Evinrude E-Tec 40 HP Service Manual

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Page 3 Technical Publications P.O. Box 597 Sturtevant, Wisconsin 53177 United States www.evinrude.com or www.johnson.com † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation.
Page 4: Table Of Contents
ERVICE ANUAL ONTENTS SECTION ........PAGE 1 REFERENCE INFORMATION .
Page 5 REFERENCE INFORMATION REFERENCE INFORMATION TABLE OF CONTENTS SAFETY NOTICE ..............4 ABBREVIATIONS USED IN THIS MANUAL .
Page 6: Reference Information
Evinrude/Johnson Special Tools. The Torque wre nch tig htening specifications must included in formation is not a substitu te for wo rk strictly be adhered to.
Page 7 REFERENCE INFORMATION SAFETY NOTICE 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
REFERENCE INFORMATION 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.
Page 9: Emission-Related Installation Instructions
EPA Emission Regulations Manufacturer’s Responsibility All new 19 99 and more recent Evinrude/Johnson Beginning with 1 999 model year o utboards, man- outboards are certified to the EPA as confo rming ufacturers o f ma rine outboards must de termine...
Page 10: Model Designation
B = Blue Paint N = 2 C = Counter Rotation D = ICON model T = 3 ® D = Evinrude E-TEC R = 4 E = Electric Start w/Remote Steering O = 5 F = Direct-Injection D = 6...
Page 11: Models Covered In This Manual
REFERENCE INFORMATION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 52.7 cubic inch (.86 L), 2-Cylinder; and 79 cubic inch (1.29 L), 3-Cylinder Evinrude E-TEC models. Description Model Displacement Gearcase Height Color E40DRLINC .86 L, 52.7 ci...
Page 12: Service Specifications
P/N 382861 Weight (RL) Models: 232 lbs. (105 kg) (may vary depending (HL, PL, SL, TL) Models: 240 lbs. (109 kg) on model) Evinrude/Johnson XD100, XD50, XD30; or Lubrication NMMA TC-W3 certified Engine Type In-line, 2 Cylinder, Two-Cycle Displacement 52.7 cu. in. (864 cc) Bore 3.601 in (91.47 mm)
Page 13 20 in. (L) Models: 21.38 (543 mm) ± one-half turn Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD Lubrication Evinrude/Johnson Biodegradable TNT Fluid Fluid Capacity 15.2 fl. oz. (450 ml) Trim Range 0°...
Page 14 (X) Models: P/N 387388 Weight (L) Models: 320 lbs. (145 kg) (may vary depending (X) Models: 335 lbs. (152 kg) on model) Evinrude/Johnson XD100, XD50, XD30; or Lubrication NMMA TC-W3 certified Engine Type In-line, 3 Cylinder, Two-Cycle Displacement 79.1 cu. in. (1296 cc) Bore 3.601 in (91.47 mm)
Page 15 25 in. (X) Models: 26.25 (666.75 mm) ± one-half turn Shift Cable Stroke 1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD Lubrication Single Piston System–Evinrude/Johnson Biodegradable TNT Fluid Fluid Capacity 21 fl. oz. (620 ml) Trim Range 0°...
Page 16: 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 006411 Nautical Orientation weak, use only authorized Evinrude/John- son Genuine Parts.
Page 17 ROUTINE SERVICE ROUTINE SERVICE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . . 16 LIFTING THE OUTBOARD .
Page 18: Inspection And Maintenance Schedule
ROUTINE SERVICE 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 19: Lifting The Outboard
ROUTINE SERVICE LIFTING THE OUTBOARD LIFTING THE OUTBOARD RIGGING OUTBOARD CONNECTIONS For complete outboard riggin g IMPORTANT: WARNING and remote control installation information, refer to To avoid personal injury, make sure the lift- the Predelivery and Installation Guide included ing capacity of the hoist is at least twice with the service manual set.
Page 20 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Cable Retainer Clip Installation Cable, Hose, and Wire Routing When installing retainer clips on control arm lin k- age pins, clips should be locked and must not be CAUTION bent or deformed. To prevent accidental starting while servic- For proper installation, review the following steps: ing, disconnect the battery cables at the battery.
Page 21: Control Cable Installation
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS If there are not enough threads on the shift cable NOTICE After installation, make sure there for the adjustment, or if the gea rcase does not is enough clearance for all cables to avoid shift fully into FOR WARD or REVERSE, refer to binding or chafing through all engine steering SHIFT ROD ADJUSTMENT on p.
Page 22: Systemcheck Harness Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS the seal only. DO NOT fill connectors with Electri- Move control handle to FOR- IMPORTANT: WARD and pull back slowly t o NEUT RAL. Make cal Grease. sure the engine throttle lever is against the stop. If not, remove slack by adjusting cable trunnion.
Page 23: I-Command Network Connections
ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS Connect the I-Command Engine Inte rface Cable I-Command Network Connections to the EMM CANbus connector. If the outbo ard will be used with I-Command, or other NMEA 2000 compliant CANbus instruments, use the following connections to su pply informa- tion to the network: Remove lower motor covers.
Page 24 ROUTINE SERVICE OUTBOARD RIGGING CONNECTIONS YLINDER ODELS ODELS EMM CANbus connector cap is clipp ed to EMM Adjust harness routing as needed and secure with cooling water h ose. Remove clip from cap tie straps. install on I-Command harness connector. Use an I-Command Ignition and Trim Harness to connect the outboard to the key switch and trim/tilt control.
Page 25: Water Pressure Gauge
006737 1. Electrical cover 2. Wire channel 3. Tab 4. Tie strap Use Evinrude Diagnostics software to adjust net- 002461 1. Water pressure hose fitting work settings in th e EMM. From the Settings screen, select Engine Options. For an I-Command water pressure display , sev- eral water p ressure senso r kit s are a vailable.
Page 26: Battery And Battery Connections
ROUTINE SERVICE BATTERY AND BATTERY CONNECTIONS Install a st arwasher on the threaded battery post. BATTERY AND BATTERY Stack cables from the outboard, then cables from accessories. Finish this connection with a hex nut. CONNECTIONS WARNING Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion.
Page 27: Oetiker Clamp Servicing
ROUTINE SERVICE OETIKER CLAMP SERVICING OETIKER CLAMP SERVICING Clamp Identification Use Oetiker clamps for making hose connections. These clamps provide co rrosion resistance, mini- mize the potential for abrasion of rigging compo- nents, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the p roper sealing of h ose connec- tions.
Page 28 Use only Oetiker re commended IMPORTANT: tools to close Oetiker stepless clamps. Oetiker p incers a re available in the Evinrude/ Johnson Genuine Parts and Accessories Catalog. 000108 Method 2: Lift end of stepless clamp with screw- driver.
Page 29: Adjustments
ROUTINE SERVICE ADJUSTMENTS ADJUSTMENTS Throttle Friction Adjustment Tiller models are equ ipped with a thro ttle frictio n Steering Friction Adjustment adjustment knob lo cated on the st eering handle. Tighten t he knob to red uce the effort requ ired to Tiller models are equipped with a stee ring friction hold a throttle setting.
Page 30: Tilt Limit Switch Adjustment (75 - 90 Hp)
ROUTINE SERVICE ADJUSTMENTS Place the outboard in normal operating position. Tilt Limit Switch Adjustment (75 – 90 HP) Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rot ate the UPPER adjustment WARNING tab DOWN to increase the maximum tilt position. If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in...
Page 31: Trim Sending Unit Adjustment (40 - 60 Hp)
ROUTINE SERVICE ADJUSTMENTS Trim Sending Unit Adjustment WARNING (40 – 60 HP) To avoid personal injury, do not adjust the The sending unit eccentric cam must be ad justed sending unit eccentric cam while the so that the gauge needle is aligned with the lowest engine is being tilted.
Page 32: Trim Sending Unit Adjustment (75 - 90 Hp)
ROUTINE SERVICE ADJUSTMENTS Observe the trim gau ge. If the needle does not Trim Sending Unit Adjustment show cen ter position, tilt the outboard up a nd (75 – 90 HP) adjust the sending unit by pivoting it up or down. Tilt the outboard and engage the tilt support.
Page 33: Trim Tab Adjustment
ROUTINE SERVICE 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 compensate for this steering torque.
Page 34: Dual-Outboard Alignment
ROUTINE SERVICE ADJUSTMENTS Dual-Outboard Alignment Alignment Adjustment Various bo at/motor comb inations respond differ- Dual outboards must b e connected with a tie bar ently to dua l-outboard a lignments. Each app lica- and adjuste d to a lign the o utboards for corre ct tion must be thoroughly tested until the idea l water flow to the gearcases and propellers.
Page 35: Operational Checks
I-Command Turn key switch to ON. The Evinrude E-TEC screen should app ear, fo l- lowed by the tachometer display. Fuel System Perform running checks o f the fuel system by fo l-...
Page 36: Cooling System
ROUTINE SERVICE COOLING SYSTEM Tachometer Pulse Setting COOLING SYSTEM (SystemCheck) Regularly inspect cooling system components for Confirm accuracy of tachometer reading. corrosion, damage, leaks, or restrictions: Adjust dial on back of t achometer to required • water intake screens • setting (the outboard should not be running).
Page 37: Engine Flushing
ROUTINE SERVICE COOLING SYSTEM Turn water supply on. Engine Flushing Flush the outboard with fresh water following each Run outboard at IDLE only until full operating tem- use in brackish, salt, or polluted water to minimize perature is reached. the accumulation of scale and silt deposits in cool- Leave the outbo ard in VERTICAL (DOWN) posi- ing system passages.
Page 38: Running The Outboard Using A Hose And Flushing Adapter
ROUTINE SERVICE COOLING SYSTEM Install flushin g adapter onto gearcase water inlet Running the Outboard Using a screens. Hose and Flushing Adapter WARNING To prevent injury from contact with rotat- ing propeller, remove the propeller before running engine with a flushing adapter. A flushing adapter may be used to provide cooling water when running the outboard to: Flush the engine...
Page 39: Lubrication
ROUTINE SERVICE LUBRICATION LUBRICATION Tiller Handle Lubricate the tiller ha ndle grease fitting s with Tri- Steering System ple-Guard grease. WARNING Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, mak- ing operator control difficult. Grease the stainless steel output end of the steer- ing cable with Triple-Guard grease.
Page 40: Swivel Bracket And Trailering Bracket
ROUTINE SERVICE LUBRICATION Swivel Bracket and Trailering Tilt Tube Bracket Lubricate the tilt tube grease fittin gs with Triple- Guard grease. Lubricate th e swivel bracket with Triple-Guard grease. Apply grease until the grea se begins to flow from the upper or lower swivel bracket areas. Coat the pivot points of the trailering bracket with Triple-Guard grease.
Page 41: Propeller Shaft
ROUTINE SERVICE LUBRICATION Shift the re mote control to the NEUTRAL/IDLE Gearcase Lubricant position. Draining Install control cables. WARNING Check proper throttle and shift function. Gearcase lubricant may be under pressure Propeller Shaft and/or hot. If plug is removed from a recently operated outboard, take precau- Debris from the water can become lodged around tions to avoid injury.
Page 42 ROUTINE SERVICE LUBRICATION Remove the lubricant level plug and th e lubricant Inspection drain/fill plug. Inspect th e lu bricant a nd th e magnet s on the plugs for metal chips. The presence of metal fuzz Use Gearcase Filler, P/N 501882, to slowly fill the can ind icate normal wear of the ge ars, be arings, gearcase with HPF PRO lu bricant thro ugh th e or shafts wit hin t he gea rcase.
Page 43: Trim And Tilt
ROUTINE SERVICE LUBRICATION Trim and Tilt • Single Ram System–Add Evinrude/Johnson Biodegradable TNT Fluid, as n eeded, to bring level to the bottom of the fill plug threads. CAUTION Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.
