw aligns with throttle bod y boss Th en rotate a nchor fo ur turns to ward the end of the cable Install washer cable an chor a...

Страница 290: ...288 MIDSECTION NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 291: ...SHAFT INSTALLATION 314 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION 316 FINAL ASSEMBLY AND ADJUSTMENT 317 GEARCASE SERVICE 75 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION 318 WATER PUMP SER...

Страница 292: ...In lbs 13 5 16 5 N m A B C 60 84 In lbs 7 9 5 N m D B C B A B 96 120 In lbs 11 13 5 N m 60 84 In lbs 7 9 5 N m B A 18 20 Ft lbs 24 5 27 N m A 40 45 Ft lbs 54 60 N m 35 40 Ft lbs 47 54 N m B 48 80 In...

Страница 293: ...0 84 In lbs 7 9 5 N m 26 28 Ft lbs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61...

Страница 294: ...bs 35 38 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 60 84 In lbs 7 9 5 N m 18 20 Ft Lbs 24 27 N m F 18 20 Ft lbs 24 27 N m 26 28 Ft lbs 35 38 N m 45 50 Ft lbs 61 68 N m A A C A A J 14 18 In lbs...

Страница 295: ...t full throttle Refer to SERVICE SPECIFICATIONS on p 10 If the propeller blades have too much pitch the engine will operate below its normal range at full throttle Power will be lost and powerhead dam...

Страница 296: ...r Propeller Hardware Installation IMPORTANT Depending on propeller style dif ferent thrust bushings sp acers and cotter pin keepers are used See the Evinrude Johnson Genuine Parts and Accessories Cata...

Страница 297: ...source of leak If the gauge does not in dicate leakage increase pressure to 16 to 18 psi 110 to 124 kPa Check for leaks Make necessary repairs and repeat test Install Gearca se V acuum T ester P N 50...

Страница 298: ...in screw and washer and remove 7 16 14 x 3 5 in screw and washer Remove the four 3 8 16 x 1 5 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being car...

Страница 299: ...rectly Shift rod does not turn and is positio ned prop erly in the shift rod lever below the crankcase Apply Triple Guard g rease to th reads o f th e gearcase retaining screws Tighten the screws to a...

Страница 300: ...ing screws Slide the wate r pump of f the driveshaft Remove the impeller key impeller plate and gasket Dis card the gasket Remove all the parts from the housing Inspection Check impeller for o verheat...

Страница 301: ...on install the impeller into the linerwith the slot for the impeller key facing out Apply a thin bead of Adhesive 847 in the seal groove and install the special shaped O ring seal Apply Gasket Sealing...

Страница 302: ...oove of the impeller housing grommet Install the grommet on the impeller housing Before installing gearcase shift rod adjustment MUST be checked Refer to SHIFT ROD ADJUSTMENT on p 300 SHIFT ROD ADJUST...

Страница 303: ...d amaged threads Shift Rod Check for misadjusted bent or binding rod A misadjusted shift rod height can cause shift difficulty loss o f boat an d outboard control and gearcase damage Hydrostatic Seal...

Страница 304: ...2 from Universal Puller Set P N 378103 Remove the two ret aining ring s using Ret aining Ring Pliers P N 331045 Remove the retainer plate from the gearcase COA3571 9437 A CAUTION Retaining rings are u...

Страница 305: ...e pinion nu t from the bottom of the driveshaft Pad han dle of the wrench to prevent damage to gearcase Remove th e four driveshaf t bearing ho using screws Remove th e drivesha ft fro m the gearcase...

Страница 306: ...inserte d be tween the puller and the gearcase unt il the driveshaf t pops loose from the pinion Shift Housing Gear and Propeller Shaft Removal Push d own o n t he shift rod This will move t he detent...

Страница 307: ...g Water Intake Screen Inspect the water int ake screen for blockage an d remove it by depressing the tabs on either side of the screen and pushing upward Pinion Bearing Installation Install the water...

