Evinrude E-TEC E115DPLSCR Service Manual
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Evinrude E-TEC E115DPLSCR Service Manual

E-tec series
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Summary of Contents for Evinrude E-TEC E115DPLSCR

  • Page 3 † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: ® Nut Lock™ Evinrude ® Screw Lock™ Johnson ®...

  • Page 4: Table Of Contents

    ABLE ONTENTS SECTION ........PAGE INTRODUCTION .
  • Page 5 INTRODUCTION INTRODUCTION CONTENTS ABBREVIATIONS USED IN THIS MANUAL ..........6 .

  • Page 6: Safety

    CAUTION When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with Indicates a potentially hazardous situation equivalent characteristics, including type, strength which, if not avoided, MAY result in minor and material.
  • Page 7 DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. 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.

  • Page 8: Abbreviations Used In This Manual

    INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft. lbs. foot pounds barometric pressure sensor horsepower...

  • Page 9: Engine Emissions Information

    Beginning with 1999 model year outboards, man- EPA Emission Regulations ufacturers of marine outboards must determine All new 1999 and more recent Evinrude/Johnson the exhaust emission levels for each outboard outboards are certified to the EPA as conforming horsepower family and certify these outboards...

  • Page 10: Model Designation

    AP = Advanced Propulsion N = 2 B = Blue Paint T = 3 C = Counter Rotation R = 4 D = Evinrude E-TEC™ O = 5 E = Electric Start w/Remote Steering D = 6 F = Direct-Injection U = 7...

  • Page 11: Models Covered In This Manual

    Gearcase E200DPLSCA 20” “O” THIS MANUAL E200DSLSCA 20” “O” This manual covers service information on all E200DPXSCA 25” “M” 105.4 and 158.2 cubic inch, 60° V Evinrude models. ® E-TEC E200DPXSCF 25” “M2” Model Number Shaft Color Gearcase E200DCXSCA 25”...

  • Page 12: Service Specifications

    (may vary depending 25 in. (X) Models: 390 lbs. (177 kg) 25 in. (X) Models: 433 lbs. (196 kg) on model) Evinrude/Johnson XD100 Oil or Evinrude/Johnson XD50 Oil Lubrication Refer to Oil Requirements on p. 66 Engine Type 60° V 4-Cylinder Loop-Charged 60°...
  • Page 13 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD 115 (Single Piston style): Evinrude/Johnson Biodegradeable TNT Fluid Lubrication 115-200 (Three Piston style): Evinrude/Johnson Power Trim/Tilt & Power Steering Fluid or GM Dextron † II Automatic Transmission Fluid Fluid Capacity 21 fl.

  • Page 14: Standard Torque Specifications

    Defi- nite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/ Johnson Genuine Parts. 006411 Nautical Orientation...
  • Page 15 SPECIAL TOOLS SPECIAL TOOLS TABLE OF CONTENTS DIAGNOSTIC TOOLS ..............14 UNIVERSAL TOOLS .

  • Page 16: Special Tools

    SPECIAL TOOLS DIAGNOSTIC TOOLS DIAGNOSTIC TOOLS 764642 002276 45583 Diagnostic Software P/N 764642 Bootstrap tool P/N 586551 Interface cable P/N 437955 UNIVERSAL TOOLS 32885 23701 42938 Universal Puller Set P/N 378103 Lifting eye P/N 321537 Flywheel holder P/N 771311 44686 46215 005314 Lifting tool P/N 342672...
  • Page 17 SPECIAL TOOLS UNIVERSAL TOOLS 23150 23148 23149 Small puller jaws P/N 432131 Large puller jaws P/N 432129 Bearing puller jaws P/N 432130 46879 33249 23146 Tilt tube nut wrench P/N 342680 Tilt tube service kit P/N 434523 Puller Bridge – 432127 45240 50110 †...

  • Page 18: Electrical / Ignition Tools

    SPECIAL TOOLS ELECTRICAL / IGNITION TOOLS ELECTRICAL / IGNITION TOOLS DRC7265 49799 45241 Digital multimeter Peak reading voltmeter Test probe kit P/N 342677 Ohms resolution 0.01 P/N 507972 Purchase through local supplier 004222 30387 49789 Stator Test Adapter P/N 5006211 Crimping pliers P/N 322696 Tachometer/timing light P/N 507980 42004...

  • Page 19: Fuel /Oil System Tools

    SPECIAL TOOLS FUEL /OIL SYSTEM TOOLS FUEL /OIL SYSTEM TOOLS 005339 004560 002465 Fuel pressure gauge (60 PSI) Fuel pressure gauge (15 PSI) Injector test fitting kit P/N 5007100 P/N 5006397 P/N 5005844 90° fitting, P/N 353322 90° fitting, P/N 353322 POWERHEAD TOOLS 005279 46543...

  • Page 20: Gearcase Tools

    SPECIAL TOOLS GEARCASE TOOLS 41029 23668 CO3768 Wrist pin bearing installer Wrist pin pressing tool Ring compressor – standard P/N 336660 P/N 326356 ·P/N 336314 DR1641 1. Wrist pin retaining ring driver P/N 318599 2. Wrist pin cone P/N 318600 GEARCASE TOOLS 002601 002805...
  • Page 21 SPECIAL TOOLS GEARCASE TOOLS 32872 004315 005072 Universal shift rod height gauge Gearcase Alignment Gauge Kit Gauging Head, “S” Type P/N 389997 P/N 5006349 Gearcases, P/N 352879 005401 006822 006823 Alignment pin kit, P/N 5007231 Gauging Head, “M2” Type Gauging Head, “L2” Type Gearcases, P/N 5007749 Gearcases, P/N 5007750 32884...
  • Page 22 SPECIAL TOOLS GEARCASE TOOLS 15356 40371 40372 Slide hammer adapter P/N 432398 1. Pinion nut holder P/N 334455 Pinion nut starting tool P/N 342216 2. Wrench retainer P/N 341438 32962 32519 32924 Bearing Installer P/N 326562 Bearing Installation Tool Seal installation tool P/N 330268 P/N 339778 32973 32880...
  • Page 23 SPECIAL TOOLS GEARCASE TOOLS 006782 006784 006788 Pressing fixture P/N 354059 Prop shaft bearing housing Prop shaft bearing housing remover/puller P/N 354060 alignment pins P/N 354140 49794 Gearcase pressure tester 006783 Prop shaft bearing housing P/N 507977 (Stevens P/N S-34) installers P/N 354058 (L2) Gearcase vacuum tester P/N 354057 (M2)

  • Page 24: Trim And Tilt Tools

    SPECIAL TOOLS TRIM AND TILT TOOLS TRIM AND TILT TOOLS 33023 33013 23694 Gauge and collar assembly Trim/tilt service kit P/N 390010 Tilt cylinder seal protector P/N 983975 P/N 326005 23665 33742A Hydraulic cylinder rod holder 1. Trim cylinder end cap 27340 1.

  • Page 25: Shop Aids

    SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 D.P.L. Spray P/N 777183 Oil - XD30™ P/N 777219 “6 in 1” Multi-Purpose Lubricant P/N 777192 Oil - XD50™ P/N 777225 HPF XR™ Gear Lube P/N 778755 Oil - XD100™ P/N 777118 Anti-Corrosion Spray P/N 777193 HPF PRO Gearcase Lube P/N 778755 Engine Tuner P/N 777185...
  • Page 26 SPECIAL TOOLS SHOP AIDS Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Electrical Grease P/N 503243 P/N 777186 P/N 775612 Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 2 + 4™ Fuel conditioner P/N 775613 Triple-Guard® Grease P/N 508298 Starter Bendix Lube P/N 337016 Gel-Seal and Gasket Remover P/N 771050 Needle Bearing Grease, P/N 378642...
  • Page 27 SPECIAL TOOLS SHOP AIDS RTV Silicone Sealant P/N 263753 Gasket Sealing Compound P/N 317201 Thermal Joint Compound P/N 322170 Fuel System Cleaner P/N 777184 Pipe Sealant with Teflon P/N 910048 Instant Bonding Adhesive P/N 509955 Gel·Seal II P/N 327361 Locquic Primer P/N 772032 1.

  • Page 28: Notes

    SPECIAL TOOLS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 29 INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............28 .

  • Page 30: Boat Rigging

    This feature can pre- vent injuries resulting from unexpected boat movement when the outboard starts. Remote control and wiring harness options are described in the Evinrude/Johnson Genuine Parts DRC40118 Dual-outboard key switches with emergency stop switch and Accessories Catalog.

  • Page 31: Battery Installation

    INSTALLATION AND PREDELIVERY BOAT RIGGING Control Installation Battery Installation Plan the installation of remote controls carefully, Each outboard requires its own starting battery. following all instructions provided with the remote Select a battery that meets or exceeds the mini- control. mum requirements.

  • Page 32: Battery Switches And Multiple Batteries

    INSTALLATION AND PREDELIVERY BOAT RIGGING Connections Battery Cable Requirements Evinrude outboards are shipped with stranded Connect the battery positive (+) IMPORTANT: copper battery cables for typical installations in cable to the battery positive (+) post FIRST. Con- which the starting battery is positioned close to nect the battery negative (–) cable to the battery...
  • Page 33 Battery switches must meet the following require- Never connect an external bat- IMPORTANT: ments. tery isolator to the stator of an Evinrude E-TEC. The switch must be approved for marine use. • The switch should be a “make before break”...

  • Page 34: Auxiliary Battery Charging

    Provide operator with the documentation sup- Never connect an external bat- IMPORTANT: plied by the battery switch manufacturer. Make tery isolator to the stator of an Evinrude E-TEC sure that the operator is informed of proper outboard. battery switch operation.

  • Page 35: Battery And Switch Wiring Diagrams

    INSTALLATION AND PREDELIVERY BOAT RIGGING Battery and Switch Wiring Diagrams One outboard: Battery disconnect One outboard: One primary starting battery; one secondary battery BOTH PRIMARY PRIMARY SECONDARY 000135rev1 Two outboards: Two starting batteries for each outboard BOTH BOTH PRIMARY SECONDARY SECONDARY PRIMARY Positive (+) Battery cables...
  • Page 36 INSTALLATION AND PREDELIVERY BOAT RIGGING Two outboards: One primary starting battery for each outboard; one isolated accessory battery BOTH BOTH PRIMARY PRIMARY ACCESSORY Two outboards: One primary starting battery for each outboard; two isolated accessory batteries BOTH BOTH PRIMARY PRIMARY ACCESSORY ACCESSORY Positive (+) Battery cables...

  • Page 37: Fuel System Requirements

    INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements Fuel System Primer Outboards require a priming system capable of Overview refilling the fuel system after periods of non-use. Boat fuel systems must meet minimum specifica- Primer bulbs that meet the outboard's minimum tions to insure the proper delivery of fuel to the inside diameter fuel line requirements are used on outboard.
  • Page 38 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.

  • Page 39: Oiling System Set-Up

    INSTALLATION AND PREDELIVERY BOAT RIGGING Replacement hose must be designated for fuel Oiling System Set-Up • or oil use and approved for marine use. Location Extend wiring harness with 16 gauge AWG • wire. Consider the installation location IMPORTANT: Protect connections with heat shrink tube. •...
  • Page 40 INSTALLATION AND PREDELIVERY BOAT RIGGING Place floor bracket on center line between end 1.8 G ALLON lines. Use the inner bracket holes as guides to drill Place rods into floor bracket and secure floor two 5/32 in. (4 mm) pilot holes. bracket with lag bolts.
  • Page 41 INSTALLATION AND PREDELIVERY BOAT RIGGING Oil Tank Profiles 1.8 Gallon Tank 3 Gallon Tank P/N 176995 P/N 176996 Remote Oil Fill Kit (Optional) The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly.

  • Page 42: Cable And Hose Installation

    INSTALLATION AND PREDELIVERY BOAT RIGGING Cable and Hose Installation Cable and Wire Harness Routing Before installation, identify all required wiring, WARNING cables, and hoses: Throttle and shift cables Improper installation and routing of out- • Instrument harnesses • board controls could wear, bind, and dam- Battery cables and switches age components, causing loss of control.
  • Page 43 Oil Supply Hose lengths. Refer to OUTBOARD RIGGING on p. 52. Evinrude E-TEC V4–V6 outboards use a single oil Next, bundle the components that route to the out- supply hose connected to the outboard and to the board with appropriate shielding, such as an boat-mounted oil tank.
  • Page 44 INSTALLATION AND PREDELIVERY BOAT RIGGING Oetiker Clamp Servicing Use Oetiker clamps for making hose connec- † tions. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging com- ponents, and provide solid, permanent connec- tions. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connec- tions.
  • Page 45 Use only Oetiker recommended IMPORTANT: tools to close Oetiker stepless clamps. pincers available Oetiker Evinrude/Johnson Genuine Parts and Accesso- ries Catalog (P/N 787145). 000108 Method 2: Lift end of stepless clamp with screw- driver. DP0886 Position correct size clamp over hose.

  • Page 46: Outboard Installation

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Control Cable Identification OUTBOARD Control cable function must be IMPORTANT: INSTALLATION identified before rigging outboard. Hull Preparation Identify each control cable: Put the control handle into NEUTRAL position. • Maximum Capacity The throttle cable casing guide will retract com- pletely and the shift cable casing guide will go to WARNING the midpoint of its travel.
  • Page 47 Refer to the outboard's parts catalog for alternate length mounting bolts or replacement parts. Use only Evinrude/Johnson Genuine Parts or • parts of equivalent type, strength, and material. Use the mounting hardware provided with out- •...

  • Page 48: Transom Measuring And Drilling

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Some steering systems Transom Measuring and Drilling IMPORTANT: require additional spacing. Refer to steering sys- Hull Centerline tem manufacturer for recommendations. Use the chines of the boat as reference points to The top edge of the transom should be more than locate the centerline of the boat transom.
  • Page 49 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Position drill fixture on top of transom or bracket Transom Height and align indicator points with centerline. Make sure the transom height matches the length of the outboard to be installed. A 19 to 21 in. (48.3 to 53.3 cm) transom height •...
  • Page 50 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Drilling and Hardware Diagrams This is not a template. IMPORTANT: 6 7/16" 6 7/16" (136.5mm) (136.5mm) 2" (50.8mm) (50.8mm) 90˚ 10 11 12 8" 8" (203.2mm) (203.2mm) 90˚ 4 15/16" 4 15/16" (125.4mm) (125.4mm) 000133m Quantity 1.