Page 44: Spark Plugs
ROUTINE SERVICE SPARK PLUGS plug with the OPEN sid e of the ground electrode SPARK PLUGS facing the fuel injector. Spark plu gs shou ld be removed and exa mined periodically. Replace worn , fou led or d amaged spark plugs. Use only recommende d spark plugs with the cor- rect gap setting.
Page 45: Fuel And Oil Systems
Replacement filter elements are available through Evinrude/Johnson Genuine Parts. Fuel Filter Evinrude E-TEC 40–9 0 HP ou tboards are equipped with an in-line fuel filter. Refer to FUEL COMPONENT SERVICING on p. 142. 002227...
Page 46: Anti-Corrosion Protection
ROUTINE SERVICE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect ohmmeter leads between engine ground PROTECTION and anode surface. Sacrificial Anodes Galvanic corrosion occurs in fre sh or salt wa ter. 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 47: Storage
Cooling system a nd/or powerhead damage could occur. Fuel System Treatment Stabilize the boat’ s fuel sup ply with Evinrude/ Johnson 2+4 Fuel Conditioner following the instructions on the container. Internal Engine Treatment Remove th e propeller , attach gard en hose to flushing port and turn on water.
Page 48: Additional Recommendations
ROUTINE SERVICE PRE-SEASON SERVICE Additional Recommendations PRE-SEASON SERVICE Fill oil reservoir. • If t he out board was remove d from the boat for Inspect the fuel filter. If there is debris in the fuel • storage, make sure it is reinstalled with fa ctory filter, it must be replaced.
Page 49: Submerged Engines
Refer to Spark Plug Indexing on p. 42. serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere. Reinstall all removed or disconnected parts. Engine Dropped Overboard Use Evinrude Diagnostics software to: Initiate Break-in • (Not Running) Check fuel pump operation •...
Page 50 ROUTINE SERVICE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 51 ENGINE COVER SERVICE ENGINE COVER SERVICE TABLE OF CONTENTS UPPER COVER SERVICE ............. 50 .
Page 52: Upper Cover Service
ENGINE COVER SERVICE UPPER COVER SERVICE UPPER COVER SERVICE LOWER COVER SERVICE Latch Hook Installation Lower Cover Removal Insert threaded bracket into pocket. Remove lower engine cover screws. 006468 1. Bracket 002168 1. Lower cover screws Apply Ultra-Lock t o screw thre ads. Place hoo k into position with opening toward the front.
Page 53: Lower Cover Installation
ENGINE COVER SERVICE LOWER COVER SERVICE Start the top fron t scr ew n ext and draw cover Lower Cover Installation halves together. Installation of lower mot or covers will be easier if the following steps are performed in order: Install air silencer on throttle body.
Page 54: 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 006470 Install nut on switch. Tighten nut to a torque of 10 Apply Ultra-Lock to sc rew threa ds.
Page 55 ENGINE MANAGEMENT MODULE (EMM) ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION ..............54 .
Page 56: Description
This section discusses the functio ns of the EMM and it s variou s in ternal and externa l sen sors. It also de scribes using Evinrude Diagnostics sof t- ware to retr ieve and adjust service information saved in the EMM 006487 1.
Page 57: Emm Inputs And Outputs Diagram
ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM EMM INPUTS AND OUTPUTS DIAGRAM INPUTS J1-A J1-B OUTPUTS x 100 3550 M E N U 008026 1. Engine Management Module (EMM) 7. Low Oil Switch 13. Fuel Injector 2. Battery (12 volt) 8.
Page 58: Internal Sensors
313 °F (156°C), a senso r circuit fault is detected and the EMM: Sensor inp uts and inte rnal EMM contro llers are used to control outboard operation. Use Evinrude Stores service code 23 Diagnostics software to troubleshoot the sensors.
Page 59: 5 V Circuit Sensor
Monitors the EMM’s 5 V sensor circuit. Sensor inpu ts and intern al EMM controllers a re used to contro l outboard operation. Use Evinrude If sensor voltage is less than 4.75 volts, the EMM: Diagnostics software to troubleshoot the sensors.
Page 60: Low Oil Switch
ENGINE MANAGEMENT MODULE (EMM) EXTERNAL SENSORS If cylinder h ead temperatu re exceeds 212° F If cylinder head does not rea ch operating temper- (100° C) above 35 00 RPM, or 23 0° F (1 10° C) ature (104°F / 40°C belo w 2300 RPM) in 1 0 min- below 3500 RPM, the EMM: utes, the EMM: Activates SHUTDOWN...
Page 61: Throttle Position Sensor
Occurred Fa ult, re fer to Control Cable Installa- tion on p. 19. Fo r tiller models, re fer to Throttle Use the Evinrude Diagnostics so ftware Monitor Cable Adjustment on p. 276, or Throttle Cable screen to check CPS opera tion. The software Adjustment on p.
Page 62: Internal Emm Functions
ENGINE MANAGEMENT MODULE (EMM) INTERNAL EMM FUNCTIONS INTERNAL EMM Exhaust Water Valve Activation (60 - 65 HP) FUNCTIONS During acceleration, the EMM opens a valve that injects water into the exhaust housing. This wa ter ROM Verification changes the tuning of the exhaust, allowing the The EMM perfo rms a se lf-test of programming engine to develop more midra nge horsepower as...
Page 63: Engine Monitor System
ENGINE MANAGEMENT MODULE (EMM) ENGINE MONITOR SYSTEM The EMM activates the warning horn and gaug e ENGINE MONITOR displays as follows: SYSTEM LOW OIL means that oil in the tank is at reserve • level (about 1/4 full). All remote controlled outboards must be equipped NO OIL indicates the oil tank is empty.
Page 64: Warning System
(code 3 3 and 5 7). Then, the EMM mus t be turned OFF and ON again. Shutdown relate d to code 57 or IMPORTANT: 33 requires th e removal of th e occurred service code. Use Evinrude Diagnostics software to cle ar a code 57 or 33.
Page 65: Diagnostic Software Functions
Disconnect the tiller handle harn ess co nnector the system. from the engine harness. Connect Power Supply Use Evinrude Diagnostics software, version 5.1 or Tool to the engine harness connector. Turn toggle higher, and a laptop computer to access progra m switch to the ON position to power the EMM.
Page 66: Static Information
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS If Diagnostic Power Supply Tool, P/N 587005, is The serial number and cylinder location displayed not ava ilable, a Bat tery Cab le, P/N 584348, can on the Injector Coefficients screen must match the be con nected to th e engine mounte d so lenoid.
Page 67: Stored Service Codes (Faults)
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Occurred Service Codes (Faults) Historical Faults Service codes are saved if an ab normal condition The Historical Faults screen keeps a history of all occurs while the outboard is running. previously saved code s, including cod e number, the number of times the event occurred, and oper- The Occurred Faults scree n of the diagnostics ating hours of the last occurrence.
Page 68: Dynamic Tests
This set- Dynamic test s are p erformed with th e outbo ard ting REQUIRES the use of Evinrude XD100 ou t- running. board lubrican t and is not recommend ed for all applications.
Page 69: Tiller/Remote Programming
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Powerhead Break-In Ignition Timing Use the diagnostics software to start break-in oil- Use the Ignition Timing scre en to check an ing after a powerhead rebuild. The break-in oiling adjust EMM timing. EMM timing must be synchro- program runs for two hours of outboard operation, nized to crankshaft position.
Page 70: Tps Calibration
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS TPS Calibration Fuel Injector Servicing TPS Calibration synchronizes throttle plate open- All E-TEC fuel inje ctors use so ftware program- ing with throttle position sensor voltage. ming to compensate fo r variat ions in fuel flow . Each injector a nd it s locat ion on the o utboard is Refer to TPS Calibration on p.
Page 71: Reports
ENGINE MANAGEMENT MODULE (EMM) DIAGNOSTIC SOFTWARE FUNCTIONS Reports Software Replacement Engine rep orts provide service records and can Engine Manag ement Sof tware is loaded into th e be used to document the running history of an out- EMM at the factory. Periodically, a new program board.
Page 72: Emm Transfer
ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING Software repla cement requires IMPORTANT: EMM SERVICING the use of Bootstrap Tool, P/N 586551. Install tool between engine and boat harness key/stop switch If a n ew EMM i s b eing installed, IMPORTANT: connectors as instructed by update program.
Page 73: Installation
ENGINE MANAGEMENT MODULE (EMM) EMM SERVICING Installation Installation is the revers e of removal. Pay close attention when performing the following tasks. Make sure isolator mounts are placed in slots in of EMM case. Slide EMM into position. 006478 1. Isolator mounts Apply Nut Lock t o t hreads o f EMM ret aining screws.
Page 74 ENGINE MANAGEMENT MODULE (EMM) NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 75 SYSTEM ANALYSIS SYSTEM ANALYSIS TABLE OF CONTENTS DIAGNOSTIC PROCEDURES ............74 .
Page 76: Diagnostic Procedures
Repair any shorted electrical circuits. TORS on p. 77. Refer to ELECTRICAL HARNESS CONNEC- • Check the Evinrude Diagnostics software Active • TIONS on p. 92. Faults and Occurred Faults screens for current Refer to WIRING DIAGRAM at the back of this •...
Page 77: Troubleshooting
If there are multiple occurred sensor codes, inspect all 5 V sensor circuits for broken or grounded wiring. Perform a Static Ign ition test using Evinrude • Diagnostics so ftware and a n ind uctive t iming light. Refer to Static Ignition Test on p. 81.
Page 78: Dynamic Tests
This feature should not be used by itself to identify a faulty injector. Use the Evinrude Diagnostics sof tware Dynamic Tests to moment arily disable one cylinder while Evinrude Diagnostics software allo ws temporary the outboard is running.
Page 79: Emm Led Indicators
SYSTEM ANALYSIS EMM LED INDICATORS EMM LED INDICATORS Starting Starting mode occurs from th e time t he flywhee l The EMM LED ind icators provide a quick refer- begins to turn until th e ou tboard is run ning for 2 ence to the st atus of several outb oard systems.
Page 80: Running
SYSTEM ANALYSIS EMM LED INDICATORS LED 3 – Sensor circuits (5 V), SENSOR FAULT. Running For LIGHT ON, check for possible fault codes: When the outbo ard is runn ing, all of the LEDs Code 12 – TPS circuit fault •...
Page 81: Ignition Output Tests
Ignition Coil Primary circu its are powered by system (55 V) • Use the Evinrude Diagnostics sof tware Occurred voltage Faults screen to check for current service code s EMM provides control signal to ignition coil •...
Page 82: Crankshaft Position Sensor (Cps) Test
When the CPS is working proper ly, EMM LED 2 turns on while the outboard is being started. Use th e Evinrude Diagnostics so ftware 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 outboa rd is cranking or running.
Page 83: Static Ignition Test
Static Ignition Test IMPORTANT: coil with 12 V battery power on the system voltage Perform the static ignition test using Evinrude (55 V) circuit. An inductive probe with low sensitiv- Diagnostics software and an inductive timing light. ity may not be able to detect the signal.
Page 84: Running Ignition Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS Running Ignition Tests Results: Steady voltage and strobe, engine misfires: Use Evinrude Diagnostics Software to monitor Inspect or replace spark plugs • system voltage (55 V). Refer to FUEL DELIVERY TESTS on p. 84 •...
Page 85: Ignition Control Circuit Tests
SYSTEM ANALYSIS IGNITION OUTPUT TESTS With EMM OFF, remove the EMM J1-B connector Ignition Control Circuit Tests and test th e continuity of each ignition control cir- Use a digital multimeter to test the following: cuit (orange). Check resistance bet ween J1-B System voltage supply to ignition coil.