Страница 308: ...the screw and tighten to a torque of 48 to 80 in lbs 5 5 to 9 0 N m Shift Housing Disassembly IMPORTANT The shif t h ousing and forward gear bea ring are serviced as an asse mbly If either are worn o...

Страница 309: ...re beginning assemb ly pro cedures Replace any damaged parts Lightly coat the detent ball and spring with Needle Bearing grease Insert the spring in the housing then the ball Insert shifter detent at...

Страница 310: ...ng grease Place the bearing on the back of the gear Set the washer on top of the thrust bear ing Insert the ge ar bearing and washer into t he bearing housing Bearing and washer must be installed in t...

Страница 311: ...ller Bridge P N 432127 and Large Puller Jaws P N 432129 Discard the seal Remove and discard the O ring from the bearing housing Clean the bearing ho using in solven t to re move sealer from the seal b...

Страница 312: ...dge and tighten jaws secu rely behind the bearing Remove fro nt bearing using Puller Brid ge P N 432127 and Bearing Puller P N 432130 Place the puller plate on top of the housing to sup port the b rid...

Страница 313: ...d of the bearing should be visible Bearing Installation Tool P N 326562 Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool...

Страница 314: ...aring housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 40 to 45 ft lbs 54 to 60 N m IMPORTANT The origina l pinion nut may be used for shimming bu...

Страница 315: ...required shims between the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driveshaft Seal Protector P N 312403 Check cl...

Страница 316: ...cator pin into the pin hole in the gearcase Apply Gasket Sealing Compound to the threads of the shift rod cover screws Tighten the screws to a torque of 60 to 84 in lbs 7 to 9 5 N m Place the cover se...

Страница 317: ...aft into the gearcase and thro ugh the pin ion gear Using Drivesha ft Sea l Protector P N 312403 slide the driveshaf t b earing ho using o nto the driveshaft and into position in the gearcase Align th...

Страница 318: ...g a nd la rger thru st washer on hu b of reverse gear Slide the gear assembly onto the propeller shaft until it engages the pinion gear Slide the bearing housing ret ainer plate into posi tion over th...

Страница 319: ...e top Place the housing into gearcase and tap the housing with a soft face mallet to seat the O ring Apply Gasket Sealing Compound t o th e threads and seals of the four prope ller housing retaining...

Страница 320: ...washer Remove the four 3 8 16 x 1 75 in gearcase retain ing screws and washers Remove the gearcase assembly from the exhaust housing being careful not to bend the shift rod A WARNING To prevent accide...

Страница 321: ...g installs correctly Shift rod does not turn and is positio ned prop erly in the shift rod lever below the crankcase IMPORTANT New gearcase screws are treated with a thread locking material Apply Trip...

Страница 322: ...n WATER PUMP SERVICE Disassembly Rotate the driveshaf t counterclockwise to unlock the impeller key Remove th e four impeller hous ing screws Slide the wate r pump of f the driveshaft Remove the impel...

Страница 323: ...g with a square index tab Make sure vent hole in impeller cup is open Install th e water tub e grommet wit h the insid e taper facing up Apply Triple Guard grease to screw threads and install the imp...

Страница 324: ...eller and slide water pump down over key Be sure impeller key does not fall out of position Make sure the impeller engages the impeller key Serious powerhead damage will result if impeller key is not...

Страница 325: ...ase in NEUTRAL rot ate the shif t rod up or d own as necessary fo r correct adjust ment Once correct height is achieved rotate rod one half turn or less to direct offset forward IMPORTANT The NEUTRAL...

Страница 326: ...d amaged threads Shift Rod Check fo r misad justed bent or binding rod A misadju sted shift rod height can cause shift difficulty loss o f boat an d outboard control and gearcase damage Hydrostatic S...

Страница 327: ...wo 5 16 18 nuts obtain locally Assemble components and pull the bearing hous ing from the gearcase Remove the thrust washer thrust bearing and reverse gear from gearcase Pinion Gear and Driveshaft Rem...

Страница 328: ...867 to break the lock Install the too ls as shown by clamp ing them around the driveshaft Alternately tighten the two vertical screws against the backing plate inserted between th e p uller an d th e...