  • Page 51: Lifting The Outboard

    OUTBOARD INSTALLATION Lifting the Outboard Steering Systems Lifting Fixtures Mechanical Cables All Evinrude outboards equipped with tilt tubes are WARNING compatible with mechanical steering systems that meet ABYC Standard P-17. Single-cable mechan- To avoid personal injury, make sure the lift-...
  • Page 52 INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Manual Hydraulic Steering Drag Links Manual hydraulic steering systems use hydraulic Use the correct drag link to allow full steering fluid to transfer motion and load from the helm to travel: the outboard. Model Drag Link Use only a hydraulic steering system designed for 60°...

  • Page 53: Outboard Mounting

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Assemble transom mounting plates on mounting Outboard Mounting bolts. Some rigging components, such IMPORTANT: Install the mounting bolts through the transom as steering cables, must be fitted to the outboard from the inside of the boat. before the outboard is mounted to the transom.

  • Page 54: Outboard Rigging

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Refer to the following diagram to ensure proper OUTBOARD RIGGING positioning of rigging components in grommet. CAUTION To prevent accidental starting while servic- ing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.

  • Page 55: Control Cable Installation

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING board side of the powerhead. Secure all cables Position retainer clip with straight section on the • with tie-straps. bottom and angled section on the top. Use long nose pliers to insert straight section of •...
  • Page 56 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Install trunnion cover and screw. Tighten retaining Make sure that idle stop of the throttle lever is screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). against the crankcase. 004956 004947 1.

  • Page 57: Electrical Harness Connections

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Route oil tank sending unit harness around the Electrical Harness Connections front to the port side. Secure all cables with tie Remove flywheel/harness connector cover. straps. 004954 Before installing electrical connectors, check that the seal is in place. Clean off any dirt from con- 004952 1.

  • Page 58: Water Pressure Gauge

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Route the harness under the front of the EMM and Water Pressure Gauge around the port side of the powerhead. Secure If a mechanical water pressure gauge is used, with tie straps. install the water pressure hose fitting in the cylin- der block.
  • Page 59 CANbus oil level sender must be installed in the oil tank. Connect the oil level sensor harness to the boat CANbus network. Use Evinrude Diagnostics software to activate CANbus control functions in the EMM. From the Settings screen, select Engine Options.

  • Page 60: Fuel And Oil Priming

    Remove portable fuel tanks from the boat before fueling. Additives Always wipe off any fuel spillage. The only fuel additives approved IMPORTANT: for use in Evinrude outboards are 2+4 fuel condi- Do not smoke, allow open flames or ® tioner Fuel...

  • Page 61: Fuel System Priming

    Oil Requirements Evinrude/Johnson XD100, XD50, or XD30 out- board oils are recommended for use in Evinrude E-TEC outboards. If these oils are not available, you must use a TC-W3 certified oil. Evinrude/Johnson XD100 outboard oil is highly recommended for all conditions and applications.

  • Page 62: Oil Injection Rate

    This set- available to label boats equipped with outboards ting REQUIRES the use of Evinrude XD100 out- that have been programmed for the reduced oil board lubricant and is not recommended for all injection ratio.

  • Page 63: Break-In Oiling

    Refer to Oil Control Settings on p. 106. Use Evinrude Diagnostics software to make sure The oil tank should be filled and the oil level • marked for reference.
  • Page 64 INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe oil flow through the oil distribution hoses. Small bubbles are acceptable. Large bubbles must be eliminated through continued priming. 004398 1. Oil distribution hose 2. Small bubbles 3. Large bubbles 004965 1. Oil distribution hoses (7) All clear “blue”...

  • Page 65: Before Start-Up

    When starting the outboard for the first time, refer DR22834 1. Filler cap to Oil Supply Priming on p. 61. • Single Piston System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. • Three Ram System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads.

  • Page 66: Running Checks

    INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS Fuel System Perform running checks of the fuel system by fol- lowing these steps: WARNING Squeeze fuel primer bulb until hard or activate • DO NOT run outboard without a water sup- electric primer. Observe all fuel hoses and con- nections.

  • Page 67: Tachometer Pulse Setting

    INSTALLATION AND PREDELIVERY RUNNING CHECKS Tachometer Pulse Setting Operating Temperature Confirm accuracy of tachometer reading. An outboard run at idle speed should achieve a temperature based on the engine’s thermostatic Adjust dial on back of tachometer to required • setting (the outboard should not be running). control.

  • Page 68: Propellers

    Water testing with various propeller designs and each situation. sizes is the best method of propeller selection. Refer to the Evinrude/Johnson Genuine Parts • and Accessories Catalog for propeller styles The correct propeller, under normal load condi- and sizes.

  • Page 69: Propeller Hardware Installation

    Depending on propeller style, dif- IMPORTANT: ferent thrust bushings, spacers, and cotter pin keepers are used. See the Evinrude/Johnson Genuine Parts book for a complete listing and descriptions. Install the spacer, engaging the propeller shaft splines.

  • Page 70: Final Adjustments

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Place the outboard in normal operating position. FINAL ADJUSTMENTS Rotate the LOWER adjustment tab UP to reduce Tilt Limit Switch Adjustment the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position. WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side,...

  • Page 71: Trim Sending Unit Adjustment

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Observe the trim gauge. If the needle does not Trim Sending Unit Adjustment show center position, tilt the outboard up and Tilt the outboard and engage the tilt support. adjust the sending unit by pivoting it up or down. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

  • Page 72: Trim Tab Adjustment

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Trim Tab Adjustment WARNING Improper trim tab adjustment can cause difficult steering and loss of control. A propeller will generate steering torque when the propeller shaft is not running parallel to the water’s surface. The trim tab is adjustable to com- pensate for this steering torque.

  • Page 73: Dual-Outboard Alignment

    INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various boat/motor combinations respond differ- Dual outboards must be connected with a tie bar ently to dual-outboard alignments. Each applica- and adjusted to align the outboards for correct tion must be thoroughly tested until the ideal water flow to the gearcases and propellers.

  • Page 74: Notes

    INSTALLATION AND PREDELIVERY NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 75 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 74 ANTI-CORROSION PROTECTION .

  • Page 76: Inspection And Maintenance Schedule

    MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary to prolong outboard life. The following chart provides guidelines for inspection and maintenance to be performed by an authorized Dealer. Outboards used in rental, commercial, or other high hour applications require more fre- IMPORTANT: quent inspections and maintenance.

  • Page 77: Anti-Corrosion Protection

    MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.

  • Page 78: Cooling System

    MAINTENANCE COOLING SYSTEM Thread garden hose into flushing port. COOLING SYSTEM Check the condition of cooling system compo- nents regularly: water intake screens • water pump • all internal water passages • thermostats • all external water hoses and fittings •...

  • Page 79: Water Intake Screens

    MAINTENANCE LUBRICATION LUBRICATION Water Intake Screens Inspect condition of water intake screens. Clean Steering System or replace as needed. Confirm function of overboard water pressure indi- WARNING cator. Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, mak- ing operator control difficult.

  • Page 80: Swivel Bracket And Trailering Bracket

    MAINTENANCE LUBRICATION Swivel Bracket and Trailering Throttle and Shift Linkage Bracket Disconnect the battery cables at the battery. Lubricate the swivel bracket with Triple-Guard Remove cable trunnion cover. Carefully, remove grease. throttle and shift cables from trunnion block. Apply grease until the grease begins to flow from DO NOT disturb cable trunnion IMPORTANT: the upper or lower swivel bracket areas.

  • Page 81: Propeller Shaft

    MAINTENANCE LUBRICATION removing the lower, drain/fill plug. A tie strap can Propeller Shaft be used to check lubricant level. Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage. WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.
  • Page 82 MAINTENANCE LUBRICATION Inspect the lubricant for water contamination. Slowly fill the gearcase with gearcase lube Water can make the lubricant milky in appear- through the drain/fill hole until it appears at the oil ance. However, normal aeration can also cause level hole.

  • Page 83: Trim And Tilt

    • unit, hold the trim switch ON an additional 5 to • Single Ram System–Add Evinrude/Johnson 10 seconds after the unit reaches the end of its Biodegradable TNT Fluid, as needed, to bring travel before activating the switch in the oppo- level to the bottom of the fill plug threads.

  • Page 84: Battery And Battery Connections

    Battery electrolyte is acidic—handle with Fuel Filter care. If electrolyte contacts any part of the Evinrude E-TEC 60° V outboards are equipped body, immediately flush with water and with an in-line fuel filter. Refer to FUEL COMPO- seek medical attention.

  • Page 85: Oil Filters And Oil Reservoir

    Oil Filters and Oil Reservoir Air Silencer Perform visual inspections to identify oiling system The air silencer on Evinrude outboards maximizes leaks. Make certain the oil tank is filled and oil air flow while minimizing noise. supply is not contaminated.

  • Page 86: Spark Plugs

    MAINTENANCE SPARK PLUGS Apply Triple-Guard grease to the gasket surface SPARK PLUGS of the spark plug. Install spark plug and tighten to a torque of 15 ft. lbs. (20 N·m). Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged If the mark is in unshaded area do not tighten any- spark plugs.

  • Page 87: Exhaust Pressure Fitting

    1. Barometric pressure reading 2. Exhaust pressure reading Operation Test Cleaning Use the Evinrude Diagnostics software Monitor screen to confirm: Cleaning with Engine Tuner maintenance product barometric pressure reading; and can dissolve carbon build-up.

  • Page 88: Storage

    Internal Engine Treatment Remove the propeller, attach garden hose to flushing port and turn on water. Evinrude E-TEC models are designed to be self- 006806 winterizing using either of the following methods: 1. Winterization start button...

  • Page 89: Additional Recommendations

    MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE Additional Recommendations Top off oil reservoir. • If the outboard was removed from the boat for inspect the fuel filter. If there is debris in the fuel • storage, make sure it is reinstalled with factory filter, it must be replaced.

  • Page 90: Submerged Engines

    If outboard cannot be started or IMPORTANT: serviced immediately, it should be resubmerged in Reinstall all removed or disconnected parts. fresh water to avoid exposure to the atmosphere. Use Evinrude Diagnostics software to: Engine Dropped Overboard Start break-in oiling • Check fuel pump operation (Not Running) •...
  • Page 91 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 90 .

  • Page 92: Upper Cover Service

    ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE Upper Cover Cap Replacement Place new upper cap into position. Latch Hook Installation Insert threaded bracket into pocket. 006815 Tighten self-tapping screws to a torque of 24 to 36 006826 1. Bracket in.

  • Page 93: Lower Cover Service

    ENGINE COVER SERVICE LOWER COVER SERVICE LOWER COVER Lower Cover Installation Install the lower engine covers and tighten all SERVICE screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m). Lower Cover Removal Remove lower engine cover screws. 005242 1.

  • Page 94: Latch Handle Installation

    ENGINE COVER SERVICE LOWER COVER SERVICE Latch Handle Installation Trim Switch Installation Apply a light coat of Triple-Guard grease to latch Place switch into position through cover. handle shaft. Insert handle into lower cover. 006746 1. Triple-Guard grease 006827 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to screw threads.
  • Page 95 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............94 EMM INPUTS AND OUTPUTS DIAGRAM .

  • Page 96: Description

    EMM by the stator. This section discusses the functions of the EMM and its various internal and external sensors. It also describes using Evinrude Diagnostics soft- ware to retrieve and adjust service information stored in the EMM...

  • Page 97: Emm Inputs And Outputs Diagram

    ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM 1. Engine Management Module (EMM) 10. Engine Temperature Sensor(s) 19. Fuel Injector 2. Battery (12 volt) 11. Water in Fuel Sensor / Fuel Filter 20. Tachometer/SystemCheck Gauge 3.

  • Page 98: Internal Sensors

    311°F (155°C) a sensor circuit fault is detected and the EMM: Sensor inputs and internal EMM controllers are used to control outboard operation. Use Evinrude Stores service code 23 Diagnostics software to troubleshoot the sensors. EMM LED 3: OFF (Cranking)

  • Page 99: Barometric Pressure Sensor

    Supplies the EMM with barometric pressure read- Sensor inputs and internal EMM controllers are ing to compensate for changes in altitude and air used to control outboard operation. Use Evinrude density. Diagnostics software to troubleshoot the sensors. Refer to the EMM Service Code Chart at the...

  • Page 100: Oil Pressure Sensor

    ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS If cylinder head temperature is greater than 248°F Oil Pressure Sensor (120°C), the EMM: The oil pressure sensor monitors oil pressure in Activates SHUTDOWN the oil distribution manifold. Stores service code 31 If the sensor fails to indicate pressure in the oil EMM LED 4: FLASHING distribution manifold, the EMM: Engine Monitor TEMP display: FLASHING...

  • Page 101: Throttle Position Sensor

    Stored Fault, refer to Control Cable Installation encoder ribs is .073 (1.85 mm). on p. 53. Use the Evinrude Diagnostics software Monitor If the TPS or TPS circuit fails (less than 0.14 volts screen to check CPS operation. The software or greater than 4.92 volts), the EMM:...

  • Page 102: Internal Emm Functions

    ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM Exhaust Valve (V4 Models) The EMM controls a valve that switches between FUNCTIONS two exhaust paths to provide the best exhaust tun- ing for various running conditions. At slower Start Assist Circuit (SAC) speeds and under acceleration, the system opens When the ignition key is ON, the EMM Start Assist a longer path, allowing the engine to develop...

  • Page 103: Engine Monitoring System

    ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITORING SYSTEM The EMM activates the warning horn and gauge ENGINE MONITORING displays as follows: SYSTEM LOW OIL means that oil in the tank is at reserve • level (about 1/4 full). The engine monitoring system warns the operator NO OIL indicates the oil tank is empty, or the oil •...

  • Page 104: Warning System

    33 and 57). Then, the EMM must be turned OFF and ON again. Shutdown related to code 57 or IMPORTANT: 33 requires the removal of the stored service code. Use Evinrude Diagnostics software to clear a code 57 or 33.

  • Page 105: Diagnostic Software Functions

    Identity screen must match the identifica- parts information, and for making adjustments to tion label on the outboard swivel bracket. the system. Use Evinrude Diagnostics software, P/N 764642, and a laptop computer to access program infor- mation. For software help, refer to the IMPORTANT: “Help”...

  • Page 106: Dynamic Information

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Dynamic Information Hard Faults Dynamic information is viewed while the outboard A hard fault is a service code that currently exists. is running. Changes in data, such as voltages or Hard faults become stored faults only if the out- temperatures, are shown as they happen.