Page 86: Fuel Delivery Tests
Fuel Injector Static Test Inspect all fuel hoses, filte rs, and co nnections. Check quality of fuel supply. Use the Evinrude Diagnostics software Fuel Injec- tor Static Test to activate each fuel injector. Listen Fuel Pump Static Test for an a udible click from each injector when it is Use the Evinrude Diagnostics software Fuel Pump actuated.
Page 87: Running Fuel System Tests
Steady light activation o n all in jector wire s an d Run or crank the outboard. consistent voltage readings, EMM injector contro l Use the Evinrude Diagnostics sof tware Monitor function is good: screen to check syste m voltage. If vo ltage is low, Use the diagnostics software Dynamic Fuel Test •...
Page 88: Exhaust Water Valve (60-65Hp)
Exhaust Water Valve Static Test With the outb oard id ling, activate the dyna mic Use Evinrude Diagnostics sof tware to test the water va lve test and check for wa ter flow . A water valve solenoid ele ctrical circuit. The water steady stream of water should flow from the hose valve is a 55 volt co il.
Page 89 ELECTRICAL AND IGNITION ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART ..............88 IGNITION SYSTEM CIRCUIT DIAGRAM, 40 –...
Page 90: Service Chart
ELECTRICAL AND IGNITION SERVICE CHART SERVICE CHART 5 to 8 in lbs. (.6 to .9 N·m) 120 to 140 in lbs. (13.5 to 16 N·m) 100 to 115 ft. lbs. (136 to 156 N·m) 168 to 192 in lbs. (19 to 21 N·m) 84 to 106 in lbs.
Page 91 ELECTRICAL AND IGNITION SERVICE CHART 24 to 36 in lbs. (2.7 to 4 N·m) 15 to 30 ft. lbs. (20 to 41 N·m) 60 to 84 in lbs. (7 to 9.5 N ·m) 30 to 42 in lbs. (3.4 to 4.8 N·m) 24 to 36 in lbs.
Page 92: Ignition System Circuit Diagram, 40 - 65 Hp
ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP 1 2 3 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Neutral switch Crankshaft position sensor Main harness ground Stator Capacitor...
Page 93: Ignition System Circuit Diagram, 75 - 90 Hp
ELECTRICAL AND IGNITION IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP 1 2 3 1 2 3 J1-A J1-B Key switch (stop circuit) Ignition coil Neutral switch Crankshaft position sensor Main harness ground Stator Capacitor...
Page 94: Electrical Harness Connections
ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS ELECTRICAL HARNESS EMM J1-A Connector CONNECTIONS Inspect wiring and electric al connectio ns. Disas- semble a nd clean all corrode d co nnections. Replace damaged wiring, con nectors, o r termi- nals. Repair any shorted electrical circuit s. Refer to wiring d iagrams and reference charts f or spe- cific wiring details.
Page 95 ELECTRICAL AND IGNITION ELECTRICAL HARNESS CONNECTIONS EMM J1-B Connector EMM J2 Connector 001876 001877 Description of Circuit Wire Color Description of Circuit Wire Color Injector, cylinder 2, 75–90 HP Purple Stator winding, 1S Yellow Injector, cylinder 2, 40–65 HP Green Stator winding, 2S Brown Injector, cylinder 3, 75–90 HP...
Page 96: Ground Circuits
ELECTRICAL AND IGNITION GROUND CIRCUITS GROUND CIRCUITS FUSE All grou nd circuit s are essential to reliable out- The engine h arness 12 V (B+) circu it is pro tected board performance. Make sure all ground connec- by one automotive style 10 amp minifuse. tions are clean and tight.
Page 97: Sensor Tests
IMPORTANT: ware to monitor sensor circuit voltages or values. Crankshaft Position Sensor (CPS) Test Use the Evinrude Diagnostics software CPS Sync 006527 1. CPS gap and engine RPM displays to confirm a valid CPS signal while the outboa rd is cranking or running.
Page 98: Engine Temperature Sensor Test
ELECTRICAL AND IGNITION SENSOR TESTS Connect red meter lea d 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 it s range of trave l. Resistance reading perature sensor.
Page 99: Stator Tests
ELECTRICAL AND IGNITION STATOR TESTS To che ck for a g rounded winding, conne ct on e STATOR TESTS meter lead to ground and alternately connect the other meter lead to each stator wire. Meter should The st ator consists of 3 windings (4 poles each) read no contin uity.
Page 100: Charging System Tests
ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS CHARGING SYSTEM TART ODELS Use a Pea k Read ing Voltmeter, P/N 507972, to TESTS check st ator output volt age. Set meter to 50 VAC scale. 12 V Charging Circuit WARNING To test the o peration of the regulator in the EMM, you must be able to run the outboard continuously To prevent accidental starting of outboard, at approximately 5000 RPM, such as in a test tank...
Page 101 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Following the manufa cturer’s dire ctions, conne ct Start and run th e outboard at appr oximately 5000 the variable lo ad teste r (carbon pile) across the RPM. Use the variable load tester to draw the bat- battery terminals.
Page 102: Electric Start Circuit
ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT ELECTRIC START CIRCUIT Start Circuit Diagram FUSE J1-A – J1-B 008049 1. Marine battery 9. PURPLE wire (switched B+) 2. RED wire (POS) 10. Engine Management Module (EMM) 3. BLACK wire (NEG) 11. YELLOW/RED wire, start 4.
Page 103 ELECTRICAL AND IGNITION ELECTRIC START CIRCUIT Start Circuit Operation Instrument Wire Harness Contains the following circuits: The st arter must engag e and tu rn the flywhee l. Red/purple wire provides 12 V to key switch ter- • The outboard must crank a minimum of 300 RPM minal “B”.
Page 104: Electric Start Tests
ELECTRICAL AND IGNITION ELECTRIC START TESTS Key Switch, START Position ELECTRIC START TESTS Key switch START: Switches 12 V to terminal “S” of key switch and Starter Solenoid Test • to the neutral safety switch (in remote control). Disconnect the B+ (POS) battery cable at the bat- A closed neu tral safety swit ch provides 12 V to •...
Page 105 ELECTRICAL AND IGNITION ELECTRIC START TESTS Observe voltage reading. Starter Voltage Drop Test • STEP 4: Connect positive (+) lead to starter cable WARNING of solenoid terminal. Connect negative (–) lead to starter motor terminal. To prevent accidental starting of outboard, Activate st arter motor a nd observe volt age disconnect crankshaft position sensor •...
Page 106: Remote Control Switch Tests
ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS REMOTE CONTROL Neutral Start Circuit Test Use an ohmmeter or con tinuity light to test SWITCH TESTS continuity of th e circu it while p ositioning t he remote control in NEUTRAL, FOR WARD, a nd Key Switch Test REVERSE.
Page 107 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 switc h can be part of the ke y switc h or tral start switch operation. installed as a separate swit ch.
Page 108: Tilt/Trim Relay Test
ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST The met er mu st indicate battery volt age ( 12 V) TILT/TRIM RELAY TEST with B+ connected to either terminal. The tilt and trim (TNT) modu le con tains the cir- cuitry and relays required for power trim and tilt operation.
Page 109: Systemcheck Circuit Tests
ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS instrument harne ss termi nal 1 (purple wire) an d SystemCheck CIRCUIT terminal 2 (black wire). TESTS Make sure the SystemCheck engine monitor can warn the opera tor during a “NO OIL,” “W ATER TEMP”...
Page 110 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two conn ectors, replace WATER TEMP/ HOT Circuit Test SystemCheck gauge. The tan wire of engine harness and the MWS har- ness receives a signal f rom the EMM. The EMM receives information from th e temperature sensor on the cylinder head.
Page 111: Tachometer Circuit Tests
ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS TACHOMETER CIRCUIT LOW OIL Circuit Test 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 en gine ground. The LOW Check voltage at the battery.
Page 112: Flywheel And Stator Servicing
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Disconnect wiring harne ss and remo ve wiring FLYWHEEL AND STATOR from cover. SERVICING Weak flywheel mag nets can IMPORTANT: cause lo w alternator output and af fect outboard performance. W eak flywheel magn ets ca n also cause low read ings on ignition test equipme such as a pe ak-reading voltmeter , which might cause unnecessary parts replacement.
Page 113: Stator Service
ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Use Flywh eel Holder, P/N 771311, or equivalent, Stator Service and a 1 5/16 in. socket to remove flywheel n ut. Disconnect stator harness connector. Discard flywheel nut. Remove three allen head screws to remove stator. 002088 006486 1.
Page 114: Ignition Coil Servicing
ELECTRICAL AND IGNITION IGNITION COIL SERVICING Thoroughly clean t he crankshaf t and f lywheel IGNITION COIL tapers with Cleaning Solvent and let dry. SERVICING Ignition Coil Removal Remove spark plug lead from ignition coil and dis- connect ignition coil electrical connector. Remove two ignition coil retaining screws.
Page 115: Timing Adjustments
Label this mark “B.” Rot ate fly- Always check timing po inter adjustment be fore wheel counterclockwise slightly to release too l using t he Evinrude Diagnostics sof tware Timing then remove it from spark plug hole. Verification procedure.
Page 116: Timing Verification
IMPORTANT: set and the outboard reaches operating tempera- ture before making any timing adjustments. TPS Calibration Use Evinrude Diagnostics sof tware to te ll t he 002092 1. Mark “A’” EMM what throttle position sensor voltage is when 2. Mark “B”...
Page 117: Electric Starter Servicing
ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING ELECTRIC STARTER Starter Installation Apply Triple-Guard grease to the th reads of th e SERVICING two st arter screws, th e doub le-ended stud, an d also to the washers. Starter Removal Position the st arter and inst all th e screws an d Do not clean the st arter drive IMPORTANT: washers.
Page 118: Connector Servicing
ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire. CONNECTOR SERVICING DEUTSCH Connectors Grease is reco IMPORTANT: Electrical mended. Incorrect grease applica tion can cause electrical or warning system problems. 42329 1. Terminal latch (plug) To disconnect th e connector, press the latch and 2.
Page 119: Amp Connectors
ELECTRICAL AND IGNITION CONNECTOR SERVICING AMP Connectors Always use the appropriate meter IMPORTANT: test probe s and ada pters 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 120 ELECTRICAL AND IGNITION CONNECTOR SERVICING UPER OWER IMER ERIES The J1-A and J1-B conn ectors of the EMM are The J2 conne ctor of the EMM is an AMP Power AMP Super Seal connectors. Timer Series connector. Disconnect Disconnect Depress BOT H latches and pull con nector from Use a screw driver to open latch.
Page 121: Packard Connectors
ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Terminal Removal Align terminal with connector housing and push A tab on the back sid e of the terminal engages a terminal with se al in to conn ector housing until shoulder in the connector housing to hold the ter- seated.
Page 122 ELECTRICAL AND IGNITION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 123 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............122 FUEL SYSTEM HOSE ROUTING .
Page 124: Service Chart
FUEL SYSTEM SERVICE CHART SERVICE CHART YLINDER ODELS NJECTORS APOR EPARATOR Tighten in 3 stages 5 ft. lbs. (7 N·m) 10 ft. lbs. (14 N·m) 24-36 in. lbs. (2.7-4 N·m) 24-26 Ft. lbs. (33-35 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in.
Page 125 FUEL SYSTEM SERVICE CHART YLINDER ODELS LATE SSEMBLY AND HROTTLE 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) Important: DO NOT lubricate IMPORTANT: TPS to throttle shaft surface DO NOT lubricate TPS to throttle shaft surface 10-14 in. lbs (1.1-1.6 n·m) 10-14 in.
Page 126 FUEL SYSTEM SERVICE CHART YLINDER ODELS NJECTORS APOR EPARATOR Tighten in 3 stages 5 ft. lbs. (7 N·m) 10 ft. lbs. (14 N·m) 24-36 in. lbs. (2.7-4 N·m) 24-26 Ft. lbs. (33-35 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in.