Страница 329: ...emble the driveshaft install new driveshaft retainer into the groove of the upper driveshaft Install the upp er driveshaf t into the lower drive shaft aligning the holes in the d riveshaft retainer an...

Страница 330: ...ter intake screens Replace if damaged GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and deb ris prior to inspe ction Inspect pinion bearing an d forward thrust surfa...

Страница 331: ...stallation Assemble the following componen ts of Pinio n Bearing Remover and Installer P N 5005927 as shown S Type Gearcases 1 Pinion bearing retaining screw 2 Water screen pocket 3 Seal DSC02370 DRC7...

Страница 332: ...be aring into the gearcase Drive the bearing into the gearcase until the washer on the tool contacts the spacer Remove the tool Place a new O ring on the pinion bearing retaining screw Appl y G asket...

Страница 333: ...h a shop cloth to cat ch ball and spring Rotate the shifter detent 90 in either direction then pull the detent out of the housing Remove the detent ball and spring Remove needle bearings from bearing...

Страница 334: ...ing t he ba ll and spring with a suitable tool Once the shifter detent is past the ball remove th e too l an d po sition detent to engage NEUTRAL position Thoroughly grease 25 needle bearings wit h Ne...

Страница 335: ...d in the correct order Align holes in the clutch dog with slot in the pro peller shaft Install the clutch dog on the shaft with PROP END facing rear of the shaft The clutch dog is not symmetrical If i...

Страница 336: ...al bore and the O ring groove Seal Installation Lightly apply Gasket Sealing Compound to a new O ring Install the O ring in top groove of the bear ing housing Do not allow sealant in oil passage Do no...

Страница 337: ...432127 and Large Puller Jaws P N 432129 Place the puller plate on top of the housing to sup port the bridge and tighten jaws secu rely behind the bearing Inspect th e b earing h ousing anode Replace a...

Страница 338: ...N 339750 O Type gearcases Rear Seal Installation Apply Gasket Sealing Compound to metal casings of the seals before installing Use Seal Installation Tool to install new seals back to back in bearing...

Страница 339: ...g the bearing housing Lightly coat the threads of the pinion nut with out board lubricant and tighten to a torque of 100 to 110 ft lbs 136 to 149 N m IMPORTANT The origina l pinion nut may be used for...

Страница 340: ...he drivesha ft from the tool and add the required shims b etween the bearing housing and the thrust washer IMPORTANT Use extreme care when removing bearing housing to avoid damaging the seals Use Driv...

Страница 341: ...it through the cover to avoid damaging the O ring Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket Place the gasket on the gearcase Thread the shift rod into t he shifter d...

Страница 342: ...aring IMPORTANT The inside t aper of the p inion gear and the driveshaft taper MUST be com pletely free of grease Clean the t apers with Cleaning Solvent Use a shop towel free of grease and lint Place...

Страница 343: ...he gear assembly onto the propeller shaft until it engages the pinion gear Lightly apply Gasket Sealing Compound to a new bearing housing O ring Install O ring in groove in the housing Install hou sin...

Страница 344: ...firm that torque on the wedge screw is 15 to 20 in lbs 1 7 to 2 3 N m Final Assembly and Adjustment To complete gearcase assembly refer to GEARCASE LEAK TEST on p 295 WATER PUMP SERVICE on p 320 SHIFT...

Страница 345: ...GENERAL 348 RESERVOIR FLUID 348 MANUAL RELEASE VALVE 348 STERN BRACKETS 348 TROUBLESHOOTING 348 ELECTRICAL CIRCUIT TESTS 349 RELAY TESTING 349 TRIM AND TILT MOTOR CURRENT DRAW TESTS 349 TRIM AND TILT...

Страница 346: ...TRIM AND TILT SERVICE CHART SERVICE CHART 40 60 HP MODELS 007632 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 A Triple Guard Grease W Biodegradable TNT Fl...