  • Page 107: Dynamic Tests

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Test Dynamic Tests Use the diagnostics software to test each ignition Dynamic tests are performed with the outboard circuit. Refer to Static Ignition Test on p. 119. running. Fuel Test Use the diagnostics software to test each fuel injector circuit.

  • Page 108: Oil Control Settings

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

  • Page 109: Ignition Timing

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Ignition Timing TPS Calibration Use the Ignition Timing screen to check and TPS Calibration synchronizes throttle plate open- adjust EMM timing. EMM timing must be synchro- ing with throttle position sensor voltage. nized to crankshaft position. Refer to TPS CALIBRATION on p.

  • Page 110: Fuel Injector Servicing

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Fuel Injector Servicing Reports All E-TEC fuel injectors use software program- Engine reports provide service records and can ming to compensate for variations in fuel flow. be used to document the running history of an out- Each injector and its location on the outboard is board.

  • Page 111: Software Replacement

    ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Software replacement requires Software Replacement IMPORTANT: the use of “Bootstrap” Tool, P/N 586551. Engine Management Software programs are loaded into the EMM at the factory. Periodically, a new program may be available to enhance the operation of an outboard.

  • Page 112: Emm Servicing

    ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING EMM SERVICING Installation Install J2 connector If a new EMM is being installed, IMPORTANT: Align slots in starboard side of EMM case with iso- refer to EMM Transfer on p. 109. lator mounts on electrical harness base. Slide EMM into position.
  • Page 113 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............112 .

  • Page 114: Diagnostic Procedures

    Repair any shorted electrical circuits. TORS on p. 115. Refer to ELECTRICAL HARNESS CONNEC- • Check the Evinrude Diagnostics software Hard • TIONS on p. 131. Faults and Stored Faults screens for current Refer to WIRING DIAGRAM at the back of this •...

  • Page 115: Troubleshooting

    If there are multiple stored sensor codes, inspect all 5 V sensor circuits for broken or grounded wiring. Perform a Static Ignition test using Evinrude • Diagnostics software and an inductive timing light. Refer to Static Ignition Test on p. 119.

  • Page 116: Dynamic Tests

    Cylinder Drop Tests be too rich or too lean. This feature should not be used by itself to identify a faulty injector. Use the Evinrude Diagnostics software Dynamic Tests to momentarily disable one cylinder while Evinrude Diagnostics software allows temporary the outboard is running.

  • Page 117: Emm Led Indicators

    SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS Starting Starting mode occurs from the time the flywheel The EMM LED indicators provide a quick refer- begins to turn until the outboard is running for 2 ence to the status of several outboard systems. seconds.

  • Page 118: Running

    SYSTEM ANALYSIS EMM LED INDICATORS Code 23 – EMM temp. sensor circuit fault Running • Code 24 – EMM temp. below expected range • When the outboard is running, all of the LEDs Code 37 – Water in fuel • should be off.

  • Page 119: Ignition Output Tests

    EMM provides 200 VDC ± 10 V output to • orange ignition primary wires. Check the Evinrude Diagnostics Software pro- Ignition Coil gram Stored Faults screen for current service EMM provides input to primary winding of coil •...

  • Page 120: Crankshaft Position Sensor (Cps) Test

    Use the Evinrude Diagnostics software Monitor screen to check system voltage. Use the Evinrude Diagnostics software CPS Sync and engine RPM displays to confirm a valid CPS signal while the outboard is cranking or running.

  • Page 121: Ignition Voltage Test

    Ignition Voltage Test Static Ignition Test Use the Evinrude Diagnostics software Monitor Perform the static ignition test using Evinrude screen to check ignition voltage to the primary Diagnostics software and an inductive timing light. ignition circuits of the ignition coils.

  • Page 122: Running Ignition Tests

    • Running Ignition Tests Test capacitor and all ground connections. • Use Evinrude Diagnostics software to monitor Refer to System Voltage Test on p. 118 • system voltage (55 V) and ignition voltage Refer to Ignition Voltage Test on p. 119 •...

  • Page 123: Ignition Primary Circuit Resistance Test

    SYSTEM ANALYSIS IGNITION OUTPUT TESTS Ignition Primary Circuit Ignition Coil Tests Resistance Test Connect a digital multimeter between coil primary terminal and clean engine ground. Disconnect the battery cables at the battery. Ignition Coil Primary Resistance Calibrate ohmmeter to low ohms scale. 0.090 ±...

  • Page 124: Capacitor Test

    Fuel Pump Static Test itor already retains some stored energy. Ground Use the Evinrude Diagnostics software Fuel Pump the capacitor and test again. test to activate the electric fuel pump. If the pump runs, the EMM and fuel pump circuit are not at fault.

  • Page 125: Fuel Injector Static Test

    123. Fuel Injector Static Test Running Fuel System Tests Use the Evinrude Diagnostics software Fuel Injec- Run or crank the outboard. tor Static Test to activate each fuel injector. Listen for an audible “click” from each injector when it is Use the Evinrude Diagnostics software Monitor actuated.
  • Page 126 SYSTEM ANALYSIS FUEL DELIVERY TESTS Steady light activation on all injector wires and Results: consistent voltage readings, EMM injector control No light activation on any injector wires (outboard function is good: cranks and starter turns flywheel): Use the diagnostics software Dynamic Fuel Test •...

  • Page 127: Exhaust Valve (V4 Models)

    Exhaust Valve Static Test exhaust tuning for various running conditions. A Use the Evinrude Diagnostics software Static Test relay module and actuator motor are used to to check operation of exhaust valve actuator. Lis- move the valve.

  • Page 128: Notes

    SYSTEM ANALYSIS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 129 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............128 DASH CONNECTIONS, INSTRUMENT HARNESS .

  • Page 130: Service Chart

    ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 12-16 In. lbs. (1.5-2 N·m) 60-84 In. lbs. (7-9.5 N·m) 24-26 Ft. lbs. (33-35 N·m) 12-16 In. lbs. 48 In. lbs. (1.5-2 N·m) (5.5 N·m) See Text 24-36 In. lbs. (2.7-4 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In.
  • Page 131 ELECTRICAL AND IGNITION SERVICE CHART 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) 168-192 in. lbs (19-21.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube 004100 Liquid Neoprene...

  • Page 132: Dash Connections, Instrument Harness

    ELECTRICAL AND IGNITION DASH CONNECTIONS, INSTRUMENT HARNESS DASH CONNECTIONS, INSTRUMENT HARNESS 3-pin connector – Connect to trim switch located in the handle of the remote control or to trim switch mounted on the boat dash. 6-pin connector – Connect to a pre-wired remote control or to a dash-mounted key switch.

  • Page 133: Electrical Harness Connections

    ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electrical connections. Disas- semble and clean all corroded connections. Replace damaged wiring, connectors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts for spe- cific wiring details.
  • Page 134 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 004046 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 1 Blue Injector, cylinder 2 Blue none Injector, cylinder 3 Green V4 Isolated B+ Red/Black Purple V6 Battery ground...

  • Page 135: Ground Circuits

    ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS Additional Ground Tests Check connections and continuity at the following All ground circuits are essential to reliable out- locations: board performance. Make sure all ground connec- Trim and Tilt module ground at main ground ter- •...

  • Page 136: Sensor Tests

    IMPORTANT: ware to monitor sensor circuit voltages or values. Crankshaft Position Sensor (CPS) Test Use the Evinrude Diagnostics software CPS Sync 005321 1. CPS gap and engine RPM displays to confirm a valid CPS signal while the outboard is cranking or running.

  • Page 137: Engine Temperature Sensor Test

    ELECTRICAL AND IGNITION SENSOR TESTS Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test meter lead to terminal “C.” Rotate the sensor lever Remove the electrical connector from the air tem- through its range of travel. Resistance reading perature sensor.

  • Page 138: Stator Tests

    ELECTRICAL AND IGNITION STATOR TESTS To check for a grounded winding, connect one STATOR TESTS meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The stator consists of 3 windings (6 poles each) read no continuity.

  • Page 139: Charging System Tests

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Following the manufacturer’s directions, connect CHARGING SYSTEM the variable load tester (carbon pile) across the TESTS battery terminals. Stevens model LB-85 and Snap-On model MT540D are examples of testers available. 12 V Charging Circuit To test the operation of the regulator in the EMM, WARNING you must be able to run the outboard continuously...

  • Page 140: Auxiliary Battery - Charge Wire

    ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Start and run the outboard at approximately 5000 With outboard running at 1000 RPM, voltage must RPM. Use the variable load tester to draw the bat- read higher than with key OFF and increase tery down at a rate equivalent to the stator’s full steadily to approximately 14.5 V as the outboard output.

  • Page 141: Electric Start Circuit

    ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A J1-B 004112 1. Marine battery 10. 26-pin J1-B EMM connector 2. RED wire (POS) 11. 34-pin J1-A EMM connector 3. BLACK wire (NEG) 12. Engine Management Module (EMM) 4.
  • Page 142 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The starter must engage and turn the flywheel. Red/purple wire provides 12 V to key switch ter- • The outboard must crank a minimum of 100 RPM minal “B”.

  • Page 143: Electric Start Tests

    ELECTRICAL AND IGNITION ELECTRIC START TESTS ELECTRIC START TESTS Key Switch, START Position Key switch START: Starter Solenoid Test Switches 12 V to terminal “S” of key switch and • to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- A closed neutral safety switch provides 12 V to •...

  • Page 144: No Load Current Draw Test

    ELECTRICAL AND IGNITION ELECTRIC START TESTS After re-installing the solenoid, coat all wires and Use an inductive ammeter or connect a 0 to 100 terminals with Black Neoprene Dip. amp ammeter in series with a heavy jumper between the battery positive (+) terminal and the starter positive (+) terminal.

  • Page 145: Remote Control Switch Tests

    ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or continuity light to test the SWITCH TESTS continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and Key Switch Test REVERSE.
  • Page 146 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS Neutral Start Switch Test Emergency Stop Switch Test Use an ohmmeter or a continuity light to test neu- This switch can be part of the key switch or tral start switch operation. installed as a separate switch. Either style con- nects the “M”...

  • Page 147: Tilt/Trim Relay Test

    ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST TILT/TRIM RELAY TEST Test Procedure Make sure red and black wires are connected to The tilt and trim (TNT) module contains the cir- 12 V battery power supply. cuitry and relays required for power trim and tilt operation.

  • Page 148: Exhaust Valve Relay Tests

    ELECTRICAL AND IGNITION EXHAUST VALVE RELAY TESTS EXHAUST VALVE RELAY TESTS The exhaust valve relay module controls the exhaust valve actuator. 005374 1. Exhaust valve relay module 005429 Exhaust Valve Relay Module Diagram 1. Purple/Black wire 2. Red/Purple wire 3. Blue/Black wire 4.
  • Page 149 Disconnect exhaust valve actuator connector • ness connector. Start and run engine. Use the from relay module Evinrude Diagnostics software Monitor screen to Start and run engine at idle • observe exhaust valve position indicator (High / Set multimeter to DC volts, check voltage with •...

  • Page 150: Systemcheck Circuit Tests

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS instrument harness terminal 1 (purple wire) and SystemCheck CIRCUIT terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL”...

  • Page 151: Check Engine Circuit Test

    ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test gauge. The tan wire of engine harness and the MWS har- ness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head.

  • Page 152: Tachometer Circuit Tests

    ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS LOW OIL Circuit Test TACHOMETER CIRCUIT Turn the key switch ON. Using a jumper wire, con- TESTS nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW Check voltage at the battery.

  • Page 153: Flywheel And Stator Servicing

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Lift the electrical harness base out of the way. FLYWHEEL AND STATOR SERVICING Weak flywheel magnets IMPORTANT: cause low alternator output and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment, such as a peak-reading voltmeter, which might cause unnecessary parts replacement.

  • Page 154: Stator Service

    ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use two 3/8-24x2 in. screws from the adaptor kit Stator Service to attach the tool to the flywheel. Two holes are Remove six allen head screws to remove stator. tapped in the flywheel for the tool. 005382 1.
  • Page 155 ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywheel Puller Adaptor Kit, P/N 5007181, Install the electrical harness base and secure with and Flywheel Service Kit, P/N 434649, to position four screws. Tighten screws to a torque of 60 to flywheel on top of crankshaft.

  • Page 156: Timing Adjustments

    EMM with the mechanical posi- tion of the number 1 piston. Use the Evinrude Diagnostics Software program to verify and adjust timing. Refer to the software’s help system for outboard timing verification proce- dures.

  • Page 157: Timing Verification

    Rotate the flywheel clockwise until the piston Timing Verification contacts the tool. Mark the flywheel directly across Use Evinrude Diagnostics software to synchronize from the pointer. Label this mark “B.” Rotate fly- the mechanical timing of the outboard with the wheel counterclockwise slightly to release tool electronic timing of the EMM.

  • Page 158: Tps Calibration

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING TPS CALIBRATION ELECTRIC STARTER Use Evinrude Diagnostics software to tell the SERVICING EMM what throttle position sensor voltage is when the throttle plates begin to open. Starter Removal Remove the air silencer. Do not clean the starter drive...

  • Page 159: Starter Disassembly

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the screws, lock washers, and pinion Hit the socket with a mallet to lower the spacer housing. and expose the retaining ring under the spacer. 30373 30371 Starter Disassembly Lift and remove the wave washer and bushing. 30360 Remove the retaining ring, spacer, and spring from pinion shaft.
  • Page 160 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove pinion and plastic weather cover from Remove the two thru-bolts. Mark the end cap ori- pinion shaft. entation, and remove the cap. 30368 30365 Remove the driven gear and thrust washer. Gently tap the starter frame with a rubber mallet to loosen it.

  • Page 161: Starter Cleaning And Inspection

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Note the alignment marks by the positive terminal Starter Cleaning and Inspection stud. Hold the armature in place, and slide the Inspect the brushes for wear and damage. frame away from the gear housing. Replace brushes if damaged or worn.

  • Page 162: Starter Assembly

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING matter which could contribute to failure of wind- Starter Assembly ings. If removed, apply Locquic Primer IMPORTANT: and Screw Lock to the brush card screws before installing. Route the brush leads and install the springs and brushes.
  • Page 163 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Align the starter frame and make sure the long Install the two thru-bolts. Tighten to a torque of 50 alignment mark matches the mark next to the pos- to 65 in. lbs. (5.6 to 7.3 N·m). itive terminal stud on the gear housing.
  • Page 164 ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Guard grease. Install the thrust washer and driven Lightly coat the pinion shaft splines (helix) with gear. Starter Bendix Lube. Lower the pinion into place without displacing the driven gear or thrust washer. 30362 Install the weather cover.