Page 127 FUEL SYSTEM SERVICE CHART YLINDER ODELS LATE SSEMBLY AND HROTTLE 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) IMPORTANT: DO NOT lubricate TPS to throttle shaft surface 10-14 in. lbs (1.1-1.6 n·m) 10-14 in. lbs (1.1-1.6 n·m) 10-18 in. lbs 60-120 in.
Page 128: Fuel System Hose Routing
FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING YLINDER ODELS Fuel Supply Fuel Return 002148 Fuel supply from boat fuel system Fuel lift pump (2 to 8 psi) Pulse hose from cylinder/crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump (20 to 30 psi) Fuel supply manifold...
Page 129 FUEL SYSTEM YLINDER ODELS Fuel Supply Fuel Return 002148a Fuel supply from boat fuel system Fuel lift pump (2 to 8 psi) Pulse hose from cylinder/crankcase Fuel filter Fuel supply to vapor separator Vapor separator Electric fuel circulation pump (20 to 30 psi) Fuel supply manifold Fuel injector(s) Fuel return manifold...
Page 130: Fuel System Circuit Diagrams
FUEL SYSTEM FUEL SYSTEM CIRCUIT DIAGRAMS FUEL SYSTEM CIRCUIT DIAGRAMS YLINDER ODELS J1-A J1-B 006479 Stator Capacitor GREEN WHITE/RED (55 V) BROWN Fuel injector BLACK ground wires Fuel circulation pump BLUE...
Page 131 FUEL SYSTEM YLINDER ODELS J1-A J1-B 006756 Stator Capacitor PURPLE WHITE/RED (55 V) GREEN (2) Fuel injector BLACK ground wires BROWN Fuel circulation pump BLUE...
Page 132: Fuel System Requirements
FUEL SYSTEM FUEL SYSTEM REQUIREMENTS FUEL SYSTEM Portable Fuel Tanks REQUIREMENTS WARNING If engine is equipped with a quick-discon- Regulations and Guidelines nect fuel hose, you MUST disconnect the Vessel man ufacturer, and /or inst aller of an EP A fuel hose from the engine and the fuel tank certified outboard, must meet minimum specifica- to prevent fuel leaks:...
Page 133: Fuel Requirements
Do not smoke, allow open flames or The only fuel additives ap proved sparks, or use electrical devices such as IMPORTANT: for use in Evinrude outboards are 2+4 fuel condi- cellular phones in the vicinity of a fuel leak ®...
Page 134: Components
FUEL SYSTEM COMPONENTS Vacuum from the fuel lift pump pulls fuel fro m the COMPONENTS fuel t ank. Once fu el reaches the pump, interna l pump pressure force s the fuel from the pump The fuel syste m includes the following compo- through the fuel filter and into the vapor separator.
Page 135 FUEL SYSTEM COMPONENTS The vapor separator is serviced a s a n a ssembly and includes the fuel circulation pump. 002180 1. Vent hose connection to intake The vapor separator vent is opened and closed by 006555 Vapor Separator Assembly a float valve.
Page 136: Fuel Circulation Pump
FUEL SYSTEM COMPONENTS Fuel Circulation Pump Fuel Manifolds The fuel circulation pump is an electric high pres- The fuel supply and return manifo lds route fue l sure fuel pump. through the high pressure side of the fuel system. Fuel Supply Fuel Supply Manifold The pump is moun ted to the va por separator and The fuel supply manifold supplies pressurized fuel...
Page 137 FUEL SYSTEM COMPONENTS The EMM is programmed to compensate for vari- Injector Fuel Supply ations in fuel flow. Each injector and its location on Fuel is supplied to the injectors by the fuel circula- the outboard is identified by the EMM. DO NOT tion pump and the fuel supply manifold.
Page 138: Fuel System Priming
FUEL SYSTEM FUEL SYSTEM PRIMING FUEL SYSTEM PRIMING Priming the Fuel System Vent Line Clamp WARNING Federal Reg ulations require that a ll o utboards Fuel vapors are highly flammable. Perform with a fuel vapor separator must be shipped with a the following procedure in a well venti- vent line clamp inst alled.
Page 139: Fuel System Tests
FUEL SYSTEM FUEL SYSTEM TESTS Shut OFF outbo ard. Mo nitor pr essure gaug e. FUEL SYSTEM TESTS Pressure should not drop below 15 psi (103 kPa). If outb oard does not run, prime WARNING IMPORTANT: fuel system and crank outboard; check circulation Use caution when working on any pres- pump operation;...
Page 140: Pressure Regulator Test
FUEL SYSTEM FUEL SYSTEM TESTS Pressure Regulator Test Fuel Injector Pressure Test Refer to Vapor Separator Service on p. 144 to This te st re quires Inj ector T est Fi tting ki t, remove vapor separator. P/N 5005844. Make su re filter is no t clogg ed. Clean or r eplace Disconnect the battery cables at the battery.
Page 141: Fuel Injector Resistance Test
FUEL SYSTEM FUEL SYSTEM TESTS Fuel Injector Resistance Test Circulation Pump Resistance Test Disconnect the battery cables at the battery. Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector Use a digital multimeter with app ropriate adapter coil resistance.
Page 142: Lift Pump Vacuum Test
FUEL SYSTEM FUEL SYSTEM TESTS Results: NOTICE Do not use fuel primer bulb, manual Normal pressure: fuel primer, or electric fuel pump primer to Perform the Lift Pump Vacuum Test on p. 140. • restart outboard. A positive pressure in the Make sure no a ir lea ks or restrictions ex ist in fuel supply could damage some vacuum the fuel supply hose or boat fuel system.
Page 143: Lift Pump Diaphragm Test
FUEL SYSTEM FUEL SYSTEM TESTS Lift Pump Diaphragm Test Anti-Siphon Valve Test Perform this test on ly if a damaged pump is sus- Remove anti-siphon valve fro m f uel tank. Install pected. This test does not confirm the p erfor- adapter fitt ings and a 36 in .
Page 144: Fuel Component Servicing
FUEL SYSTEM FUEL COMPONENT SERVICING Wrap a shop t owel comp letely ar ound th e pres- FUEL COMPONENT sure test valve while conne cting fitting from Fue l Pressure Ga uge, P/N 5007 100, to top test fittin g SERVICING of fuel pump/vapor separator assembly.
Page 145: Fuel Filter Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Filter Service Fuel Lift Pump Service The fuel lif t pump is serviceab le as a comple te Removal assembly or can be repaired with a fuel pump Disconnect the battery cables at the battery. repair kit.
Page 146: Vapor Separator Service
FUEL SYSTEM FUEL COMPONENT SERVICING Remove vapor sep arator/fuel pump from t he Installation mounting stud and slide va por separator housing Place fue l pump in po sition on crankcase. Apply from the grooves of the isolator mounts. Nut Lock to mounting screws. Tighten screws to a torque of 24 to 36 in.
Page 147: Fuel Manifold Service
FUEL SYSTEM FUEL COMPONENT SERVICING Fuel Manifold Service Installation Check condition of sealing O-rings on fuel man i- Removal fold fittings. Lubricate O-rings with outboard lubri- Disconnect the battery cables at the battery. cant a nd insert fuel manifo ld fittings into injecto r. Both fittings must be fu lly seated into the in jector Relieve fuel system pressure.
Page 148: Fuel Injector Service
Fuel Injector Service Mark fuel injectors to show cylinder locations. NOTICE Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers for each cylinder.
Page 149 If a disk is not included with the injector, coefficient dat a ca n be downloade d from th e 002196 1. Adaptor Evinrude/Johnson dealer website. Ref er to th e instructions provided with the injector kit. Upload Coefficient Files to EMM If using Diagnostic Power Supply...
Page 150 FUEL SYSTEM FUEL COMPONENT SERVICING Use the drop down menu to navigate to the saved Install Injector coefficient file location. The following ite ms and their ma ting surfaces must be cleaned prior to reassembly: The coefficient file name must ma tch the serial Injector •...
Page 151: Intake Manifold Service
FUEL SYSTEM FUEL COMPONENT SERVICING Tighten scre ws in stages, st arting wit h the lower Intake Manifold Service screw. Removal First torque is 5 ft. lbs. (7 N·m). • Disconnect vapor separator vent hose, main bear- Second torque is 10 ft. lbs. (14 N·m). •...
Page 152 FUEL SYSTEM FUEL COMPONENT SERVICING Disassembly Inspection All reed pla te assemb ly an d reed va lve assem- Inspect the leaf plate a ssemblies for da mage or blies must be clea ned prior to rea ssembly. DO contamination: NOT use strong ca rburetor cleane r or the hot Leaf plates must not be distorted.
Page 153 FUEL SYSTEM FUEL COMPONENT SERVICING Prime screw th reads with Locquic Primer and let Tighten the center screws first and exp and o ut- dry. Apply Nut Lock to threads. Position reed valve ward. Tighten in st ages to a final to rque of 60 to on reed plate an d inst all screws.
Page 154 FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 155 OILING SYSTEM OILING SYSTEM TABLE OF CONTENTS SERVICE CHART ..............154 OIL SUPPLY DIAGRAMS .
Page 156: Service Chart
OILING SYSTEM SERVICE CHART SERVICE CHART 40 – 65 HP 30 to 42 in lbs. (3.5 - 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 tp 42 in lbs. (3.5 - 5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock...
Page 157 OILING SYSTEM 75 – 90 HP 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) 30 to 42 in lbs. (3.5 to 5 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant...
Page 158: Oil Supply Diagrams
OILING SYSTEM OIL SUPPLY DIAGRAMS OIL SUPPLY DIAGRAMS 40 – 65 HP 008060 Oil tank Oil distribution manifold Oil pick-up/filter Crankcase oil inlet (port) Oil injection pump Cylinder oil inlet (starboard)
Page 159 OILING SYSTEM 75 – 90 HP 008061 Oil tank Oil distribution manifold Oil pick-up/filter Crankcase oil inlet (port) Oil injection pump Cylinder oil inlet (starboard)
Page 160: Oil Recirculation Diagrams
OILING SYSTEM OIL RECIRCULATION DIAGRAMS OIL RECIRCULATION DIAGRAMS 40 – 65 HP Starboard view Port view 002483a 75 – 90 HP Port view Starboard view 002223...
Page 161: Oiling System Circuit Diagram
OILING SYSTEM OILING SYSTEM CIRCUIT DIAGRAM OILING SYSTEM CIRCUIT DIAGRAM J1-A J1-B 008050 Stator Main harness ground (BLACK) Alternator grounds (BLACK) Alternator output, WHITE / RED wires (55 V) Capacitor (55 V) EMM injector control (BLUE) 55 V to injection pump (WHITE / RED) Oil injection pump Low oil switch Low oil switch to EMM (TAN/BLACK)
Page 162: Oil System Requirements
Oil injection pump and manifold assembly • Evinrude/Johnson XD100, XD50, or XD30 out- Oil level switch board oils are recommende d for use in Evinrude • Electrical circuit E-TEC outbo ards. If these oils are no t available, • LOW OIL and NO OIL warning systems you must use a TC-W3 certified oil.
Page 163: Oil Injection Pump
OILING SYSTEM COMPONENTS The oil manifold distributes the oil supplied by the YLINDER ODELS pump. Oil Tank Components: Tank, 2 quart. (1.87 liter) capacity • Oil pickup and filter assembly • Oil injection pump and manifold assembly • LOW OIL switch •...
Page 164: Low Oil Warning
OILING SYSTEM COMPONENTS LOW OIL Warning Cylinder and Crankcase A switch in the oil tank assembly monitors the oil The oil d istribution mani fold provides crankcase level in the oil tank. lubrication thro ugh oil distributio n h oses a nd pressed-in fittin gs on the crankcase and cylind er If the oil level falls below one-quarter capacity, the block.