Страница 347: ...TRIM AND TILT SERVICE CHART 345 13 75 90 HP MODELS 005002 A Triple Guard Grease W Biodegradable TNT Fluid 30 to 50 In lbs 4 to 5 6 N m A A W 45 to 55 In lbs 5 to 6 N m 45 to 55 In lbs 5 to 6 N m...

Страница 348: ...outboard through the tilt range IMPORTANT When in tilt range ma ke sure water is available to gearcase water pickups Manual Adjustment The outboard can be ma nually raised or lo wered through its enti...

Страница 349: ...c system from damage Tilt the outboard up fully engage the bracket then tilt the outboard down until the bracket is firmly in position For mooring or storing the boat with the outboard tilted a tilt s...

Страница 350: ...k the manual release valve with a torq ue 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...

Страница 351: ...ric motor s cu rrent draw and trim tilt unit operating speed aids evalu ation of the electric motor a nd certain mechanical components Use a battery rated at 360 CCA 50 Ah or higher that is in good co...

Страница 352: ...Ah or higher that is in good condition and fully charged to per form this test Connect a 0 to 25 A ammeter in series with the battery positive terminal ammete r red le ad toward terminal Attach or ho...

Страница 353: ...rim UP position If results are different replace the trim gauge If results agree refer to Trim Sender Test Trim Sender Test IMPORTANT To avoid immedia te me ter dam age never apply an ohmmeter to an e...

Страница 354: ...hile the tab is depressed pull on the wire from the rear of the connector to release it from the connector Separate the trim tilt unit wires in the braided tube to p ermit remo val t hrough the hole i...

Страница 355: ...ugh to remove the ground lead from the pump motor mounting screw 75 90 HP MODELS Remove the externa l snap rings from the up per pin Use a punch to remove the upper pin Retract the tilt cylinder rod R...

Страница 356: ...the bushings Install the ground lead Place trim tilt unit into position Lubricate th e an gle adjustment ro d with Triple Guard grease Install the rod Tighten the locknuts to a torque of 20 to 25 ft...

Страница 357: ...ilt cylinder rod to match with ho les in swivel bracket Apply Triple Guard grease to upper pin and install the pin Install e xternal snap rings o nto upp er pin with sharp edge facing out ALL MODELS P...

Страница 358: ...vidual com ponents may cause fla kes of paint to e nter the hydraulic p assages du ring a ssembly T ape the trim tilt piston rods before painting IMPORTANT Before re moving manual r elease valve relie...

Страница 359: ...pect the manual release valve Discard the O rings on the housing Remove t he fou r larg e mo tor flange retaining screws Remove the motor and discard O rin g screws and washers Remove drive coupler fr...

Страница 360: ...the manifold and install four new screws and lock washers Tighten the screws 35 to 50 in lbs 4 to 5 6 N m Oil O rings and install them on the manual release valve Oil and inst all th e ma nual release...

Страница 361: ...T Fluid Install the fill plug Run the motor then recheck oil level Cycle the unit several times and check the oil level when the cylinder is fully e xtended Oil should be level with bottom of fill por...

Страница 362: ...360 TRIM AND TILT NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 363: ...1 14 MANUAL STARTER TABLE OF CONTENTS SERVICE CHART 362 RECOIL STARTER REMOVAL 363 RECOIL STARTER DISASSEMBLY 363 RECOIL STARTER CLEANING AND INSPECTION 365 RECOIL STARTER ASSEMBLY 365 RECOIL STARTER...

Страница 364: ...ERVICE CHART SERVICE CHART E Red Ultra Lock F Blue Nut Lock V Lubriplate 777 96 to 120 in lbs 11 to 13 5 N m V V F 60 to 84 in lbs 7 to 9 5 N m 120 to 144 in lbs 13 5 to 16 N m F 120 to 144 in lbs 13...

Страница 365: ...handle anchor and remove the han dle Release the slip knot and ease the rope back in until the rewind spring is fully unwound If nec essary remove the starter handle bracket from the starter housing R...

Страница 366: ...g and remove ring from the starter Remove the friction plates and friction plate spring washer Hold the pulley in the starter housing while turning the starter over legs do wn Hold fingers clear of th...