  • Page 165: Starter Installation

    ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING To test the assembly and operation of the starter, refer to No Load Current Draw Test on p. 142. Starter Installation Apply Locquic Primer and Nut Lock to the threads of the four starter mounting screws. Position the starter and install the screws and lock washers.

  • Page 166: Connector Servicing

    ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire. CONNECTOR SERVICING DEUTSCH Connectors recom- IMPORTANT: Electrical Grease mended. Incorrect grease application can cause electrical or warning system problems. 42329 1. Terminal latch (receptacle) 2. Terminal latch (plug) To disconnect the connector, press the latch and pull the connectors apart.
  • Page 167 ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors Always use the appropriate meter IMPORTANT: test probes and adapters when testing compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. † UPERSEAL Disconnect Lift latch. Pull connectors apart. 002447 1.
  • Page 168 ELECTRICAL AND IGNITION CONNECTOR SERVICING † † UPER OWER IMER ERIES The J1-A and J1-B connectors of the EMM are The J2 connector of the EMM is a AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOTH latches and pull connector from Use a screw driver to open latch.
  • Page 169 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back side of the terminal engages a terminal with seal into connector housing until shoulder in the connector housing to hold the ter- seated.
  • Page 170 ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Install wire gasket on wires and feed wires through the correct terminal position of the con- nector housing. Terminal is crimped onto wire and then pulled back into connector housing until lock- ing tab engages and terminal is seated. 002304 Crimping Terminals Strip insulation back 3/16 in.
  • Page 171 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............170 FUEL SYSTEM HOSE ROUTING .

  • Page 172: Service Chart

    FUEL SYSTEM SERVICE CHART SERVICE CHART ILTER APOR EPARATOR 60-80 in. lbs. (7-9 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant Pipe Thread Sealing Compound 004940 Permatex #2...
  • Page 173 FUEL SYSTEM SERVICE CHART LATE SSEMBLY AND HROTTLE Bond seals to air silencer Important:: DO NOT lubricate TPS to throttle shaft surface 10-18 in. lbs. (1-2 N·m) 96-120 in. lbs. (11-13.5 N·m) Start at center and use a spiral torque pattern 60-80 in.

  • Page 174: Fuel System

    FUEL SYSTEM SERVICE CHART ANIFOLDS AND NJECTOR Tighten in 3 stages 60-84 in. lbs. (7-9.5 N·m) 120 in. lbs. (14 N·m) 24-26 Ft. lbs. 24-36 in. lbs (33-35 N·m) (2.7-4 N·m) S = Supply R = Return Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock...

  • Page 175: Fuel System Hose Routing

    FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING V4 M ODELS Fuel Supply Fuel Return 005194 V6 M ODELS Fuel Supply Fuel Return 004943 Fuel supply from boat fuel system Electric fuel circulation pump (20 to 35 psi) Fuel lift pump (2 to 8 psi) Fuel supply manifold Pulse hose(s) from cylinder/crankcase...

  • Page 176: Fuel System Circuit Diagram

    FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAM FUEL SYSTEM CIRCUIT DIAGRAM 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Injector No. 1 Injector No. 5 Capacitor Injector No. 2 Injector No. 6 Grounds (neg) Injector No.

  • Page 177: Components

    FUEL SYSTEM COMPONENTS COMPONENTS Fuel Filter The fuel filter protects the vapor separator and the The fuel system includes the following compo- high-pressure components of the fuel system from nents: contaminants. Refer to INSPECTION AND MAIN- Fuel Lift Pump • TENANCE SCHEDULE on p.

  • Page 178: Vapor Separator

    FUEL SYSTEM COMPONENTS Vapor Separator Venting The fuel vapor vent regulates fuel vapor pressure The vapor separator: in the reservoir. Serves as a water-cooled fuel reservoir to accu- • mulate incoming fuel from the fuel lift pump and from the fuel return manifold Contains a float controlling the venting of fuel •...

  • Page 179: Fuel Circulation Pump

    FUEL SYSTEM COMPONENTS Pressure Regulator Fuel Manifolds The fuel pressure regulator helps maintain consis- The fuel supply and return manifolds route fuel tent fuel pressure in the fuel system. through the high pressure side of the fuel system. Fuel returning from the injectors enters the fuel Fuel Supply Manifold chamber of the vapor separator through a pres- The fuel supply manifold supplies pressurized fuel...

  • Page 180: Fuel System Tests

    FUEL SYSTEM FUEL SYSTEM TESTS Each service injector includes its fuel flow infor- FUEL SYSTEM TESTS mation on a 3.5 in. floppy disk. This software allows the EMM to be reprogrammed for this injec- WARNING tor’s unique fuel flow characteristics. Use caution when working on any pres- The cylinder location of each IMPORTANT:...

  • Page 181: Pressure Regulator Test

    FUEL SYSTEM FUEL SYSTEM TESTS Shut OFF outboard. Monitor pressure gauge. Pressure Regulator Test Pressure should not drop below 15 psi (103 kPa). Refer to Vapor Separator Service on p. 185 to remove vapor separator. If outboard does not run, prime IMPORTANT: fuel system and crank outboard;...

  • Page 182: Fuel Injector Pressure Test

    FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Pressure Test Fuel Injector Resistance Test This test requires Injector Test Fitting kit, Disconnect the battery cables at the battery. P/N 5005844. Use a digital multimeter to measure the injector Disconnect the battery cables at the battery. coil resistance.

  • Page 183: Circulation Pump Resistance Test

    FUEL SYSTEM FUEL SYSTEM TESTS Circulation Pump Resistance Test Results: Normal pressure Disconnect the battery cables at the battery. Perform the Lift Pump Vacuum Test on • Use a digital multimeter to measure the fuel pump p. 181. Make sure no air leaks or restrictions circuit and coil resistance.

  • Page 184: Lift Pump Diaphragm Test

    FUEL SYSTEM FUEL SYSTEM TESTS START outboard and run at FULL THROTTLE for Anti-Siphon Valve Test at least two minutes. Monitor clear vinyl hose for Remove anti-siphon valve from fuel tank. Install the presence of air. Air bubbles indicate a faulty adapter fittings and a 36 in.

  • Page 185: Fuel Component Servicing

    FUEL SYSTEM FUEL COMPONENT SERVICING Pressure Gauge, P/N 5007100, to top test fitting FUEL COMPONENT of fuel pump/vapor separator assembly. SERVICING WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.

  • Page 186: In-Line Fuel Filter Service

    FUEL SYSTEM FUEL COMPONENT SERVICING In-Line Fuel Filter Service Optional Fuel Filter Service Accessory kit, P/N 5007045, is available to add a Removal water-separating cannister fuel filter to 60° V out- Disconnect the battery cables at the battery. boards. Remove filter carefully to prevent spilling con- Removal tents.

  • Page 187: Fuel Lift Pump Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Lift Pump Service Vapor Separator Service The fuel lift pump is serviceable as a complete Removal assembly. Refer to parts catalog for service parts. Disconnect the battery cables at the battery. Removal Relieve fuel system pressure. Refer to Relieving Disconnect the battery cables at the battery.

  • Page 188: Fuel Manifold Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Disconnect fuel manifold fittings from fuel injector Fuel Manifold Service ports, then remove the manifold assemblies. Removal Installation Disconnect the battery cables at the battery. Check condition of sealing O-rings on fuel mani- Relieve fuel system pressure. Refer to Relieving fold fittings.

  • Page 189: Fuel Injector Service

    Fuel injectors must be installed in IMPORTANT: Fuel System Pressure on p. 183. the correct cylinder locations. Use Evinrude Diag- nostics Software to make sure that EMM program- Remove fuel manifolds. Refer to Fuel Manifold ming matches injector positioning. The Injector Service on p.
  • Page 190 FUEL SYSTEM FUEL COMPONENT SERVICING Crush Ring Replacement Injector crush rings must be IMPORTANT: replaced if injector is installed in a different head or cylinder location. Use Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, compo- nents to remove injector from mounting cup.
  • Page 191 Install injector service data (3.5 IMPORTANT: tor retaining screws. Install screws and washers in. floppy disk) by using the Injector Replacement Utility of Evinrude Diagnostics software. Check the Injector Coefficients screen to make sure that all injectors are positioned properly.

  • Page 192: Intake Manifold Service

    FUEL SYSTEM FUEL COMPONENT SERVICING Remove oil distribution hoses from oil pump/mani- Intake Manifold Service fold and reed plate bracket. Refer to OIL COMPO- Removal NENT SERVICING on p. 211. Disconnect vapor separator vent hose, throttle Remove oil recirculation hose from starboard side position sensor connector, and throttle link arm.

  • Page 193: Installation

    FUEL SYSTEM FUEL COMPONENT SERVICING Use caution to prevent damaging reed valve Assembly assemblies. Remove old adhesive from reed valve retaining screws. Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate and install screws. Tighten screws to a torque of 30 to 42 in.
  • Page 194 FUEL SYSTEM FUEL COMPONENT SERVICING Place gasket on throttle body. Install throttle body, Install oil filter and oil and fuel supply hoses. with oil pump bracket on reed plate and install screws. Tighten the center screws first and expand out- ward.
  • Page 195 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............194 OILING SYSTEM CIRCUIT DIAGRAM .

  • Page 196: Service Chart

    P/N 351520 XD 100 Tank Label (Accessory) *IMPORTANT* This outboard has been programmed for the use of Evinrude ® /Johnson ® XD 100 XD100 ™ outboard oil ONLY. Boat Label Failure to use Evinrude/Johnson XD100 outboard oil may harm engine performance and shorten engine life.

  • Page 197: Oiling System Circuit Diagram

    OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM J1-B J1-A Oil Injection Pump 55 V Circuit (WHITE/RED) Grounds, NEG (BLACK) EMM to Oil Solenoid (BLUE) Oil Pressure Sensor, +5 V analog (RED) Oil Pressure Sensor Signal (TAN/WHITE) Capacitor 005358...

  • Page 198: Oil Supply Diagrams - V4

    OILING SYSTEM OIL SUPPLY DIAGRAMS – V4 OIL SUPPLY DIAGRAMS – V4 Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3 and #4 crankcase fittings Primary Oil Manifold 1. Cylinder 4 2. Cylinder 1 3. Cylinder 2 4.
  • Page 199 OILING SYSTEM OIL SUPPLY DIAGRAMS – V4 Port Side View Starboard Side View 005354...

  • Page 200: Oil Supply Diagrams - V6

    OILING SYSTEM OIL SUPPLY DIAGRAMS – V6 OIL SUPPLY DIAGRAMS – V6 Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3, #4, #5 and #6 crankcase fittings Primary Oil Manifold 1. Cylinder 6 2. Cylinder 5 3.
  • Page 201 OILING SYSTEM OIL SUPPLY DIAGRAMS – V6 Port Side View Starboard Side View 005356...

  • Page 202: Oil Recirculation Diagrams - V4

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V4 OIL RECIRCULATION DIAGRAMS – V4 Port Side View Oil from auxiliary oil manifold Starboard Side View Check valve 005351...
  • Page 203 OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V4 Direction of flow* Check valves - Main bearings to cylinders Direction of flow* Check valves - Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards cylinders 005350...

  • Page 204: Oil Recirculation Diagrams - V6

    OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V6 OIL RECIRCULATION DIAGRAMS – V6 Port Side View Oil from auxiliary oil manifold Starboard Side View Check valves 005353...
  • Page 205 OILING SYSTEM OIL RECIRCULATION DIAGRAMS – V6 Direction of flow* Check valves - Main bearings to cylinders Direction of flow* Check valves - Intake manifold to lower main bearing * All check valves are oriented with direction of flow towards cylinders 005352...

  • Page 206: Components

    OILING SYSTEM COMPONENTS COMPONENTS Oil Injection Pump The oil injection pump is an electric (55 V) actua- The oiling system consists of the following compo- tor style pump. It draws oil from the oil tank nents: through the oil supply hose (25 ft. [7.6 m] maxi- Oil tank •...

  • Page 207: Electrical Circuit (55 V)

    OILING SYSTEM COMPONENTS The sensor provides an output voltage to the LOW OIL Warning EMM based on oil manifold pressures. A sending unit in the oil tank pick-up assembly 5 VDC Input on RED wire • monitors the oil level in the oil tank. This sending 0.5 - 4.5 V Output on TAN / WHITE wire •...

  • Page 208: Oil Recirculation System

    OILING SYSTEM COMPONENTS der/crankcase has a pressed-in fitting which is External fittings and in-line check valves on each connected to an oil distribution hose. side of the cylinder block control the movement of oil from the lower cylinder port to the upper cylin- der port.

  • Page 209: Oil Control Settings

    IMPORTANT: removed or replaced. the outboard not running. Refer to Oil Supply Priming on p. 61. Use Evinrude Diagnostics software to activate the Oil Injector test. This test starts the EMM control Oiling Rates function for the oil injection pump.

  • Page 210: Oil Injection Pump Voltage Test

    OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Voltage Test Oil Injection Pump Circuit Resistance Test Check voltage at pin 1 (white/red wire) of oil tank electrical connector. The complete oil injection pump IMPORTANT: Acceptable voltage readings: electrical circuit includes EMM alternator output, Key switch ON: approximately 30 V •...

  • Page 211: Oil Supply Vacuum Test

    OILING SYSTEM OILING SYSTEM TESTS Attach a vacuum tester to the outboard side of oil Oil Supply Vacuum Test supply hose and draw 7 in. Hg (24 kPa) vacuum on the hose for at least five minutes. Repair or WARNING replace any leaking components.

  • Page 212: Oil Injection Pump Function Test

    Static Test Once the warning has been confirmed, refill the oil Use the Evinrude Diagnostics software oil injector tank. The LOW OIL warning should stop when the test to activate injector. Confirm that a small oil level exceeds one-quarter of oil tank’s capacity.

  • Page 213: Oil Component Servicing

    OILING SYSTEM OIL COMPONENT SERVICING Once hose is removed from the manifold, make OIL COMPONENT sure hose support is in the end of the hose. SERVICING WARNING To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery. Oil Distribution Hoses The oil distribution hoses from each manifold MUST be the same length.