Page 165: Oil Recirculation System
OILING SYSTEM COMPONENTS Crankcase / Main Bearing Recirculation YLINDER ODELS The movement of oil through the main bearings is controlled by int ernal p assages, e xternal fittings and hoses, and check valves. Lower to upper main bearing oil flow: Lower main bearing cavity to internal crankcase •...
Page 166: Oil Control Settings
This set- that have be en programme d for the reduced oil ting REQUIRES th e use of Evinrude XD100 out- injection ratio. board lub ricant and is not re commended for all applications.
Page 167: Break-In Oiling
40 – 90 HP: First two hours above 2000 RPM • Follow these steps for outboard set-up: Use Evinrude Diagnostics sof tware to m ake • sure the break-in program has been started on a new outboard.
Page 168: Oiling System Tests
OILING SYSTEM OILING SYSTEM TESTS Observe oil flow through all oil distribution hoses. OILING SYSTEM TESTS Air must be purged during the priming procedure. Always perform visual inspections IMPORTANT: to identify oiling system lea ks. Make sure th e oil tank is filled and oil supply is not contaminated.
Page 169: Oil Injection Pump Resistance Test
OILING SYSTEM OILING SYSTEM TESTS Use the Oil Injector te st o f Evinrude Diagnostic Set digit al multimeter to a scale that re ads 55 V software Static Test screen to activate the oil (DC). pump. Start the engine. Observe voltage at pin A.
Page 170: Oil Injection Pump Function Test
OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Function Test Oil Injection Fittings Flow Test Remove oil distribution hose from fitting at oil dis- Make sure the oil injection fittings of the cylind er tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.
Page 171: Oil Component Servicing
OILING SYSTEM OIL COMPONENT SERVICING OIL COMPONENT Installation Cut Repla cement Oil Hose , P/N 778708, to the SERVICING correct length. Insert hose support in manifold end of hose. WARNING DO NOT insert distribution hoses IMPORTANT: into manifold without a hose support. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.
Page 172 006573 1. Tie strap 008075 Run outboard and check for leaks. Use Evinrude 1. Oil pump connector Diagnostics sof tware to activate “Oil Prime.” Disconnect the electrical co nnector to the lo w oil Check oil flow through oil distrib ution hoses.
Page 173: Oil Injection Pump
OILING SYSTEM OIL COMPONENT SERVICING Oil Injection Pump Installation Apply a dro p of out board lubricant to a new oil Removal pump o-ring. Install o-ring on oil pump flange. Remove oil distribution h oses fro m oil manifold. Refer to Oil Distribution Hoses on p. 169. Remove oil from oil tank.
Page 174 OILING SYSTEM OIL COMPONENT SERVICING YLINDER ODELS Install oil pump and manifold straight into oil tank. Be sure oil pick u p assemb ly is IMPORTANT: positioned in front of oil t ank ba ffle to prevent interference with the LOW OIL switch. 008183 1.
Page 175 COOLING SYSTEM COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS ........174 COMPONENTS .
Page 176: Hose Routing And Water Flow Diagrams
COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS HOSE ROUTING AND WATER FLOW DIAGRAMS YLINDER ODELS 60, 65 HP Water intake screens Water pump Exhaust housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply, EMM to vapor separator Overboard indicator, outgoing water from vapor separator...
Page 177 COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS YLINDER ODELS Outgoing water (warm/hot) Incoming water (cool) Water intake screens Water pump Water tube Adapter housing Cylinder block Pressure relief valve Thermostat Water supply to EMM Water supply, EMM to vapor separator Overboard indicator, outgoing water from vapor separator.
Page 178: Components
COOLING SYSTEM COMPONENTS The water pump hou sing on 2- COMPONENTS IMPORTANT: cylinder models includes a small hole to the rear of the wa ter outlet. This hole provides cooling Water Pump and Intakes water for the tip of the exhaust passage. Be sure External water int akes mo unted in t he ge arcase to use the correct parts when replacing the water housing collect water a nd must su pply the inlet...
Page 179: Adapter/Inner Exhaust Housing
COOLING SYSTEM COMPONENTS Adapter/Inner Exhaust Housing Pressure Relief Valve A pressure relief valve is used to control wa YLINDER ODELS flow and operating temperature at highe r speeds Adapts the cylin der/crankcase assembly (pow- • (above appro ximately 1800 RPM). The pressure erhead) to the exh aust housing and the water relief valve ope ns a s water pressure incre ases.
Page 180: Block Venting
COOLING SYSTEM COMPONENTS Block Venting Water Pressure Connection A fit ting an d hose conn ected to the top of the A fitting and hose for an accessory water pressure exhaust cover allows the const ant mo vement of gauge can be connected at the top of the cylinder water and/o r air from the block.
Page 181: Operation
COOLING SYSTEM OPERATION At higher speeds, wate r pressure op ens th e OPERATION pressure relief valve at approximately 1800 RPM. Water flows through the valve to the cylinder head All models use a two-stage cooling system and byp asses the th ermostat. All wa ter flo ws design.
Page 182: Engine Temperature Check
COOLING SYSTEM ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Software Method Use Evinrude Diagnostics sof tware to read tem- CHECK perature displays. The engine tempe ratures listed IMPORTANT: below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C).
Page 183 COOLING SYSTEM ENGINE TEMPERATURE CHECK Check thermost at for cracks, hea t damage, or If you get low or in accurate read- IMPORTANT: signs of corrosion. Check for proper operation. ings with a digital pyrometer, coat the probe loca- Thermostat opens at 143°F (62°C). tion with Thermal Joint Compound, P/N 322170.
Page 184: Temperature Sender Servicing
COOLING SYSTEM TEMPERATURE SENDER SERVICING TEMPERATURE SENDER THERMOSTAT SERVICING SERVICING Removal Disassembly Loosen sensor and remove by hand. Use care to Remove the thermostat cover and O-ring from cyl- avoid breaking threads. inder head. 008346 008347 Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Page 185: Inspection
COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING HEAD” facing thermostat. Refer to Cylinder Head PRESSURE RELIEF Installation on p. 207. VALVE SERVICING The pressure relief valve assembly should be ser- viced at the same time as the thermostat. Disassembly Remove screws and cove r from pressure valve assembly.
Page 186: Inspection
COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING Inspection Inspect all parts for cracks, heat damage, or signs of corrosion. Re place dama ged p arts. Clean debris from housing and parts. 002442 Pressure Relief Valve Assembly Components Assembly Assembly is the rever se of disassemb ly. Pa y close attent ion when pe rforming the following additional tasks.
Page 187 POWERHEAD POWERHEAD TABLE OF CONTENTS SERVICE CHART ..............186 COMPRESSION TESTING .
Page 188: Service Chart
POWERHEAD SERVICE CHART SERVICE CHART YLINDER ODELS 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16 N·m) 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) IMPORTANT See Spark Plug Indexing Procedure Apply to water passages Apply to crankcase mating flange 26-30 Ft.
Page 189 POWERHEAD SERVICE CHART YLINDER ODELS 30-32 Ft. lbs. (41-43 N·m) Must have alignment tool Triple-Guard Grease Gasket Sealing Compound Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Outboard Lubricant Permatex No. 2 Gel Seal II 002284 Extreme Pressure Grease...
Page 190 POWERHEAD SERVICE CHART YLINDER ODELS 60-84 In. lbs. (7-9.5 N·m) 120-144 In. lbs. (13.5-16 N·m) 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) IMPORTANT See Spark Plug Indexing Procedure Apply to crankcase mating flange Apply to water passages 60-84 In.
Page 191 POWERHEAD SERVICE CHART YLINDER ODELS 30-32 Ft. lbs. (41-43 N·m) Must have alignment tool Triple-Guard Grease Gasket Sealing Compound Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Outboard Lubricant Permatex No. 2 Gel Seal II Extreme Pressure Grease 15-20 Ft.
Page 192: Compression Testing
POWERHEAD COMPRESSION TESTING COMPRESSION TESTING POWERHEAD REMOVAL Start and run outboard until it achieves o perating 2-Cylinder Models temperature, then shut OFF. WARNING Disconnect crankshaft position sensor (CPS) con- nector. Remove all spark plugs. Protect against hazardous fuel spray. Before starting any fuel system service, Advance throttle linkage to WOT.
Page 193 POWERHEAD POWERHEAD REMOVAL Remove pin and wa sher from shif t rod lever to ODELS release the lower shift rod. Install Lifting Fixture, P/N 396748, on flywheel and seat the three screws completely. NOTICE Be sure to use only the 1 1/8 in. (short) screws, P/N 398067, included with the tool to avoid damage to electronic compo- nents under the flywheel.
Page 194: 3-Cylinder Models
POWERHEAD POWERHEAD REMOVAL Remove six retaining screws and exha ust relief 3-Cylinder Models muffler. 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. 142. To prevent accidental starting while ser- vicing, twist and remove spark plug leads.
Page 195: Powerhead
POWERHEAD POWERHEAD DISASSEMBLY Remove the small powerhead screw at rear. POWERHEAD DISASSEMBLY Systems Removal To simplify reassembly and wirin g installation, lay out the various screws a nd clamps in the order of their proper location. Remove the electric st arter.
Page 196: Throttle Linkage Removal
POWERHEAD POWERHEAD DISASSEMBLY Throttle Linkage Removal Shift Linkage Removal Remove throttle cam and throttle lever. Remove shoulder screw from shift arm and retain- ing screw from shift rod lever. Remove t he co tter pin and wa sher hold ing t he shift shaft (2-cylinder models).
Page 197: Crankcase Disassembly
POWERHEAD POWERHEAD DISASSEMBLY Do not use a t apered pun ch or Crankcase Disassembly IMPORTANT: any othe r tool th at co uld jam in or damage th e Remove screws and carefully pry off exhaust side taper bore when removing the pin. water cover.
Page 198: Cylinder Head Removal
POWERHEAD POWERHEAD DISASSEMBLY Use Torquing Socket, P/N 331638, t o loo sen in Cylinder Head Removal stages the ro d cap ret aining screws. DO NOT Remove thermostat cover and thermostat assem- remove the screws. bly. Re fer to THERMOSTAT SERVICING on p.
Page 199: Crankshaft Removal
POWERHEAD POWERHEAD DISASSEMBLY Use an approp riate ring exp ander to remove all necting rod. If nece ssary, use Wrist Pin Pressin g piston rings from pistons. Discard the rings. Tool, P/N 326356, to remove the wrist pin bearing. WARNING Wear safety glasses to avoid injury.
Page 200 POWERHEAD POWERHEAD DISASSEMBLY Remove the upper main bearing. Use a punch to remove the housing seal. Discard seal. 002034 1. Upper oil seal 2. Upper main bearing 002053 1. Punch Remove the lower bearing seal housing. Inspect housing and replace if necessary. Remove the O-ring from cr ankshaft sleeve a nd inspect it.
Page 201 POWERHEAD POWERHEAD DISASSEMBLY Inspect the crankshaft sleeve a nd replace if ne c- Use a be aring sep arator to support th e bearing, essary. To remove the sleeve, use Slide Hammer, and press off the crankshaft. P/N 432128, and Large Puller Jaws, P/N 432129. 002052 002041 Remove center ma in be arings an d sp lit sleeves...
Page 202: Cylinder Block Cleaning
POWERHEAD CYLINDER BLOCK CLEANING sealant from th e cylinder block, crankcase, cylin- CYLINDER BLOCK der head, and water cover. CLEANING WARNING Before inspecting or assembling IMPORTANT: To avoid personal injury, wear eye protec- powerhead, all internal components must be com- tion and rubber gloves when using Gel pletely clean and free of co ntaminants.
Page 203: Powerhead Inspection
POWERHEAD POWERHEAD INSPECTION POWERHEAD Crankshaft Measure the diame ter of each crankp in and main INSPECTION bearing journal. The lower main be aring journal would only b e measu red if the bearing was For d imensions, refer t o SERVICE SPECIFICA- removed for another reason.