Страница 367: ...length of 1 2 in 12 mm Examine the pulley and the starter housing Look for shar p edge s an d rough surf aces that cou ld fray the starter rope File and polish to remove Examine the st arter and star...

Страница 368: ...e starter winder base Remove the crank retainer screw and the cran k and pin asse mbly from the st arter win der base Remove the starter winder base from the vise Install the rewind spring into the st...

Страница 369: ...oss of t he st arter pawl Pla ce spring washer on the boss of the starter pawl Place the starter pawl in the pulley Place th e st arter hou sing sp ring in t he st arter housing Install the starter pa...

Страница 370: ...e a knot in one end of the starter rope With the starter housing upside down on a bench wind the pulley counterclockwise until the rewind spring is tight Back off the rewind spring until the rope cavi...

Страница 371: ...LLATION Apply Nut Lock to the thre ads of st arter ratch et screws Install washers and ratchet on flywheel Tighten screws to a torque of 120 to 14 4 in lbs 13 5 to 16 N m Place t he st arter a ssembly...

Страница 372: ...370 MANUAL STARTER NOTES NOTES Technician s Notes Related Documents Bulletins Instruction Sheets Other...

Страница 373: ...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 374: ...S 2...

Страница 375: ...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 recommendati...

Страница 376: ...RWARD or REVERSE propeller still powered turning unknown to operator or outboard will START in gear and boat will move suddenly boat will move opposite to direction wanted by operator How can loss of...

Страница 377: ...OP propeller What could happen If Operat or ca nnot slow do wn the ou tboard o r shift into NEUTRAL gea r stop prope ller Ope rator could panic and lose control of boat How can loss of speed control b...

Страница 378: ...l and ends here at the trim tab on the outboard What could happen If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams operato...

Страница 379: ...weaken Tilt outboard into boat then turn it transom mounted steerer stop to stop Be aware that raising or lowering outboard on transom ca n change a set up which was OK earlier If moved up or down eve...

Страница 380: ...akage must be eliminated Stray electric sparks must be avoided What could happen When not boating fuel leaking in car trunk or van or place where portable tank is stored base ment or cottage could be...

Страница 381: ...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 382: ...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 383: ...t s transom Outboard may S L I D E on transom Boat may turnand be hard to steer Outboard may T I L T on transom Boat may turn and be hard to steer If outboard hits something solid and does not stay on...

Страница 384: ...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 385: ...suddenly Boat may SINK At high speeds suddentrimming in too far may dive boat under water or spin it around Read understand and follow manufacturer s instructions Follow warnings marked closely Test y...

Страница 386: ...and ends here in the ignition system on the powerhead What is most important The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key...

Страница 387: ...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 388: ...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 389: ...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 390: ...remember loose clothing open shirt sleeves neckties hair jewelry rings watches bracelets hands and arms can be caught by the spinning flywheel Handling high voltage parts like spark plugs and coils c...

Страница 391: ...haust fumes from the engine o r other boats provide proper ventilation shut off the engine when not needed and be aware of the risk of backdrafting and conditions that create CO accu mulation In hig h...

Страница 392: ...t Do not allow anyone near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people i...

Страница 393: ...r leads 3 Always charge in a well ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Bat...

Страница 394: ...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 395: ...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 396: ...al as a whole and this Safety section in par ticular contain essential information to help prevent personal injury and damage to equipment and your customers 6 Have you received training related to co...

Страница 397: ...cting Rod 209 Crankshaft 198 199 203 204 Driveshaft 309 334 Pinion Gear 305 329 Propeller Shaft 310 335 336 Wrist Pin 197 205 Break In EMM Programming 165 220 Gearcase 298 317 320 342 Oiling 165 Proce...

Страница 398: ...ming 68 146 Fuel Injector Tests 84 Fuel Pump Test 84 I Command settings 23 Idle Speed Control 68 Oil Injector Test 167 Oil Priming 170 Oiling Rate 66 164 Reports 69 Sensor Monitoring 95 Service Codes...