  • Page 214: Oil Injection Pump

    OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Route oil distribution hoses from the oil distribu- Removal tion manifold to the crankcase oil delivery fittings Disconnect the battery cables at the battery. as they were before removal. Refer to OIL SUP- PLY DIAGRAMS –...
  • Page 215 OILING SYSTEM OIL COMPONENT SERVICING Install oil pump bracket and retaining screws. Reconnect oil supply hose to the inlet fitting of oil Tighten small screw to a torque of 24 to 36 in. lbs. pump. Fasten with Oetiker clamp. (3 to 4 N·m) and longer screw to 96 to 120 in. lbs. (11 to 13.5 N·m).

  • Page 216: Notes

    OILING SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 217 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........216 COMPONENTS .

  • Page 218: Hose Routing And Water Flow Diagrams

    COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V4 M ODELS Hose Routing & Water Flow Diagram 115HP/60°V4 Water intake screens Water pump 1. Water intake screens Water tube 2. Water pump 3. Water tube Adapter housing 4.
  • Page 219 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS V6 M ODELS Hose Routing & Water Flow Diagram 150-200 HP/60°V6 Water intake screens 1. Water intake screens Water pump 2. Water pump Water tube 3. Water tube Adapter housing 4.

  • Page 220: Components

    COOLING SYSTEM COMPONENTS COMPONENTS Water Supply Tube The water pump outlet connects with the water Water Pump and Intakes supply tube located in the outboard’s midsection. Grommets seal the water tube to the water pump External water intakes mounted in the gearcase housing and the inner exhaust housing.

  • Page 221: Pressure Relief Valve

    COOLING SYSTEM COMPONENTS Overcooling: Debris may prevent the thermostat Pressure Relief Valve from closing completely. A pressure relief valve is used to control water flow and operating temperature at higher speeds (above approximately 2500 RPM / 21 PSI). The pressure relief valve opens as water pressure increases.

  • Page 222: Operation

    COOLING SYSTEM OPERATION When the thermostat opens, water flows down OPERATION through the cylinder head to a passage in the cyl- inder block. Water flows through the block to the All models use a two-stage cooling system exhaust housing and then out of the outboard. design.

  • Page 223: Engine Temperature Check

    COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use Evinrude Diagnostics software to read tem- CHECK perature displays. The engine temperatures listed IMPORTANT: below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and place outboard in a test tank or in the water.

  • Page 224: Idle Operating Temperature Troubleshooting (Below Range)

    COOLING SYSTEM ENGINE TEMPERATURE CHECK To test pressure relief valve operation, monitor temperature at the thermostat housing with Tem- perature Gun, P/N 772018, or digital pyrometer. Confirm normal IDLE operating temperature. Slowly increase engine speed from IDLE, up through 3000 RPM. Engine temperature should decrease from normal IDLE temperatures as pressure relief valve opens.

  • Page 225: Thermostat Servicing

    COOLING SYSTEM THERMOSTAT SERVICING THERMOSTAT Inspection Inspect all parts for cracks, heat damage, or signs SERVICING of corrosion. Replace damaged parts. Clean debris from housing and parts. Disassembly Remove the thermostat cover and O-ring from cyl- inder head. 000756 Assembly Assembly is the reverse of disassembly.

  • Page 226: Pressure Relief Valve Servicing

    COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING PRESSURE RELIEF Inspection Inspect all parts for cracks, heat damage, or signs VALVE SERVICING of corrosion. Replace damaged parts. Clean debris from housing and parts. The pressure relief valve assembly should be ser- viced at the same time as the thermostat. Disassembly Remove the EMM.
  • Page 227 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............226 POWERHEAD REMOVAL .

  • Page 228: Service Chart

    POWERHEAD SERVICE CHART SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 168-192 In. lbs. (19-21.7 N·m) 40-50 In. lbs. (5-6 N·m) 60-84 In. lbs. (7-9.5 N·m) 15-30 Ft. lbs. (20-41 N·m) 40-50 In. lbs. (4.5-5.5 N·m) 40-50 In.
  • Page 229 POWERHEAD SERVICE CHART 48 In. lbs. (5.5 N·m) 30-32 Ft. lbs. (41-43 N·m) H, X Triple-Guard Grease Gasket Sealing Compound Red Ultra Lock Needle Bearing Grease Outboard Engine Lubricant See Service Manual Text 005229 DSS135...

  • Page 230: Powerhead Removal

    POWERHEAD POWERHEAD REMOVAL Disconnect power trim connectors. POWERHEAD REMOVAL WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 183. To prevent accidental starting while ser- vicing, disconnect the battery cables at the battery.
  • Page 231 POWERHEAD POWERHEAD REMOVAL Disconnect electrical harness from exhaust valve Fasten appropriate chain hook to eye of tool and actuator (V4 models). It is not necessary to support weight of powerhead with hoist. remove actuator from exhaust housing. Remove the four small powerhead screws, seven large powerhead screws, and the upper mount screws.

  • Page 232: Powerhead Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY POWERHEAD Throttle Linkage Removal Remove throttle cam and throttle lever. DISASSEMBLY General To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p.

  • Page 233: Crankcase Disassembly

    POWERHEAD POWERHEAD DISASSEMBLY Separate crankcase and cylinder block. It may be Crankcase Disassembly necessary to tap on crankshaft with a rawhide or Use a 1/8 in. diameter pin punch to push crank- rubber mallet to loosen. case taper pin toward the front side of the engine. Carefully remove the crankcase from the cylinder Do not use a tapered punch or IMPORTANT:...

  • Page 234: Connecting Rods And Pistons

    POWERHEAD POWERHEAD DISASSEMBLY Reattach each rod cap to its rod Connecting Rods and Pistons IMPORTANT: as soon as the piston is removed. Each cap is Use a permanent marker to identify each connect- unique and can only be installed on its mated rod. ing rod cap, connecting rod, and piston by cylinder Do not allow rod to contact inside surface of cylin- number.

  • Page 235: Crankshaft Removal

    POWERHEAD POWERHEAD DISASSEMBLY The wrist pin fit is loose on both sides. Push the Remove upper seal from crankshaft. Discard the wrist pin through to free the piston from the con- seal. A new upper seal must be installed on necting rod.
  • Page 236 POWERHEAD POWERHEAD DISASSEMBLY Use a punch to remove the housing seal. Discard Remove the lower main bearing only if it needs to seal. be replaced. Use external retaining ring pliers to remove the lower bearing retaining ring. 002053 1. Punch 24384 Inspect housing and replace if necessary.

  • Page 237: Cylinder Block Cleaning

    POWERHEAD CYLINDER BLOCK CLEANING Remove and inspect crankcase seal rings. Iden- CYLINDER BLOCK tify each ring for installation in original location. CLEANING Before inspecting or assembling IMPORTANT: powerhead, all internal components must be com- pletely clean and free of contaminants. Remove any carbon accumulation from exhaust port areas.

  • Page 238: Powerhead Inspection

    POWERHEAD POWERHEAD INSPECTION Use Gel Seal and Gasket Remover to remove all POWERHEAD traces of gaskets, adhesives, and Gel-Seal II™ INSPECTION sealant from the cylinder block and crankcase. For dimensions, refer to SERVICE SPECIFICA- WARNING TIONS on p. 10. To avoid personal injury, wear eye protec- tion and rubber gloves when using Gel Before any inspection process IMPORTANT:...

  • Page 239: Crankshaft

    POWERHEAD POWERHEAD INSPECTION Crankshaft Cylinder Bore Measure the diameter of each crankpin and main Use Cylinder Bore Gauge, P/N 771310, to inspect bearing journal. The lower main bearing journal each cylinder bore for an out-of-round, oversize, would only be measured if the bearing was or tapered condition.

  • Page 240: Pistons

    POWERHEAD POWERHEAD INSPECTION Pistons Bearings Visually inspect pistons for signs of abnormal Inspect center main bearing and split sleeves for wear, scuffing, cracks, or burning. excess wear, nicks, or scratches. Replace, if nec- essary. Piston Rings For new ring sets, place each ring separately in its respective bore.

  • Page 241: Powerhead Assembly

    POWERHEAD POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installa- POWERHEAD tion, thread Slide Hammer, P/N 391008, into ASSEMBLY installer and pull it off. Inspect sleeve after installation. IMPORTANT: Proceed slowly. Make no forced IMPORTANT: Sleeve must not be used if surface is damaged. assemblies unless a pressing operation is called for.

  • Page 242: Pistons And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY lower housing with extended lip facing down. Thoroughly clean upper seal area of the crank- Lubricate seal lip with Triple-Guard grease. shaft. Install new upper seal on crankshaft. Do not apply sealer to outside diameter of the seal. 002036 1.
  • Page 243 POWERHEAD POWERHEAD ASSEMBLY dots and the diagonal oil hole facing up, toward Install wrist pin through piston and connecting rod, the flywheel. pushing bearing tool out through the piston. 002055 46521 1. Oil hole 2. Raised dots Use Wrist Pin Cone, P/N 318600, and Driver, Apply Needle Bearing Grease to the wrist pin P/N 318599, to install new wrist pin retaining rings bearings.

  • Page 244: Cylinder Head Installation

    POWERHEAD POWERHEAD ASSEMBLY Installing Pistons Cylinder Head Installation When all pistons and connecting rods are assem- Install a new thermostat seal in cylinder head with bled, install piston ring sets. Be sure rings are side marked “TO CYL HEAD” facing toward ther- installed in the cylinder used to test ring end gap.

  • Page 245: Crankshaft And Connecting Rods

    POWERHEAD POWERHEAD ASSEMBLY Apply a 1/16 in. (2 mm) bead of RTV adhesive Crankshaft and Connecting around each water passage on the block and cyl- Rods inder head as shown. Apply adhesive with a brush Apply Gasket Sealing Compound to lower oil seal around thermostat seat area on block.
  • Page 246 POWERHEAD POWERHEAD ASSEMBLY dowel pin hole will help in the alignment pro- Install rod cap screws finger tight (NO MORE than cess. 6 in. lbs. (1 N·m) maximum). 49080 005291 1. Gaps (up) Be sure alignment dot on rod cap IMPORTANT: 2.
  • Page 247 POWERHEAD POWERHEAD ASSEMBLY setting (one line showing). Rotate adjustment Apply a light coat of outboard lubricant to the cor- knob 180° to lock in position. ners of the connecting rod and rod cap. Place frame on connecting rod using the following pro- cedure: Position frame onto the connecting rod so the •...

  • Page 248: Crankcase Assembly

    POWERHEAD POWERHEAD ASSEMBLY Use Torquing Socket, P/N 331638, to tighten rod Crankcase Assembly cap screws in three stages: Thoroughly clean and degrease the mating Apply first torque of 40 to 60 in. lbs. (5 to 7 N·m) • flanges of the crankcase and cylinder block with a to both rod cap screws.
  • Page 249 POWERHEAD POWERHEAD ASSEMBLY Apply outboard lubricant to the main bearing Start in the center and work outward in a spiral screws. Install screws finger tight, no more than pattern. 60 in. lbs. (7 N·m). 005313 005308 Apply Nut Lock to crankcase flange screws. Install When the crankcase is seated, install and firmly screws and tighten to a torque of 60 to 84 in.

  • Page 250: Shift Linkage Installation

    POWERHEAD POWERHEAD ASSEMBLY Shift Linkage Installation Throttle Linkage Installation Lubricate shift linkage bosses at the base of the Apply Nut Lock to threads of throttle lever screw. crankcase with Triple-Guard grease. Insert bush- Insert spring into cavity of throttle lever. ings into bosses.

  • Page 251: Final Powerhead Assembly

    POWERHEAD POWERHEAD ASSEMBLY Install oil pump, rear oil manifold, and oil injection Final Powerhead Assembly hoses. Refer to OIL COMPONENT SERVICING Install the reed plate and throttle body assemblies. on p. 211. Refer to Intake Manifold Service on p. 190. Install flywheel and stator.

  • Page 252: Upper Mount Servicing

    POWERHEAD UPPER MOUNT SERVICING Dislodge mount assemblies and remove. UPPER MOUNT SERVICING Removal Remove mount retainer screw. 005312 Inspect mounts and replace if necessary. The motor mount, washer, and IMPORTANT: screw are serviced as an assembly. Do not disas- 005309 semble.

  • Page 253: Powerhead Installation

    POWERHEAD POWERHEAD INSTALLATION POWERHEAD Installation Place mount assemblies in position, with flats fac- INSTALLATION ing away from each other. Apply Permatex No. 2 to both sides of a new base Apply Moly Lube to all sides of retainer and install gasket around the exhaust port only.
  • Page 254 POWERHEAD POWERHEAD INSTALLATION Install pins from Alignment Pin Kit, P/N 5007167, With alignment pins in place, loosely install as shown. Tighten pins until fully seated. remaining powerhead screws and upper mount screws. 005274 005277 1. Large powerhead screws 2. Small powerhead screws 3.
  • Page 255 POWERHEAD POWERHEAD INSTALLATION Place the shift rod in the shift rod lever. Install the Connect the power trim connectors. retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 005254 1. Tilt limit switch connector 2.
  • Page 256 Indexing on p. 84. Adjust timing pointer and check engine timing. • Refer to TIMING ADJUSTMENTS on p. 154. Use Evinrude Diagnostics software to start pow- • erhead break-in oiling. Refer to Powerhead Break-In on p. 106. Prime oiling system. Refer to Oiling System Oil •...

  • Page 257: Powerhead Views

    POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS V4 Starboard – Hose Routings 006790...

  • Page 258: V4 Port - Hose Routings

    POWERHEAD POWERHEAD VIEWS V4 Port – Hose Routings 006791 02406...

  • Page 259: V4 Starboard

    POWERHEAD POWERHEAD VIEWS V4 Starboard 006792...

  • Page 260: V4 Port

    POWERHEAD POWERHEAD VIEWS V4 Port 006793 02406...

  • Page 261: V4 Front

    POWERHEAD POWERHEAD VIEWS V4 Front 006794...

  • Page 262: V4 Rear

    POWERHEAD POWERHEAD VIEWS V4 Rear 006795...

  • Page 263: V4 - V6 Top - Hose Routings

    POWERHEAD POWERHEAD VIEWS V4 – V6 Top – Hose Routings 006796...

  • Page 264: V4 - V6 Top

    POWERHEAD POWERHEAD VIEWS V4 – V6 Top 006797...

  • Page 265: V6 Starboard - Hose Routings

    POWERHEAD POWERHEAD VIEWS V6 Starboard – Hose Routings 006798...