Page 204 POWERHEAD POWERHEAD INSPECTION The dimensional dif ference between the two Ring end g ap increases ap proxi- IMPORTANT: areas is cylinder taper. mately 0.003 in. (0. 076 mm) for e ach 0 .001 in. The cylin der t aper must n ot exceed 0.002 in. (0.025 mm) incre ase in cylinder bo re diamet er.
Page 205: Powerhead Assembly
POWERHEAD POWERHEAD ASSEMBLY If the inst aller sticks on the sleeve af ter installa- POWERHEAD tion, thread Slide Hamme r, P/N 391008, in to installer and pull it off. ASSEMBLY Inspect sleeve af ter inst allation. IMPORTANT: Proceed slowly . Make no forced IMPORTANT: Sleeve must not be used if surface is damaged.
Page 206 POWERHEAD POWERHEAD ASSEMBLY lower housing with exte nded lip facing down. Lubricate upper main bearing with outboard lubri- Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft. 002036 002033 1. Seal lip 1. Upper main bearing Pack lip of upper o il seal with Moly Lube. Place seal o n crankshaf t wit h lip do wn and enclosed face up.
Page 207: Pistons And Connecting Rods
POWERHEAD POWERHEAD ASSEMBLY Apply Needle Bearing Grease to the wrist pin Pistons and Connecting Rods bearings. Inst all the b earings in the small end of the connecting rod. Align be arings with Wrist Pin NOTICE It is very important that the pistons Bearing Tool, P/N 336660.
Page 208 POWERHEAD POWERHEAD ASSEMBLY Use W rist Pin Cone , P/N 3 18600, and Driver , Be sure gap of ring fit s squ arely IMPORTANT: P/N 318599, to install new wrist pin retaining rings around dowel pin. in each wrist pin hole. Gap of retaining ring faces up, away from notch in piston.
Page 209: Cylinder Head Installation
POWERHEAD POWERHEAD ASSEMBLY Apply a 1/16 in. (2 mm) be ad of RTV Adhesive Cylinder Head Installation around each water passage on the block and cyl- Install a new thermostat seal in cylinder head with inder head as shown. side marked “TO CYL HEAD” facing toward ther- mostat.
Page 210: Crankshaft And Connecting Rod Installation
POWERHEAD POWERHEAD ASSEMBLY Following seq uence st amped on cylinder he ad, Crankshaft and Connecting tighten all screws in stages to a torque of 168 to Rod Installation 192 in. lbs. (19 to 21.7 N·m). Apply Gasket Sealing Compound to lower oil seal groove in cylinder block.
Page 211 POWERHEAD POWERHEAD ASSEMBLY Lubricate e ach crankpin and bearing a ssembly Be sure alignment dot on rod cap IMPORTANT: with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dot s face fly- up to crankshaft and install bearing halves. wheel.
Page 212 POWERHEAD POWERHEAD ASSEMBLY Secure restraining jaw “C” and forcing jaw “D” to Tighten the forcing screw to a torque of 14 to 16 • frame. in. lbs. (1.6 to 1.8 N·m). 21591 Restraining Jaw “C” 002071 1. Contact area of jaw 2.
Page 213: Crankcase Assembly
POWERHEAD POWERHEAD ASSEMBLY Test at least three corners of the rod and cap joint Gel-Seal II ha s a shelf life o f at IMPORTANT: with a pick. Joint must be smooth with no step. least one year when stored at room temperatu re. Test the Gel-Seal II or replace it if the age of the tube cannot be determined.
Page 214: Shift Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Start in the ce nter a nd work out ward in a spiral Note: 3-Cylind er mode ls in clude a double-end ed pattern. stud and use a lock washer under the J-clamp. 002254 002242r 2-Cylinder models 1.
Page 215: Throttle Linkage Installation
POWERHEAD POWERHEAD ASSEMBLY Lubricate sh ift lin kage bosses at the ba se of the Throttle Linkage Installation crankcase with Triple-Guard grease. Insert bush- Apply Nut Lock to threads of throttle lever screw. ings into bosses. Insert spring into cavity of throttle return lever. Apply Triple-Guard grease to the shaft and detent of the sh ift lever assembly .
Page 216: Final Powerhead Assembly
POWERHEAD POWERHEAD ASSEMBLY and tighten screw to a torque of 120 to 144 in. lbs. Final Powerhead Assembly (13.5 to 16 N·m). Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 149. Install oil recirculatin g hoses and che ck valves. Refer to OIL RECIRCULATION DIAGRAMS on p.
Page 217: Upper Mount Servicing (3-Cylinder)
POWERHEAD UPPER MOUNT SERVICING (3-CYLINDER) Inspect mounts and replace if necessary. UPPER MOUNT The motor mount , washer , and IMPORTANT: SERVICING (3-Cylinder) screw are serviced as an assembly. Do not disas- semble. Removal Remove mount retainer screw. 39820 Installation 002069 Place mount assemblies in position, with flats fac- ing away from each other.
Page 218: Powerhead Installation
POWERHEAD POWERHEAD INSTALLATION Loosely install all powerh ead screws before tig ht- POWERHEAD ening: INSTALLATION Powerhead Mounting – 2-Cylinder Models Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only. Install gasket on exha ust h ousing. T o ensure pro per sealing, mating surfaces must be clean and dry.
Page 219 POWERHEAD POWERHEAD INSTALLATION Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing. retaining pin an d washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m). 004298 1.
Page 220: Powerhead Mounting - 3-Cylinder Models
POWERHEAD POWERHEAD INSTALLATION Install r ecoil st arter ratch et and h ousing on out- Use Lif ting Fixture, P/N 396748, and hoist to board. Refer to RECOIL STARTER INSTALLA- slowly lower powerhead ont o exhaust hou sing. TION on p. 369. Guide into positio n over alignment pin at rear of exhaust housing.
Page 221 POWERHEAD POWERHEAD INSTALLATION Apply Gasket Sealing Compound to exhaust relief Tighten the upper mount screws to a torque of • muffler gasket and retaining screws. Install muffler 110 to 130 ft. lbs. (149 to 176 N·m). Make sure and tighten screws to a to rque of 60 to 84 in. lbs. that screw heads are tight against steering arm.
Page 222: Shift Linkage Adjustment
Refer to TPS Calibration on p. 114. moved durin g this procedure. Re fer to SHIFT ROD ADJUSTMENT on p. 300, or SHIFT ROD Use Evinrude Diagnostics sof tware to m ake • ADJUSTMENT on p. 323. sure engine ma nagement software version a nd revision are current.
Page 223: Powerhead Views
POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS 2-Cylinder Port – Hose Routings 006490 2-Cylinder Starboard – Hose Routings 006491...
Page 224 POWERHEAD POWERHEAD VIEWS 2-Cylinder Port Dressed Powerhead 008428 2-Cylinder Starboard Dressed Powerhead 008159...
Page 225 POWERHEAD POWERHEAD VIEWS 2-Cylinder Port Rope Start Models 008370 2-Cylinder Starboard Rope Start Models 008185...
Page 226 POWERHEAD POWERHEAD VIEWS 2-Cylinder Front 008160...
Page 227 POWERHEAD POWERHEAD VIEWS 2-Cylinder Rear 008161...
Page 228 POWERHEAD POWERHEAD VIEWS 2-Cylinder Top 008162...
Page 229 POWERHEAD POWERHEAD VIEWS 2-Cylinder Top, Rope Start Models 008186...
Page 230: 3-Cylinder Models
POWERHEAD POWERHEAD VIEWS 3-Cylinder Port – Hose Routings 006760 3-Cylinder Starboard – Hose Routings 006761...
Page 231 POWERHEAD POWERHEAD VIEWS 3-Cylinder Port Dressed Powerhead 008163 3-Cylinder Starboard Dressed Powerhead 008164...
Page 232 POWERHEAD POWERHEAD VIEWS 3-Cylinder Front 008166...
Page 233 POWERHEAD POWERHEAD VIEWS 3-Cylinder Rear 008167...
Page 234 POWERHEAD POWERHEAD VIEWS 3-Cylinder Top 008165...
Page 235 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHARTS ..............234 TILT TUBE, 75 –...
Page 236: Service Charts
MIDSECTION SERVICE CHARTS SERVICE CHARTS , 40 – 65 HP XHAUST OUSING 24-26 Ft. lbs. 18-20 Ft. lbs. (32.5-35 N·m) (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 ft. lbs (24.5-27 N·m) 60-84 in. lbs (7-9.5 N·m) 16-18 ft. lbs (22-24.5 N·m) Triple-Guard Grease Gasket Sealing Compound...
Page 237 MIDSECTION SERVICE CHARTS , 75 – 90 HP XHAUST OUSING 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. lbs. (24.5-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 150-180 In. lbs. (17-20 N·m) Triple-Guard Grease Gasket Sealing Compound Adhesive 847...
Page 238 MIDSECTION SERVICE CHARTS , 40 – 60 HP P TERN RACKET OWER 45-50 Ft. lbs. (61-68 N·m) 10-16 In. lbs. (1-2 N·m) 144-168 In. lbs. (16-19 N·m) 45-50 Ft. lbs. (61-68 N·m) IMPORTANT Triple-Guard grease on all pivot points Triple-Guard Grease 002220 Gasket Sealing Compound...
Page 239 MIDSECTION SERVICE CHARTS , 75 – 90 HP P TERN RACKET OWER 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.
Page 240 MIDSECTION SERVICE CHARTS , 40 – 65 HP M TERN RACKET ANUAL 40-45 Ft. lbs. (54-61 N·m) 144-168 In. lbs. See Text (16-19 N·m) 144-168 In. lbs. (16-19 N·m) 40-45 Ft. lbs. (54-61 N·m) See Text 144-168 In. lbs. (16-19 N·m) IMPORTANT Triple-Guard Grease Triple-Guard...
Page 241 MIDSECTION SERVICE CHARTS , 90 HP M TERN RACKET ANUAL IMPORTANT Triple-Guard grease on all pivot points 110-130 Ft. lbs. (149-176 N·m) 18-20 Ft. lbs. (24-27 N·m) 60-84 In. lbs. (7-9.5 N·m) 18-20 Ft. lbs. 60-84 In. lbs. (24-27 N·m) (7-9.5 N·m) 28-30 Ft.
Page 242 MIDSECTION SERVICE CHARTS ILLER ANDLE 18-20 Ft. lbs. (24.5-27 N·m) 24-36 In. lbs. (2.7-4 N·m) 36-48 In. lbs. (4-5.4 N·m) 18-20 Ft. lbs. (24.5-27 N·m) 36-40 Ft. lbs. 20-30 In. lbs. 18-20 Ft. lbs. (49-54 N·m) (2.3-3.4 N·m) (24.5-27 N·m) 18-20 Ft.
Page 243: Tilt Tube, 75 - 90 Hp
MIDSECTION TILT TUBE, 75 – 90 HP Remove the nut from the starboard side. TILT TUBE, 75 – 90 HP 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 244 MIDSECTION TILT TUBE, 75 – 90 HP Thread Slide Hammer, P/N 432128, into the Install the starboard locknut. adapter until at least 2 in. (51 mm) of threa d are engaged. WARNING Replace locknut if definite resistance is not felt. Tighten starboard tilt tube nut to a torque of 45 to 50 ft.
Page 245: Exhaust Housing, 40 - 65 Hp
MIDSECTION EXHAUST HOUSING, 40 – 65 HP EXHAUST HOUSING, 40 – 65 HP The exhaust ho using cont ains no se rviceable internal p arts. The exhaust wate r valve a nd the exhaust relief muffler can both be serviced without removing the exhaust housing.