Страница 399: ...l Lift Pump 132 139 141 143 Fuel Manifolds 145 Fuel Requirements 131 Hose Routing 126 Injector Servicing 68 Intake Manifold 149 Minimum Octane 10 12 131 Pressure Tests 137 Priming 136 Relieving Pressu...

Страница 400: ...cing 215 243 245 251 253 258 Muffler Installation 219 Removal 192 Servicing 244 N New Engines Outboard Rigging Procedure 17 O Oetiker Clamp Servicing 25 Oil Injector Electrical Circuit 55 V 161 Electr...

Страница 401: ...le Adjustment 19 Rigging Outboard 17 Rope Replacement 368 RPM Limit 11 13 59 60 S S A F E Description 62 Low Oil 58 No Oil 162 Temperature 56 57 Safety 1 Sensor Tests 95 Sensors Air Temperature Sensor...

Страница 402: ...Tilt 265 Removal 254 SystemCheck Circuits 107 LOW OIL Warning Signal 162 NO OIL Warning Signal 162 Outboard connections 20 Tests 107 108 109 Winterization Procedure 45 T Tachometer Pulse Setting 33 Te...

Страница 403: ...ting Kit P N 5005844 138 Key Switch Assembly P N 176408 64 Large Puller Jaws P N 432129 199 309 310 334 335 Lifting Fixture P N 396748 191 192 216 218 Lower Driveshaft Puller P N 342681 326 Oetiker Pi...

Страница 404: ...ion 354 Lubrication 41 Removal 352 Reservoir Fluid 11 348 Troubleshooting 348 349 Trim Gauge Test 351 Trim Sender Adjustment 29 30 Test 351 Trim Tab Adjustment 31 Installation 297 Removal 296 318 Trou...

Страница 405: ...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 406: ...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 407: ...eck 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 C...

Страница 408: ...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 409: ...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 410: ...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 411: ...tube 4 Cylinder block 5 Pressure valve 6 Thermostat 7 Water supply to EMM 8 Water supply EMM to vapor separator 9 Overboard indicator outgoing water from vapor separator 10 Water valve Hose Routing an...

Страница 412: ...hot Incoming water cool 6 4 8 9 10 1 Intake water screens 2 Water pump 3 Water tube 4 Adaptor housing 5 Cylinder block 6 Pressure valve 7 Thermostat 8 Water supply to EMM 9 Water supply EMM to vapor...

Страница 413: ...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 414: ...1 I Command Keyswitch TNT Wiring Harness Ground B A Trim down B Trim up C Trim sender 5 Battery 12V 1 Stop circuit 2 Start solenoid 3 Ground B 6 Choke 4 Switched B 12V A B C Switched B 12V 47 ohm 5 wa...

Страница 415: ...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 416: ......

Страница 417: ...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 418: ...tion Mode Stop circuit OK FLASHING LED URGENT overheat or no oil condition Engine will not start Correct problem and clear codes Sensors 5V Circuits OK FLASHING LED URGENT conditon Code 57 Engine will...

Страница 419: ...ition Sensor 3 Neutral Switch 4 Stator 5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Con...

Страница 420: ......

Страница 421: ...5 Crankshaft Position Sensor 6 Trim Tilt Connector 7 SystemCheck Connector 8 Key Switch Connector 9 High Pressure Fuel Pump 10 CANbus Connector 11 Diagnostic Connector 12 Temperature Sensor 13 Igniti...

Страница 422: ......

Страница 423: ...ure ABOVE range 3 3 LED 4 ON Running WATER TEMP HOT 8 seconds EMM Temperature 176 F 80 C Engine limited to 1200 RPM See Code 29 26 12 V circuit BELOW range 3 LED 1 ON Running LOW BATTERY 5 minutes Bat...

Страница 424: ...ltage 4 75 V Check sensors and related wiring Check for pinched or chafed wiring 81 Ignition timing circuit 1 OPEN LED 2 ON Running 10 instances EMM counts failed ignition events Check wiring Test wit...

Страница 425: ......

Страница 426: ......

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