  • Page 266: V6 Port - Hose Routings

    POWERHEAD POWERHEAD VIEWS V6 Port – Hose Routings 006799...

  • Page 267: V6 Starboard

    POWERHEAD POWERHEAD VIEWS V6 Starboard 006801...

  • Page 268: V6 Port

    POWERHEAD POWERHEAD VIEWS V6 Port 006800...

  • Page 269: V6 Front

    POWERHEAD POWERHEAD VIEWS V6 Front 006802...

  • Page 270: V6 Rear

    POWERHEAD POWERHEAD VIEWS V6 Rear 006803...
  • Page 271 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............270 TILT TUBE .

  • Page 272: Service Chart

    MIDSECTION SERVICE CHART SERVICE CHART 8-12 In. lbs. 40-50 In. lbs. (0.9-1.4 N·m) (4.5-5.5 N·m) 110-130 Ft. lbs. (149-176 N·m) 10-16 In. lbs. (1.1-1.8 N·m) 30-50 In. lbs. (3.3-5.5 N·m) 60-84 In. lbs. 40-50 In. lbs. (7-9.5 N·m) (4.5-5.5 N·m) 28-30 Ft.
  • Page 273 MIDSECTION SERVICE CHART 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. 216-240 In. lbs. (7-9.5 N·m) (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 20-22 Ft. lbs. (27-30 N·m) 156-180 In. lbs. (18-20 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube...

  • Page 274: Midsection

    MIDSECTION SERVICE CHART...

  • Page 275: Tilt Tube

    MIDSECTION TILT TUBE Remove the nut from the starboard side. TILT TUBE The tilt tube may be serviced without major disas- sembly of the outboard using Tilt Tube Service Kit, P/N 434523. Removal WARNING Support the outboard with a suitable hoist.

  • Page 276: Installation

    MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of thread are WARNING engaged. Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.

  • Page 277: Exhaust Housing

    MIDSECTION EXHAUST HOUSING Remove the exhaust housing. EXHAUST HOUSING Exhaust Housing Removal Before removing the midsection: The gearcase must be removed. Refer to Gear- • case GEARCASE REMOVAL AND INSTAL- LATION on p. 301. The powerhead must be removed. Refer to •...

  • Page 278: Exhaust Housing Disassembly

    MIDSECTION EXHAUST HOUSING Remove the water tube. Inspect water tube grom- Exhaust Housing Disassembly met and replace if necessary. Remove three screws and exhaust valve actuator (V4 models). 005210 1. Water tube grommet 005206 1. Actuator screws V4 M ODELS Remove circlip and washers from exhaust valve Remove the front and rear screws retaining the shaft on starboard side of inner exhaust housing.

  • Page 279: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING Inspect the water tube for obstructions or kinks, Cleaning and Inspection which may restrict water flow. WARNING Exhaust Housing Assembly Wear safety glasses to avoid personal V4 M ODELS injury, and set compressed air to less than Assemble linkage to exhaust valve shaft as 25 psi (172 kPa).
  • Page 280 MIDSECTION EXHAUST HOUSING Place exhaust valves in inner exhaust housing. Secure shaft with spring washer, flat washer, and circlip. 005215 005211 1. Circlip Push valves into housing until they drop into 2. Spring washer notch. ODELS Apply Adhesive 847 to the bottom flange of the inner exhaust housing.
  • Page 281 MIDSECTION EXHAUST HOUSING Clean and degrease the adapter housing and rear screw to a torque of 60 to 84 in. lbs. (7 to 9.5 outer exhaust housing mating surfaces with N·m). Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing. 005205 1.

  • Page 282: Exhaust Housing Installation

    MIDSECTION EXHAUST HOUSING Rotate and push actuator into position. Apply Tri- V4 M ODELS ple-Guard grease to screw threads and install Check that exhaust valve linkage is oriented as screws and washers. Tighten screws to 60 to 84 shown. “OUT” marking on lever must be visible. in.

  • Page 283: Stern Bracket

    MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer. It STERN BRACKET may be necessary to tap the steering shaft out using a wood dowel and mallet. Stern Bracket Removal Before servicing the stern bracket: Remove gearcase. Refer to Gearcase GEAR- •...
  • Page 284 MIDSECTION STERN BRACKET Remove the anode. Remove the tilt limit switch and retainer from the swivel bracket. 30762 1. Anode 30758 1. Tilt limit switch Remove the swivel bracket. Inspect and, if neces- 2. Retainer sary, replace the tilt tube bushings. Disconnect the trail lock spring and remove it from the swivel bracket.

  • Page 285: Stern Bracket Assembly

    MIDSECTION STERN BRACKET Remove the two trim rod rollers from the swivel Stern Bracket Assembly bracket. Before proceeding, make sure all IMPORTANT: components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evi- dence of deterioration.
  • Page 286 MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in. (25 to 27 N·m).
  • Page 287 MIDSECTION STERN BRACKET Install the steering shaft keeper. Apply Locquic Coat the bushings and seal lips with Triple- • Primer and Nut Lock to the splines of the steering Guard grease. shaft and lower mount bracket. 30765 / 30764 Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket.

  • Page 288: Exhaust Relief Muffler Assembly

    MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY The overboard indicator and flush port in the EXHAUST RELIEF exhaust relief grommet connect to the vapor sepa- MUFFLER ASSEMBLY rator with a hose. This hose is not connected to the muffler assembly. The exhaust relief muffler is located at the rear of the powerhead and concealed by the lower motor covers.
  • Page 289 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHARTS ..............289 GEARCASE TYPES .
  • Page 290 GEARCASE GEARCASE – COUNTER ROTATION ..........338 GEARCASE DISASSEMBLY .

  • Page 291: Service Charts

    GEARCASE SERVICE CHARTS SERVICE CHARTS V4 20 “S2”-T TANDARD OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. 37-41 Ft. lbs. (24-27 N·m) (50-56 N·m) 26-28 Ft.

  • Page 292: Gearcase

    GEARCASE SERVICE CHARTS V6 20 V4 25 “O”-T TANDARD OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft.
  • Page 293 GEARCASE SERVICE CHARTS V4 25 “O”-T OUNTER OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 18-20 Ft.
  • Page 294 GEARCASE SERVICE CHARTS V6 P “L”-T ERFORMANCE ODELS EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 18-20 Ft. lbs. (24-27 N·m) 60-84 In.
  • Page 295 GEARCASE SERVICE CHARTS V6 P “L2”-T ERFORMANCE ODELS ESIGN EARCASE 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. 24-36 In. lbs. (13.5-16.5 N·m) (3-4 N·m) 60-84 In. lbs. (7-9.5 N·m) 40-50 Ft. lbs. (54-68 N·m) 18-20 Ft. lbs. 26-28 Ft. lbs. (24-27 N·m) (35-38 N·m) 60-84 in.
  • Page 296 GEARCASE SERVICE CHARTS V6 S , 25 “M”- TANDARD OTATION ODELS TYPE EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft.
  • Page 297 GEARCASE SERVICE CHARTS V6 C “M”-T OUNTER OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. 120-144 In. lbs. (7-9.5 N·m) (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. Lbs. (24-27 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 18-20 Ft.
  • Page 298 GEARCASE SERVICE CHARTS V6 S , 25 “M2”– TANDARD OTATION ODELS TYPE EARCASE 60-84 In. lbs. 24-36 In. lbs. (7-9.5 N·m) (3-4 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 18-20 Ft.
  • Page 299 GEARCASE SERVICE CHARTS V6 C “M2”-T OUNTER OTATION EARCASE 24-36 In. lbs. (3-4 N·m) 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m) 40-50 Ft. lbs. (54-68 N·m) 60-84 in. lbs. 18-20 Ft.

  • Page 300: Gearcase Types

    GEARCASE GEARCASE TYPES GEARCASE TYPES Housing Outboard Model Description of Features Gear Ratio Type* I-3 20 in. “S” standard gearset (I-3) 13:26 (.500) V4 20 in. “S2” unique driveshaft with bolted pinion, oversized gearset 13:26 (.500) I-3 / V4 25 in. special gear ratio, uses V6 style prop 12:27 (.444) V4 25 in.
  • Page 301 GEARCASE GEARCASE TYPES Housing Profiles V6 “O” Type V4 “S”, “S2” Type 19.079 19.20 4.124 4.625 V6 “L” Type V6 “L2” Type (0.54 & 0.58 Ratios) 19.20 19.20 4.918 4.918 V6 “M” Type V6 “M2” Type 19.20 19.20 5.078 5.082 006832...

  • Page 302: Propeller Service

    (+) cable so the outboard cannot A shift interrupt switch signal is not used on 60°V4 be started accidentally. or 60°V6 Evinrude ETEC models. Low idle speeds do not require shift interrupt function. GEARCASE LEAK TEST On V4 models a neutral (shift position) switch is used when an accessory tiller conversion kit is Drain lubricant before testing.

  • Page 303: Gearcase Removal And Installation

    GEARCASE GEARCASE REMOVAL AND INSTALLATION Remove the forward screw with the washer, and GEARCASE REMOVAL remove middle screw. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly.

  • Page 304: Gearcase Installation

    GEARCASE GEARCASE REMOVAL AND INSTALLATION Apply Gel-Seal II to gearcase mating surface pads Gearcase Installation on exhaust housing. Slide the gearcase into place, making sure: WARNING Driveshaft engages the crankshaft. • During service, the outboard may drop Water tube enters the water pump. •...
  • Page 305 GEARCASE GEARCASE REMOVAL AND INSTALLATION Apply Gasket Sealing Compound to threads of the 35 to 40 ft. lbs. (47 to 54 N·m). For adjustment, gearcase retaining screws. Tighten the screws to refer to Trim Tab Adjustment on p. 70. a torque of: 3/8 in.

  • Page 306: Water Pump Service

    GEARCASE WATER PUMP SERVICE WATER PUMP SERVICE Assembly Apply a drop of Adhesive 847 in the seal ring Disassembly groove at each of the four ribs. Rotate the driveshaft counterclockwise to unlock Do not allow any sealer to get IMPORTANT: the impeller cam.
  • Page 307 GEARCASE WATER PUMP SERVICE Install the water tube grommet with the inside Run a thin bead of Adhesive 847 in the seal taper facing up. groove, and install the special shaped O-ring seal. 32000 34815 1. Water tube grommet 1. O-ring Install the impeller housing cover and tighten Apply Gasket Sealing Compound to both sides of screws to a torque of 24 to 36 in.

  • Page 308: Shift Rod Adjustment

    GEARCASE SHIFT ROD ADJUSTMENT impeller, and slide water pump down over cam. SHIFT ROD Be sure impeller cam does not fall out of position. ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

  • Page 309: Gearcase - Standard Rotation

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Hydrostatic Seal Grooves — Must be in good GEARCASE – STANDARD ROTATION GEARCASE • condition to help prevent propeller ventilation. DISASSEMBLY Pre-Disassembly Inspection WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).

  • Page 310: Propeller Shaft Bearing Housing Removal - "S2", "O", "L" And "M" Type

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove the propeller shaft bearing housing from Propeller Shaft Bearing Housing the gearcase using the following: Removal – “S2”, “O”, “L” and “M” Puller body, screw, and handle from Universal • Type Puller Set, P/N 378103. Two 5/16-18 x 11 in.

  • Page 311: Propeller Shaft Bearing Housing Removal - "L2" And "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove the propeller shaft bearing housing from Propeller Shaft Bearing Housing the gearcase using: Removal – “L2” and “M2” Type Propeller Shaft Bearing Housing Puller Kit, • P/N 354060. Identify gearcase type before dis- IMPORTANT: assembly.

  • Page 312: Pinion Gear And Driveshaft Removal - "S2" Type

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Pull propeller shaft and bearing housing far Pinion Gear and Driveshaft enough to loosen the PRESSED bearing housing Removal – “S2” Type from the gearcase housing. To separate the upper driveshaft IMPORTANT: from the lower driveshaft, the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft.
  • Page 313 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Lift and remove upper driveshaft from lower drive- shaft. Refer to Propeller Shaft Bearing Housing Removal – “S2”, “O”, “L” and “M” Type on p. 308. Remove propeller shaft bearing housing and reverse gear, thrust bearing and thrust washer.
  • Page 314 GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY With driveshaft bearing housing and screws in counterclockwise direction. Loosen screw com- place, insert Lower Driveshaft Spline Tool, pletely P/N 5007052, into lower driveshaft. 005407 1. Lower Driveshaft Spline Tool 005409 Insert Lower Driveshaft Wrench, P/N 352877, Remove the four driveshaft bearing housing through Lower Driveshaft Spline Tool and lower screws and then the bearing housing.

  • Page 315: Pinion Gear And Driveshaft Removal - "O", "L", "L2", "M" And "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove pinion gear from gearcase housing. Remove the four driveshaft bearing housing screws. 005420 COA3153 1. Driveshaft bearing housing screws Pinion Gear and Driveshaft Remove driveshaft from the gearcase. The bear- Removal – “O”, “L”, “L2”, “M” ing housing, shims, thrust bearing, and thrust washer will come out with the driveshaft.

  • Page 316: Driveshaft Service

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Remove the pinion gear and pinion nut from the in driveshaft. Thread Slide Hammer, P/N 391008, gearcase. into puller and remove driveshaft. COA3159 46905 Locked Driveshaft Removal Driveshaft Service The driveshaft to pinion taper is a locking taper. If To separate the upper driveshaft (if needed) from necessary, use Driveshaft Puller, P/N 390706, and the lower driveshaft, remove the roll pin.

  • Page 317: Shift Housing, Gear And Propeller Shaft Removal

    GEARCASE – STANDARD ROTATION GEARCASE DISASSEMBLY Install the upper driveshaft into the lower drive- Discard the cover gasket. Remove and discard shaft, aligning the holes in the driveshaft retainer the shift rod O-ring from inside of cover. and the lower driveshaft. COA3141 1.

  • Page 318: Gearcase Housing Inspection

    GEARCASE – STANDARD ROTATION GEARCASE HOUSING INSPECTION GEARCASE HOUSING SHIFTER, BEARING AND INSPECTION SEAL SERVICE Thoroughly clean gearcase housing to remove all Shift Housing Disassembly dirt and debris prior to inspection. Inspect pinion bearing and forward thrust surface of gearcase WARNING housing.