Page 246: Exhaust Water Valve (60-65 Hp)
MIDSECTION EXHAUST HOUSING, 40 – 65 HP Apply Nut Lock to screws, install and tighten 60 to Exhaust Water Valve (60–65 HP) 84 in. lbs. (7 to 9.5 N.m). Disconnect water valve electrical connector. Remove screws and bracket holding valve to exhaust housing.
Page 247: Exhaust Housing Installation
MIDSECTION EXHAUST HOUSING, 40 – 65 HP Place lo wer thrust washer on th e stee ring shaf t Exhaust Housing Installation and place the lower front mount into position. Bring the exhaust housing into positio n with the stern bracket. 17526 1.
Page 248: Exhaust Housing, 75 - 90 Hp
MIDSECTION EXHAUST HOUSING, 75 – 90 HP Remove the exhaust housing. EXHAUST HOUSING, 75 – 90 HP Exhaust Housing Removal Before removing the exhaust housing: Remove the gearcase. Refer to • GEARCASE REMOVAL AND INSTALLATION on p. 296. Remove the p owerhead. Refer to •...
Page 249: Exhaust Housing Installation
MIDSECTION EXHAUST HOUSING, 75 – 90 HP If re moved, coat the lower mount s with soap y Exhaust Housing Installation water and press into the exhaust housing with the Bring the exhaust housing into position with th e “OUTSIDE” mark facing outward. stern bracket.
Page 250: Exhaust Housing Disassembly
MIDSECTION EXHAUST HOUSING, 75 – 90 HP Exhaust Housing Disassembly Remove the front and rear screws retaining the adapter/inner exhaust hou sing to the e xhaust housing. 001974 1. Lower inner exhaust housing screws Remove the wa ter tube from the inne r exhaust housing.
Page 251: Cleaning And Inspection
MIDSECTION EXHAUST HOUSING, 75 – 90 HP Inspect the water tube for obst ructions or kinks, Cleaning and Inspection which may restrict water flow. WARNING Exhaust Housing Assembly Wear safety glasses to avoid personal Place a new gasket between the exha ust meg a- injury, and set compressed air to less than phone and adapt er housing .
Page 252 MIDSECTION EXHAUST HOUSING, 75 – 90 HP Install the water tube through the top of the inner Apply Adhesive 847 to the bottom flange of the exhaust housing and align as shown: inner exhaust hou sing. Inst all a new seal. Apply Triple-Guard grease to outer seal surface.
Page 253: Stern Bracket, 40 - 60 Hp Power Tilt
MIDSECTION STERN BRACKET, 40 – 60 HP POWER TILT the hole in the outer ho using and th e alignment STERN BRACKET, pin into the adapter housing. 40 – 60 HP Power Tilt Stern Bracket Disassembly Remove th e bumpers from th e uppe r mou nt retaining screws.
Page 254: Stern Bracket Assembly
MIDSECTION STERN BRACKET, 40 – 60 HP POWER TILT To sep arate the swivel b racket from the stern Stern Bracket Assembly bracket, remove one tilt tube nut. Assemble the tie bar to the stern b rackets. Place the ground lead and starwasher between the port stern bracket and tie bar.
Page 255: Stern Bracket, 75 - 90 Hp Power Tilt
MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Install the tilt tu be. Tighten the tilt tube nu ts 40 to STERN BRACKET, 45 ft. lbs. (54 to 61 N· m), then back of f 1/8 to 1/4 turn. 75 –...
Page 256 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Remove the steering shaf t and thrust wa sher. It Remove the anode. may be necessary to tap the st eering shaft out using a wood dowel and mallet. 30762 1. Anode Remove the swivel bracket.
Page 257 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Remove the tilt limit switch and ret ainer from the Remove the two trim rod rollers from the swivel swivel bracket. bracket. 30758 30754 1. Tilt limit switch 1. Trim rod roller 2.
Page 258: Stern Bracket Assembly
MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Install the two trim rod rollers on the swivel Stern Bracket Assembly bracket. Tighten to a torque of 216 to 240 in. lbs. (25 to 27 N·m). Before proceeding, make sure all IMPORTANT: components h ave b een tho roughly clean ed.
Page 259 MIDSECTION STERN BRACKET, 75 – 90 HP POWER TILT Install the tilt limit switch and retainer on the swivel Coat the bushing s and sea l lip s with Triple- • bracket. Tighten screws to a torque of 40 to 50 in. Guard grease.
Page 260: Stern Bracket, 40 - 60 Hp Manual Tilt
MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Install the steerin g shaf t keep er. Ap ply Locquic STERN BRACKET, Primer and Nut Lock to the splines of the steering shaft and lower mount bracket. 40 – 60 HP Manual Tilt Clamp Screw Service Inspect clamp screw assemblies).
Page 261 MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Slide the pivot sha ft and upp er thrust washer out Loosen t he ste ering friction screw while pu shing of the swivel bracket. outward on the steering friction p in. When the pin is flush with the inside surface of the ca sting, remove the steering friction thrust ring.
Page 262 MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Drive the steering frict ion bushing up and out of Remove the two st ern bracket flange screws a nd the swivel bracket. separate the stern bracket s from the swive bracket.
Page 263: Stern Bracket Assembly
MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Remove the st arboard sto p link retaining screw Stern Bracket Assembly and nut from the swivel bracket. Place the reve rse lock sp rings in the swive l bracket. Insert the reverse lock pins in the swive l bracket and p art wa y throu gh the reverse lock springs.
Page 264 MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Install th e bushing, the po rt stop link, and the Place the swivel bracket between the stern brack- tilt/run lever in the swivel bracket. The tilt/run lever ets. should be in the RUN position. Install the tilt tube through the following parts and install the tilt tube nuts loosely: Starboard stern bracket...
Page 265 MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Install and tighten the nut to a torque of 144 to 168 Place the steerin g friction bu shing in the swivel in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews. COA2984 COA2986 1.
Page 266: Tilt Assist Cylinder
MIDSECTION STERN BRACKET, 40 – 60 HP MANUAL TILT Install n ew upper an d lower seals in the swivel Tilt Assist Cylinder bracket with lip s o f sea ls f acing away from the The tilt assist cylinder can be replaced without dis- bracket.
Page 267: Stern Bracket, 90 Hp Manual Tilt
MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Remove set screw fro m starboard stern b racket STERN BRACKET, lower pivot pin access hole and use an appropri- ate tool to remove lower pivot pin. 90 HP Manual Tilt Stern Bracket Disassembly Loosen set scre w a nd remove reve rse lock release collar.
Page 268 MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Remove cotter pins, pins and locking lever. Remove port reverse lock link. 006699 006695 1. Pins 1. Port reverse lock link 2. Locking lever Loosen bellcrank set screw, remove bellcrank and Remove starboard reverse lock link. handle link rod.
Page 269 MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Remove retaining ring and bellcrank shaf t spacer Remove port trail lock leve r and trail lock shaf t as from reverse lock pivot shaft. an assembly. 006693 006704 1. Retaining ring 1. Port trail lock lever and shaft Remove screw from trail lock lever .
Page 270: Stern Bracket Assembly
MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Apply blue Nut Lock to screw and assemble port Stern Bracket Assembly trail lock le ver on tra il lo ck shaf t wi th screw , Reverse Lock and Trail Lock Reference washer and nylon washer.
Page 271 MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Assemble st arboard t rail lock lever and trail lock Install remaining bellcrank shaft spacer on reverse spring to reverse lock pivot shaft. lock pivot shaft, then install retaining ring. 006691 006693 1. Trail lock lever 1.
Page 272 MIDSECTION STERN BRACKET, 90 HP MANUAL TILT Tighten screw to a torque of 60 to 84 in. lbs. (7 to Install reverse lock r elease collar a nd t ighten set 9.54 N·m). screw. 006695 006697 1. Port reverse lock link 1.
Page 273: Tiller Handle Service - Standard
MIDSECTION TILLER HANDLE SERVICE – STANDARD Remove the electrical cover. TILLER HANDLE SERVICE – Standard Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Use Ba ll Socket Re mover tool, P/N 342226, to 002509 1.
Page 274: Disassembly
MIDSECTION TILLER HANDLE SERVICE – STANDARD Pull the throttle pin out of the cable. Disassembly Loosen throttle friction control so th ere is no restriction on grip. Do not back screw out co m- IMPORTANT: pletely. Nut is under spring tension. 24294 Remove stop switch cover screws and cover/stop switch assembly.
Page 275: Inspection
MIDSECTION TILLER HANDLE SERVICE – STANDARD Remove the th rottle cable re taining clip. Pry the outer handle. After removing, chip away remnants cable trunnion o ut of t he steerin g han dle a nd of inner handle. remove cable. 24284 Remove throttle cable seal from the inner handle.
Page 276 MIDSECTION TILLER HANDLE SERVICE – STANDARD Install the metal outer handle over the plastic inner Install the throttle control plate on outer handle. handle and drive the outer handle into place. 24295 1. Throttle control plate Push the th rottle cable pin throug h the e nd of t he 31202 throttle cable.
Page 277: Installation
MIDSECTION TILLER HANDLE SERVICE – STANDARD Be sure the twist -grip's spe ed in dicator line is Installation positioned with the speed range symbol on the Apply Triple-Guard grease to the two steering handle. Snap the grip into place. handle bushin gs. Place the bushin gs into the steering bracket.
Page 278: Throttle Cable Adjustment
MIDSECTION TILLER HANDLE SERVICE – STANDARD Install electrical cover. Secure electrical harness with tie strap. 002509 006526 1. Electrical cover 1. Cable anchor 2. Boss 3. Cable retainer Throttle Cable Adjustment 4. Tie strap Place t hrottle cab le in position. Use Ball Socket Installer too l, P/N 342225, to snap t hrottle cab le connector onto throttle lever.
Page 279: Tiller Handle Service - Long Handle
MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove the electrical cover. TILLER HANDLE SERVICE – Long Handle Removal WARNING To avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Use Ba ll Socket Re mover tool, P/N 342226, to 002509 1.
Page 280: Disassembly
MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove locknuts from screws on top of steering Disassembly arm. Loosen th rottle frict ion control so the re is no restriction on grip. Do not back screw out com- IMPORTANT: pletely. Nut is under spring tension. 006362 1.
Page 281 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Disconnect trim switch co nnector. Remove con- Remove the throttle friction control. nector from trim switch wires. Refe r to CONNEC- TOR SERVICING on p. 116. Use Twist-Grip Remover, P/N 390767, to depress the grip de tents.
Page 282 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Use an app ropriate tool to ca refully pry up on the Remove cotter pin from shift handle pin. Remove inner handle retaining tab. shift cable. 006679 006708 1. Inner handle retainer tab 1.
Page 283: Inspection
MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Remove the shift pin if necessary. Coat de tent ball, spring a nd guide with Triple- Guard grease and install into shif t ha ndle. Place one washer on shift handle mounting boss. 006716 1.
Page 284 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Install shift cable on shift pin with a new cotter pin. Secure tab of the inner h andle into the outer han- dle. Tab must be flush with the back of the flange and top of tab must be flush with top of flange.
Page 285 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Install the throttle control plate on outer handle. ing. If wire guide is forced into place, it WILL dam- age trim switch wiring. 006671 1. Throttle friction control 006684 1. Inner tiller handle Install trim switch wiring t hrough in ner steering 2.
Page 286 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Install the handle en d of the th rottle ca ble. Snap Place th e gu ides over the roller p in a nd into t he the th rottle cable tru nnion into the recess in the slots of the inner handle.
Page 287: Installation
MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Be sure the twist -grip's spe ed in dicator line is Installation positioned with the speed range symbol on the The ste ering arm ca n be positioned straight, or handle. Snap the grip into place. angled 15°...