  • Page 319: Shift Housing Assembly

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Remove the gear, thrust bearing, and thrust Wrap the housing with a shop cloth to catch ball washer from the shift housing. and spring. Rotate the shifter detent 90° in either direction, then pull the detent out of the housing.
  • Page 320 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE the ball, remove the tool and position detent to Rest the cradle on the shift shaft. engage NEUTRAL position. DSC02506 4512 TYPICAL 1. Cradle 2. Shift shaft Thoroughly grease 25 needle bearings with Nee- dle Bearing grease and place in the bearing case.

  • Page 321: Pinion Bearing Removal

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE of the pin, MAKING SURE NONE OF THE COILS Bearing and washer must be IMPORTANT: OVERLAP OR ARE LOOSE. installed in the correct order. DSC02297 1. Thrust bearing COB3101 2. Thrust washer 1.

  • Page 322: Pinion Bearing Installation

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE “S2” T Pinion Bearing Installation EARCASE Use a mallet to drive the bearing from the hous- Assemble the following components of Pinion ing. Bearing Remover and Installer, P/N 391257, as shown: 824163 1.

  • Page 323: Driveshaft Bearing Housing Service

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Spacers are different sizes and IMPORTANT: Driveshaft Bearing Housing cannot be interchanged. Service Apply Needle Bearing grease to the needle bear- The driveshaft bearing is not serviceable. Replace ings and insert them into the bearing case. (Note: the bearing housing assembly if the bearing is “S2”...

  • Page 324: Propeller Shaft Bearing Housing Service

    GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE groove is an oil passage. Gearcase damage could Propeller Shaft Bearing Housing result. Service Rear Seal Removal Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.
  • Page 325 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Inspect the bearing housing anode. Replace Bearing Installation anode if it is reduced to two-thirds of original size. Oil, then install new bearings in bearing housing. Tighten screws to a torque of 108 to 132 in. lbs. Place the lettered end of the bearing case on the (12 to 15 N·m).
  • Page 326 GEARCASE – STANDARD ROTATION SHIFTER, BEARING AND SEAL SERVICE Install inner seal with lip facing toward the bearing OUNTER OTATION HOUSING housing, then outer seal with lip facing away from Bearing Installation Tool: the bearing housing. P/N 432401 – “O”, “M”, “M2” type counter rota- •...

  • Page 327: Driveshaft Shimming

    GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING DRIVESHAFT SHIMMING “O”, “L”, “L2”, “M” “M2” T EARCASES If new pinion gear is needed, IMPORTANT: Degrease pinion and driveshaft IMPORTANT: replace gear set before shimming. tapers prior to assembly. Check tapers for any damage or material transfer.
  • Page 328 GEARCASE – STANDARD ROTATION DRIVESHAFT SHIMMING with end of threads. Tighten locking ring on pre- sure clearance between the gauge bar and the load screw. pinion at several locations. If variance is greater than 0.002 in. (0.050 mm) replace the pinion or driveshaft, as necessary, and repeat check.

  • Page 329: Gearcase Assembly

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Cover Lubricate a new shift rod cover O-ring with Triple- Water Intake Screens Guard grease. Install the O-ring into the shift rod cover. Install water intake screens. Tighten screws to a torque of 60 to 84 in.
  • Page 330 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Place the shift rod grommet on the shift rod. Install “M2” T EARCASES shift rod spacer under grommet on 25 in. models. Apply Adhesive 847 to seal groove of shift rod cover. Place a new shift rod cover seal in groove. COA3568 1.

  • Page 331: Pinion Gear And Driveshaft Installation - "S2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install pinion gear in gearcase housing Pinion Gear and Driveshaft Installation – “S2” Type Refer to DRIVESHAFT SHIMMING on p. 325. Position the driveshaft thrust bearing, thrust washer, and correct shim(s) on driveshaft as shown.
  • Page 332 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Temporarily install bearing hous- Make sure Lower Driveshaft IMPORTANT: IMPORTANT: ing for support during pinion tightening procedure. Wrench is fully seated in head of pinion screw. Use a long 3/4 in. combination wrench to hold Driveshaft Spline Tool and a 1/2”...
  • Page 333 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown. 005412 1. Retainer(s) Hold lower retainer and align upper driveshaft with lower driveshaft. Force upper driveshaft down until seated.

  • Page 334: Pinion Gear And Driveshaft Installation - "O", "L"' "L2", "M" And "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install new seals in driveshaft bearing housing. Pinion Gear and Driveshaft Refer to Driveshaft Bearing Housing Service on Installation – “O”, “L”’ “L2”, “M” p. 321. Using Driveshaft Seal Protector, and “M2” Type P/N 318674, slide the driveshaft bearing housing onto the driveshaft.
  • Page 335 GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Washer must be snapped into recess of pinion Apply Gasket Sealing Compound to the threads of gear. the driveshaft bearing housing screws. Tighten screws in stages to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

  • Page 336: Propeller Shaft Bearing Housing And Gear Installation - "S2", "O", "L" And "M" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Install two retainers, washers and screws. Apply Propeller Shaft Bearing Housing Ultra Lock to threads and tighten screws to a and Gear Installation – “S2”, “O”, torque of 18 to 20 ft. lbs. (24 to 27 N·m). “L”...

  • Page 337: Propeller Shaft Bearing Housing And Gear Installation - "L2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY gearcase. Align and level gearcase assembly in Propeller Shaft Bearing Housing fixture as shown. Secure fixture to floor press. and Gear Installation – “L2” Type The propeller shaft bearing hous- IMPORTANT: ing on the “L2” type gearcases is PRESSED into the gearcase housing.

  • Page 338: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Align retaining holes in bearing housing with Propeller Shaft Bearing Housing screw holes in gearcase. Thread Alignment Pins, and Gear Installation – “M2” Type P/N 354140, into gearcase. The propeller shaft bearing hous- IMPORTANT: ing on the “M2”...

  • Page 339: Final Assembly And Adjustment

    GEARCASE – STANDARD ROTATION GEARCASE ASSEMBLY Housing must be completely seated in gearcase Final Assembly and Adjustment to install retainer screws. Bearing housing is To complete gearcase assembly, refer to: approximately level with gearcase. GEARCASE LEAK TEST on p. 300 •...

  • Page 340: Gearcase - Counter Rotation

    GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY To remove the propeller shaft, bearing housing GEARCASE – COUNTER ROTATION GEARCASE and forward gear from gearcase, thread Propeller DISASSEMBLY Shaft Adapter, P/N 432398, onto Slide Hammer, P/N 432128, until it seats. Thread adapter com- pletely onto propeller shaft and pull propeller Counter rotation (CR) gearcases IMPORTANT:...

  • Page 341: Pinion Gear Removal And Driveshaft Servicing

    GEARCASE – COUNTER ROTATION GEARCASE DISASSEMBLY DO NOT use tools designed to push on the pro- Pull propeller shaft and bearing housing far peller shaft. Pushing against the propeller shaft enough to loosen the PRESSED bearing housing could damage the forward gear thrust bearing or from the gearcase housing.

  • Page 342: Shift Housing, Gear And Propeller Shaft Removal

    GEARCASE – COUNTER ROTATION GEARCASE HOUSING INSPECTION Shift Housing, Gear and Water Intake Screens Propeller Shaft Removal Remove and clean water intake screens. Replace if damaged. Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out.

  • Page 343: Shifter, Bearing And Seal Servicing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the gear, thrust bearing, and thrust SHIFTER, BEARING AND washer from the shift housing. SEAL SERVICING Shift Housing Disassembly WARNING Wear safety glasses to avoid injury. The shift housing and bearing are IMPORTANT: serviced as an assembly.

  • Page 344: Shift Housing Assembly

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Wrap the housing with a shop cloth to catch ball able tool. Once the detent is past the ball, remove and spring. Pull the shifter detent straight out of the tool and position detent to engage NEUTRAL. the housing.
  • Page 345 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Install arms of shift lever into detent slots. Align Coat thrust bearing and thrust washer with Needle the pivot holes and insert the retaining pin. Push Bearing grease. Place the bearing on the back of shifter detent down.

  • Page 346: Pinion Bearing

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Slide the propeller shaft onto the shift shaft, align Remove gear housing retaining ring. the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring.
  • Page 347 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the thrust bearing. Remove the forward gear bearing only if it needs to be replaced. If removal of the bearing is neces- sary, use Large Puller Jaws, P/N 432129, and Puller Bridge, P/N 432127, with an appropriate base.
  • Page 348 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING For seal and bearing service refer to Propeller Place the bearing housing on the forward gear. Shaft Bearing Housing Service on p. 322. Assembly If removed, install a new forward gear bearing. Apply Needle Bearing grease to 25 new rollers.
  • Page 349 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Position the gear assembly so the indicator nee- Apply Needle Bearing grease to the thrust washer. dle makes contact with the flange on the housing. Place washer in recess of bearing housing. The indicator needle must be parallel with the side of the gear housing and perpendicular to the table surface.

  • Page 350: Propeller Shaft Bearing Housing And Forward Gear - "M" And "M2" Type

    GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING To prevent damage to threads, IMPORTANT: Propeller Shaft Bearing install forward gear bearing housing assembly by Housing and Forward Gear – hand until fully seated against propeller shaft “M” and “M2” Type bearing housing.
  • Page 351 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Remove the shim(s). Remove the thrust washer and thrust bearing. 006852 13593 1. Thrust washer 2. Thrust bearing Inspect the forward gear and bearing housing For seal and bearing service refer to Propeller assembly for excessive wear or damage.
  • Page 352 GEARCASE – COUNTER ROTATION SHIFTER, BEARING AND SEAL SERVICING Apply Needle Bearing grease to the thrust washer. Install forward gear assembly with correct shims Place washer in recess of bearing housing. in bearing housing. (“M” type uses retainer ring and shims.) 006856 1.

  • Page 353: Driveshaft Shimming

    GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Inspect the bearing housing anode. Replace DRIVESHAFT SHIMMING anode if it is reduced to two-thirds of original size. Tighten screws to a torque of 108 to 132 in. lbs. If new pinion gear is needed, IMPORTANT: (12 to 15 N·m).
  • Page 354 GEARCASE – COUNTER ROTATION DRIVESHAFT SHIMMING Select collar, P/N 341440, and shim gauge bar: between each pair of screw holes. Replace the bearing housing and repeat check if variance is “M” and “M2”: Shim gauge bar, P/N 349957 • greater than 0.004 in. (0.010 mm). “O”: Shim gauge bar, P/N 328367 •...

  • Page 355: Gearcase Assembly

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY GEARCASE ASSEMBLY Shift Rod Cover Refer to Shift Rod Cover on p. 327. Water Intake Screens Pinion Gear and Driveshaft Install water intake screens. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). Installation Refer to Pinion Gear and Driveshaft Installation –...

  • Page 356: Propeller Shaft Bearing Housing And Gear Installation - "M2" Type

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Housing must be completely seated to install Re-tighten two retainer screws to 18 to 20 ft. lbs. retainer tabs. (24 to 27 N·m). Confirm that torque on the wedge screw is 15 to 20 in. lbs. (1.7 to 2.3 N·m). Propeller Shaft Bearing Housing and Gear Installation –...

  • Page 357: Final Assembly And Adjustment

    GEARCASE – COUNTER ROTATION GEARCASE ASSEMBLY Apply Ultra Lock to threads and install two retain- Pinion, clutch dog and forward IMPORTANT: ing screws. Tighten screws to a torque of 18 to 20 gears must align properly for bearing housing to ft.

  • Page 358: Notes

    GEARCASE – COUNTER ROTATION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 359 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............358 SYSTEM DESCRIPTION .

  • Page 360: Service Chart

    TRIM AND TILT SERVICE CHART SERVICE CHART 20” 115 HP M ODELS INGLE ISTON YSTEM 30-50 In. lbs. (4-5.6 N·m) 45-55 In. lbs. (5.1-6.2 N·m) 45-55 In. lbs. (5.1-6.2 N·m) Triple-Guard Grease 005002 Biodegradable TNT Fluid...
  • Page 361 TRIM AND TILT SERVICE CHART 25” M ODELS HREE ISTON YSTEM 35-52 In. lbs. (4.0-5.9 N·m) 12-24 In. lbs. (1.4-2.7 N·m) 84-108 In. lbs. 58-87 Ft. lbs. (9.5-12 N·m) (79-118 N·m) 60-84 In. lbs. 60-70 Ft. lbs. (7-9.5 N·m) (81-95 N·m) DO NOT OVER TIGHTEN 58-87 Ft.

  • Page 362: System Description

    TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION Trailering Bracket And Tilt Support The power trim/tilt hydraulic system is completely Use the trailering bracket to support the outboard contained between the outboard's stern brackets. when trailering in the tilted position. This bracket The system consists of: protects the hydraulic system from damage.

  • Page 363: Modes Of Operation (Three Piston System)

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) MODES OF OPERATION (Three Piston System) The trim/tilt hydraulic assembly achieves trim and tilt movement through the following modes of operation. Trim-OUT / Tilt-UP Mode When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.

  • Page 364: Tilt-Down / Trim-In Mode

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, the trim/tilt motor rotates counterclockwise (as viewed from pump end) and turns the pump gears. Fluid pressure passes through the DOWN shuttle valve to the UP shuttle valve, which mechanically opens the UP check valve.

  • Page 365: Impact Relief

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is com- pressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact.

  • Page 366: Shallow Water Drive Tilt Relief

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve.

  • Page 367: Manual Release - Up

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve. Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring.

  • Page 368: Manual Release - Down

    TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM) Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylin- ders (in the trim range), and past the manual release valve.

  • Page 369: Routine Inspections

    TRIM AND TILT ROUTINE INSPECTIONS ROUTINE INSPECTIONS TROUBLESHOOTING General Three Piston System Check for external signs of fluid leakage. Correct If the power trim/tilt system has malfunctioned and causes as necessary. the cause has not been determined, the Symp- toms Chart on p. 368 should help locate the Check the battery and make sure it is in good problem.
  • Page 370 TRIM AND TILT TROUBLESHOOTING If the outboard does not tilt as high as it should, STEP 3 and the tilt motor TURNS OFF at maximum tilt Go to TILT/TRIM RELAY TEST on p. 145 to (does not sound like it is stalled at the maximum determine if problem is power supply.
  • Page 371 TRIM AND TILT TROUBLESHOOTING bypass the reservoir cap. These steps will relieve The “B” adapter, P/N 336659, checks operation • the pressure in the unit. of the DOWN circuit. 41739 27340 1. Manual release valve 1. A Adapter 2. Reservoir cap 2.
  • Page 372 TRIM AND TILT TROUBLESHOOTING all rods must be completely extended to check Remove the manual release valve. Install pres- fluid level. sure gauge and adapter “B” to check problems in the DOWN circuit. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure.

  • Page 373: Single Piston System

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS ELECTRICAL CIRCUIT Single Piston System Use the following guidelines to check a single pis- TESTS ton trim/tilt unit that is not working correctly. Relay Testing Cylinder Leakdown: Manual release valve seals • When the trim-UP button is pressed, the UP relay External leaks •...

  • Page 374: Trim And Tilt Motor No Load Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Connect a 0 to 100 A DC ammeter in series Test results include three basic possibilities: between the battery side of the starter solenoid A. Low current draw – Check for: and the red lead to the trim/tilt relay module. Valves leaking •...

  • Page 375: Trim Gauge Test

    TRIM AND TILT ELECTRICAL CIRCUIT TESTS Monitor motor RPM and current draw. Trim Gauge Test STEP 1 Turn key switch ON. Using a voltmeter, check for voltage between the trim gauge “I” and “G” termi- nals. If no voltage, check condition of instrument har- •...

  • Page 376: Trim Sender Test

    TRIM AND TILT TRIM AND TILT SERVICE Trim Sender Test TRIM AND TILT SERVICE To avoid immediate meter dam- IMPORTANT: Removal age, never apply a multimeter to an electrical cir- Remove lower engine cover and disconnect the cuit where voltage is present. trim/tilt connectors.
  • Page 377 TRIM AND TILT TRIM AND TILT SERVICE Separate the trim/tilt unit wires in the braided tube Remove the external snap rings from the upper to permit removal through the hole in the stern pin. bracket. 25064 Use a punch to remove the upper pin. 25078 Unscrew the manual release valve, raise the unit, and lock it in place with the tilt support.
  • Page 378 TRIM AND TILT TRIM AND TILT SERVICE Use a punch to remove the lower pin and remove Install external snap rings onto upper pin with the trim/tilt unit from the stern brackets. sharp edge facing out. 25076 25064 Installation Place trim/tilt wires in braided tube and install Place trim/tilt unit into position.

  • Page 379: Servicing - Three Piston System

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Release the tilt support and lower the outboard. SERVICING – THREE Tighten the manual release valve to a torque of 45 PISTON SYSTEM to 55 in. lbs. (5.1 to 6.2 N·m). Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position,...
  • Page 380 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Screw the manual release valve in. Remove the Remove the three Pozidriv screws securing the retaining ring using retaining ring pliers. Remove reservoir to cylinder body. Remove reservoir. the manual release valve. 41753 41739 Remove the reservoir O-ring from the cylinder...
  • Page 381 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the four screws securing motor to pump solvent and inspect it for tears, clogging, or other manifold assembly. damage. 41760 41763 1. Coupler 2. Filter screen Remove the wire shield from the pump manifold. Remove the three Allen head screws securing the Remove the motor and inspect the motor O-ring pump manifold assembly to cylinder body.

  • Page 382: Tilt Piston Removal

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the manifold. Remove five O-rings from Slowly pull the piston out with a rag wrapped cylinder body. Check machined surfaces for nicks around the rod and the top of the cylinder. Drain and scratches.

  • Page 383: Tilt Piston Identification

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the washer. Slide the tilt piston off the Three of the four springs are one length, and the rod. Be careful not to lose the springs, plungers, fourth spring is shorter. On assembly, the shorter or small check valves in the piston assembly.

  • Page 384: Tilt Rod Assembly

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Use a screwdriver to carefully pry the scraper out Use a wire brush to clean all thread-locking mate- of the end cap. Discard the scraper. Remove and rial from the threads on the tilt rod. discard the large outer O-ring.

  • Page 385: Trim Rod Removal

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Clean any thread-locking material from the Trim Rod Removal threads on the inside of the nut. Spray threads of Unscrew trim cylinder end caps using Trim Cylin- with Locquic Primer and let dry. Apply a small der End Cap Remover/Installer, P/N 436710, or amount of Nut Lock to the threads.

  • Page 386: Trim Rod Assembly

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Drain the remaining fluid from the cylinders. Remove the rod from the vise. Use a small screw- Inspect both bores of the trim cylinders for exces- driver to carefully pry the scraper out of the end sive scoring.

  • Page 387: Manifold And Reservoir Installation

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Lubricate and install a new O-ring and two new Manifold and Reservoir back-up rings on the trim rod piston. Place one Installation back-up ring on each side of the O-ring. Position Lubricate five new manifold body O-rings. Place the open end of the back-up rings 180°...

  • Page 388: Trim Rod Installation

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM removed later for the Pressure Leakdown Test Attach the reservoir to the cylinder body with three on p. 368. Pozidriv screws. Torque the screws to 35 to 52 in. lbs. (4.0 to 5.9 N·m). 41851 41866 Install the reservoir filter screen in the cylinder...

  • Page 389: Tilt Rod Installation

    TRIM AND TILT SERVICING – THREE PISTON SYSTEM Spanner Wrench, P/N 912084. Torque caps to 60 P/N 912084. Torque cap to 58 to 87 ft. lbs. (79 to to 70 ft. lbs. (81 to 95 N·m). 118 N·m). 41868 41870 Tilt Rod Installation Motor Installation Lubricate the tilt rod piston.
  • Page 390 TRIM AND TILT SERVICING – THREE PISTON SYSTEM Install the filter screen. Fill the reservoir to the bottom of the fill hole with Power Trim/Tilt & Steering Fluid. Install and tighten the reservoir cap. Turn the manual release valve in until it seats. Cycle the unit up and down several times to purge air.

  • Page 391: Servicing-Single Piston System

    TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Check the tilt rod bushings. Replace them if they SERVICING–SINGLE are worn excessively. PISTON SYSTEM Disassembly Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from con- taminating internal parts.

  • Page 392: Assembly

    004281 004285 Assembly Inspect the manual release valve. Discard the O-rings on the housing. Use only Evinrude/Johnson Bio- IMPORTANT: degradable TNT Fluid to fill the hydraulic system. Install drive coupler in pump assembly. Install a new motor O-ring. 004284 Remove the four large motor flange retaining screws.
  • Page 393 Fill the oil reservoir up to the fill plug with new screws and lock washers. Tighten the screws Biodegradable Fluid. Evinrude/Johnson 35 to 50 in. lbs. (4 to 5.6 N·m). Install and tighten the fill plug. Do not torque the plug at this time.

  • Page 394: Adjustments

    TRIM AND TILT ADJUSTMENTS ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p. 69. Refer to Tilt Limit Switch Adjustment on p. 68.
  • Page 395 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 396 S–2...

  • Page 397: Marine Products And The Safety Of People Who Use Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.

  • Page 398: Outboard Shift Systems And Safety

    SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...

  • Page 399: Outboard Speed Control System And Safety

    SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...

  • Page 400: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: Must not come apart; • Must not jam; and •...
  • Page 401 SAFETY How can loss of steering control be minimized? Use a steering system recommended by the outboard manufacturer which meets • Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions • When Follow warnings marked “ ” closely. •...

  • Page 402: Outboard Fuel, Electrical System, And Safety

    SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? Fuel leakage must be eliminated.
  • Page 403 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads •...
  • Page 404 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard Check for leaks GASOLINE under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 405: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: outboard parts • bolts, nuts, and washers • boat’s transom • What is most important? Outboard must stay in position on boat’s transom. • What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
  • Page 406 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.

  • Page 407: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

    SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? Shock absorption system must always be ready to absorb • some blows to the lower parts of the outboard. Outboard must not trim in too far suddenly. •...

  • Page 408: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..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 •...
  • Page 409 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.

  • Page 410: Summing Up

    SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...

  • Page 411: Marine Products And The Safety Of People Who Fix Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: Rigging boats •...
  • Page 412 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, 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 can shock...
  • Page 413 SAFETY Running outboard too fast (Overspeeding) “Too fast” means running faster than outboard normally runs on boat. • Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 414 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. 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.

  • Page 415: Handling Lead/Acid Batteries

    SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.

  • Page 416: Gasoline - Handle With Care

    SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...

  • Page 417: Hazardous Products

    SAFETY Hazardous Products Know how items in the shop can hurt people... READ “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an • emergency arise “How to dispose of can” •...

  • Page 418: Safety Awareness Test

    6) Have you received training related to common shop safety practices to protect your- self and others around you? 7) When replacement parts are required, will you use Evinrude /Johnson ® ®...
  • Page 419 INDEX INDEX Batteries n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Battery Charge Isolator 32 Abbreviations 6 Battery Switches 30...
  • Page 420 INDEX Control Cable Cylinder Head Adjustments 53, 54 Inspection 236 Identification 44 Installation 242 Installation 53 Removal 231 Routing 29, 40 Cooling System n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Components 218 Dash Connections 130 Cylinder Block Venting 219...
  • Page 421 INDEX Disassembly 276 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Installation 280 Electrical Circuits Removal 275...
  • Page 422 INDEX Priming 59 Instrument Harness 55, 130 Relieving Pressure 183 Intake Manifold Requirements 35 Assembly 191 Troubleshooting 178 Disassembly 190 Vapor Separator 176, 185 Inspection 191 Installation 191 Fuse 133 Removal 190 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Gauges n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n CANbus 56...
  • Page 423 INDEX New Engines Pistons Fuel and Oil Priming 58 Assembly 240 Outboard Rigging Procedure 52 Inspection 238 Installation 242 Removal 232 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Oetiker Clamp Servicing 42 Powerhead Assembly 239...
  • Page 424 INDEX Remote Controls Shift Linkage Cable Adjustment 53, 54 Installation 248 Cable Installation 53 Lubrication 78 Installation 29 Removal 230 Selection 28 Shift Rod Adjustment 306 Rigging Boat 28 Housing Installation 327 Electrical Harness 55 Shimming, Driveshaft 325 Outboard 52 Spark Plugs Indexing 84 RPM Limit 99, 100...
  • Page 425 INDEX SystemCheck Tools Circuits 148 Alignment Pin Kit, P/N 5007167 252 Dash Connections 130 Alignment Pins, P/N 354140 336 Gauges 28, 101 Backing Plate, P/N 325867 314 Oil System Warnings 205 Bearing Installation Tool, P/N 326562 323 Tests 148, 149, 150 Bearing Installation Tool, P/N 339750 323 Winterization Procedure 86 Bearing Installation Tool, P/N 339778 346...
  • Page 426 INDEX Lifting Tool, P/N 342672 229, 251 Test Propeller 10 Lower Driveshaft Puller, P/N 342681 314 Thermal Joint Compound, P/N 322170 222 Lower Driveshaft Spline Tool, P/N Thread Alignment Pins, P/N 354140 354 5007052 311, 330 Tilt Cylinder End Cap Remover/Installer, P/ Lower Driveshaft Wrench, P/N 352877 330 N 326485 380, 387 Lower driveshaft Wrench, P/N 352877 311...
  • Page 427 INDEX Trim Gauge Test 373 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n Trim Sender Upper Mount Adjustment 69...

  • Page 429: Trouble Check Chart

    TROUBLE CHECK CHART OUTBOARD WILL NOT START TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Battery switch not ON Check battery switch operation Discharged battery Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit.
  • Page 430 TROUBLE CHECK CHART OUTBOARD WILL NOT START OUTBOARD WILL NOT START OBSERVATION POSSIBLE CAUSE PROCEDURE Check wiring and emergency stop switch. Check Stop circuit grounded the safety lanyard is installed and stop circuit is not grounded. In gear–Tiller models Make sure outboard is in neutral No Fuel Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return...
  • Page 431 TROUBLE CHECK CHART OUTBOARD HARD TO START OUTBOARD HARD TO START OBSERVATION POSSIBLE CAUSE PROCEDURE Weak battery Check battery, recharge or replace Clean and tighten connections, check voltage Battery cables and connections drop on high amperage circuit Starter or bendix/drive gears Check starter, inspect bendix/drive gears Check water separator/fuel filter, sample fuel from Water in fuel system...
  • Page 432 TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OBSERVATION POSSIBLE CAUSE PROCEDURE Check key switch and ground to key switch, refer Key switch or wire harness to SYSTEM ANALYSIS and ELECTRICAL AND ground IGNITION Outboard starts and Check EMM LED indicators.
  • Page 433 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE Access EMM service codes and check System- SystemCheck light Outboard is in S.A.F.E. Check warning Refer to specifications, check recommended WOT Incorrect propeller RPM;...
  • Page 434 TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSERVATION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F.E. Access EMM fault codes Incorrect, fouled, or worn spark Replace spark plugs plugs Check water separator/fuel filter, sample fuel from Water in fuel system fuel return manifold test port Contaminated or poor fuel...
  • Page 435 MWS Instrument Wiring Harness DRC6165R...
  • Page 436 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
  • Page 438 CANbus Keyswitch/TNT Wiring Harness A. Trim down B. Trim up C. Trim sender 47 ohm 1/4 watt resistor 5. Battery + (12V) 1. Stop circuit 2. Start solenoid 3. Ground (B-) 6. Choke 4. Switched B+ (12V) Switched B+ (12V) 10 Amp Fused B+ (12V) Ground (B-)
  • Page 439 MWS DASHBOARD SYSTEM CHECK TACHOMETER SPEEDOMETER PUL / +12V LIGHT SWITCH WATER PRES. FUEL VOLTMETER TRIM/TILT FUEL TANK SENDER WARNING HORN TO OUTBOARD DRC6278R...
  • Page 440 Evinrude E-TEC EMM LED Diagnostic Indicators V Models In-line Models Charging / 55V Circuit CPS OK - Injection/Ignition/Fault Sensors / 5V Circuits Stop Circuit - No Oil/Overheat For more information, refer to SYSTEM ANALYSIS in the Service Manual. KEY ON : LED’s illuminate to indicate circuit function...
  • Page 441 J1-B 1. Oil Injector 2. Electric Starter J1-A 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12.
  • Page 442 J1-B 1. Oil Injector 2. Electric Starter J1-A 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12.
  • Page 443 EVINRUDE 115 – 300 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY TPS Voltage > 0.65 V with key ON (or cranking). Becomes stored fault when outboard starts.
  • Page 444 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY 51 Fuel injector circuit #1 OPEN LED 2: ON (Running) 10 seconds 52 Fuel injector circuit #2 OPEN LED 2: ON (Running) 10 seconds 53 Fuel injector circuit #3 OPEN LED 2: ON (Running)

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