Page 288: Control Cable Installation
MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Route shift and throttle cables and electrical har- Control Cable Installation ness through grommet in lower motor cover. Con- nect harness to engine wiring harness. DO NOT complete fina l att ach- IMPORTANT: ment of cables to shif t and throttle levers until all cables, wires, an d h oses have be en routed a nd grommet has been pla ced in to the lower engine...
Page 289 MIDSECTION TILLER HANDLE SERVICE – LONG HANDLE Install washer, cable an chor, and cable anchor Throttle Cable Adjustment screw o n th rottle body b oss. Tighten screw Place t hrottle cab le in position. Use Ball Socket securely. Installer too l, P/N 342225, to snap t hrottle cab le connector onto throttle lever.
Page 290 MIDSECTION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 291 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHARTS ..............290 GEARCASE TYPES, 75 –...
Page 292: Service Charts
GEARCASE SERVICE CHARTS SERVICE CHARTS 40 – 65 HP 60-84 In. lbs. (7-9.5 N·m) 96-120 In. lbs. (11-13.5 N·m) 60-84 In. lbs. (7-9.5 N·m) 10-12 Ft. lbs. (13.5-16 N·m) 28-30 Ft. lbs. (38-40 N·m) 60-84 In. lbs. 18-20 Ft. lbs. (7-9.5 N·m) (24.5-27 N·m) 18-20 Ft.
Page 293 GEARCASE SERVICE CHARTS “S”–T 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) 45-50 Ft. lbs. (61-68 N·m) 60-84 In.
Page 294 GEARCASE SERVICE CHARTS “O”– – S TYPE EARCASE TANDARD OTATION 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) 45-50 Ft.
Page 295: Gearcase Types, 75 - 90 Hp
GEARCASE GEARCASE TYPES, 75 – 90 HP GEARCASE TYPES, 75 – 90 HP Gearcase General Service Procedure Outboard Model Type Comparison Comparison (L) Models with Unique housing, shafts, “S” 20 in. shaft gears, and bearings Similar (X) Models with Unique housing, shafts, “O”...
Page 296 Refer to the Evinrude/Johnson Genuine Parts • Apply Triple Guard grea se t o the entire pro peller and Accessories Catalog for propeller style s shaft before installing the propeller.
Page 297: Gearcase Leak Test
GEARCASE GEARCASE LEAK TEST If cotter pin holes in t he nut (without keeper) and GEARCASE LEAK TEST shaft do not align, tighten further. Do not loosen. Drain lubricant before testing. Install keeper (if applicable). Install new cotter pin. Use Gearcase Pressure Tester, P/N 507977.
Page 298: Gearcase Service, 40 - 65 Hp Models
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE REMOVAL AND INSTALLATION GEARCASE SERVICE, 40 – 65 HP MODELS Remove the 5/16-18 x 1.25 in. screw and washer, GEARCASE REMOVAL and remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser-...
Page 299: Gearcase Service, 40 - 65 Hp Models
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE REMOVAL AND INSTALLATION Driveshaft engages the crankshaft. Gearcase Installation • Inner exhaust housing installs correctly. • Shift ro d does not turn an d is positio ned pro p- WARNING • erly in the shift rod lever below the crankcase. During service, the outboard may drop unexpectedly.
Page 300: Water Pump Service
GEARCASE SERVICE, 40 – 65 HP MODELS WATER PUMP SERVICE (47 to 54 N·m). For ad justment, refer to Trim Tab WATER PUMP SERVICE Adjustment on p. 31. Disassembly Remove the four impeller housing screws. 001996 1. Trim tab screw Place the shift rod in the shift rod lever.
Page 301 GEARCASE SERVICE, 40 – 65 HP MODELS WATER PUMP SERVICE Apply a thin bead of Adhesive 847 in the seal Assembly groove, and install the special shaped O-ring seal. Lightly co at the exterior rim of the impeller cup with Gasket Sealing Compound. Install the cup in the impeller housing.
Page 302: Shift Rod Adjustment
GEARCASE SERVICE, 40 – 65 HP MODELS SHIFT ROD ADJUSTMENT slide water pump down over key. Be sure impeller SHIFT ROD key does not fall out of position. ADJUSTMENT Check the shift rod height from the shift rod hole to the surface of the gea rcase using Universa l Shift Rod Height Gauge, P/N 389997.
Page 303: Gearcase Disassembly
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE DISASSEMBLY Hydrostatic Seal Grooves — Must be in goo d 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 304: Propeller Shaft Bearing Housing Removal
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE DISASSEMBLY Remove the two ret aining ring s using Ret aining Propeller Shaft Bearing Housing Ring Pliers, P/N 331045. Removal Use a 5/16 in. thin wall socket to remove the four CAUTION screws with O-rings ho lding th e pr opeller shaf t Retaining rings are under extreme pres- bearing housing.
Page 305: Pinion Gear And Driveshaft Removal
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE DISASSEMBLY Remove the larger th rust washer, t hrust bearing, Remove th e four driveshaf t bearing ho using and reverse gear from the gearcase. Remove the screws. smaller thrust washer located in front of the gear. COA3671 1.
Page 306: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE DISASSEMBLY Locked Driveshaft Removal Shift Housing, Gear and The driveshaft to pinion taper is a locking taper. If Propeller Shaft Removal necessary, u se Puller , P/ N 387206, and Backing Push d own o n t he shift rod. This will move t he Plate, P/N 325867, to break the lock.
Page 307: Shifter, Bearing And Seal Service
GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE SHIFTER, BEARING AND Water Intake Screen Inspect the water int ake screen for blockage an d SEAL SERVICE remove it by depressing the tabs on either side of the screen and pushing upward.
Page 308 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Place the bearing on the installer tool with the let- unwrapping it from aro und the clut ch dog. Dis- tered side of the bearing facing the top of t he card the spring.
Page 309 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Remove th e shif t lever pin from the ho using. Shift Housing Assembly Remove shif t shaf t, crad le an d shif t leve r. Move shifter detent as need ed to help ease removal of Clean and inspect all parts before IMPORTANT:...
Page 310 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE With shif ter detent in NEUTRAL , inst all arms of Coat thrust bearing and thrust washer with Needle shift lever int o det ent slot s. Alig n th e pivot holes Bearing grease.
Page 311 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Slide the pro peller shaft onto the shif t shaft, align Clean the bearing ho using in solven t to re move the hole in the sh aft with the h ole in the clutch sealer from the seal bore and the O-ring groove.
Page 312 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE port the b ridge, and tighten jaws securely behind Propeller Shaft Bearing Housing the bearing. Service Rear Seal Removal Remove se als using Puller Bridge, P/N 432127, and Lar ge Puller Jaws, P/N 432129. Pla ce the plate on top of the housing to support the brid ge, and tighten jaws securely behind the inner seal.
Page 313 GEARCASE SERVICE, 40 – 65 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Thoroughly clean the four bearing housing retain- Rear Seal Installation ing screws in solvent. Discard the O-rings. Apply Gasket Sealing Compound to metal casings of the seals before installing. Bearing Installation Oil, then install new bearings in bearing housing.
Page 314: Driveshaft Shimming
GEARCASE SERVICE, 40 – 65 HP MODELS DRIVESHAFT SHIMMING Select correct collar and shim gauge bar: DRIVESHAFT SHIMMING Collar: P/N 328363 • Shim gauge bar: P/N 328366 • NOTICE If a new pinion gear is needed, Slide the collar o nto the driveshaft with large e nd replace gear set before shimming.
Page 315: Gearcase Assembly
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE ASSEMBLY between the gauge b ar and t he bea ring ho using GEARCASE ASSEMBLY between each pair of screw holes. Replace the bearing housing and re peat check if va riance is Shift Housing, Gear, and greater than 0.004 in.
Page 316: Pinion Gear And Driveshaft Installation
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE ASSEMBLY Apply Triple-Guard grease to the threa ded end of Place the cover seal on the shift rod cover. the shift rod a nd insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring.
Page 317 GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE ASSEMBLY the driveshaft bearing housing. Do not coat inside Lightly coat the thre ads of a new pinion nut with bearing housing bore surface of the gearcase. outboard lubricant. Use Pinion Nut Starting Tool, P/N 320675, to install nut on the driveshaft.
Page 318: Propeller Shaft Bearing Housing And Gear Installation
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE ASSEMBLY Use Driveshaft Holding Socket, P/N 334995, and assembly onto the propeller shaft until it en gages an 11/16 in. open-end wrench, to tighten the pin- the pinion gear. ion n ut to a torque of 40 t o 45 ft. lbs. (54 to 60 s N·m).
Page 319: Final Assembly And Adjustment
GEARCASE SERVICE, 40 – 65 HP MODELS GEARCASE ASSEMBLY Make su re the retaining rings are sea ted in the Install O-rin g in groove in the bearing hou sing. grooves in the gearcase. Lightly apply Gasket Sealing Compound to th e O-ring flange and aft support flange of the bearing housing.
Page 320: Gearcase Service, 75 - 90 Hp Models
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION GEARCASE SERVICE, 75 – 90 HP MODELS Remove the 3/8 -16 in. screw and wa sher, and GEARCASE REMOVAL remove 7/16-14 x 3.5 in. screw and washer. AND INSTALLATION Gearcase Removal WARNING To prevent accidental starting while ser-...
Page 321 GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE REMOVAL AND INSTALLATION Slide the gearcase into place, making sure: Gearcase Installation Driveshaft engages the crankshaft. • Water tube enters the water pump. WARNING • Lower inner exhaust housing installs correctly. • During service, the outboard may drop Shift ro d does not turn an d is positio ned pro p- •...
Page 322: Water Pump Service
GEARCASE SERVICE, 75 – 90 HP MODELS WATER PUMP SERVICE Apply Triple-Guard gre ase to threads o f the trim WATER PUMP SERVICE tab screw . In stall and align the trim t ab with the index marks n oted prior to disassembly. Tighten Disassembly the trim t ab screw to a t orque of 35 to 40 f t.
Page 323 GEARCASE SERVICE, 75 – 90 HP MODELS WATER PUMP SERVICE Install th e water tub e grommet wit h the insid e Assembly taper facing up. Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs. Do not allow any sealer to get into IMPORTANT: the air bleed groove in the impeller housing.
Page 324 GEARCASE SERVICE, 75 – 90 HP MODELS WATER PUMP SERVICE Apply a thin bea d of Adhesive 847 in the s eal slide water pump down over key. Be sure impeller groove, and install the special shaped O-ring seal. key does not fall out of position. CO2995 1.
Page 325: Shift Rod Adjustment
GEARCASE SERVICE, 75 – 90 HP MODELS SHIFT ROD ADJUSTMENT With the gea rcase in NEUTRAL , rot ate the shif t SHIFT ROD rod up or d own as necessary fo r cor rect a djust- ment. Once correct height is achieved, rotate rod ADJUSTMENT one half turn or less to direct offset forward.
Page 326: Gearcase Disassembly
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Hydrostatic Seal Grooves — Must be in go od 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 327: Propeller Shaft Bearing Housing Removal
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Assemble components and pull the bearing hous- Propeller Shaft Bearing Housing ing from the gearcase. Removal Remove the t wo screws, washers, and ret ainers holding the propeller shaft bearing housing. 22775 Remove the thrust washer, thrust bearing, and reverse gear from gearcase.
Page 328 GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Remove t he four d riveshaft bea ring h ousing Locked Driveshaft Removal screws. The driveshaft to pinion taper is a locking taper. If necessary, use Driveshaft Puller, P/N 390706, and Backing Plate , P/N 325867, to break the lock.
Page 329: Driveshaft Service
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE DISASSEMBLY Driveshaft Service “S” Type Gearcases Install the roll pin flush. To separate the uppe r driveshaft (if ne eded) from the lower d riveshaft, remove the roll pin. Replace the damaged component. DR4596 1.
Page 330: Shift Housing, Gear And Propeller Shaft Removal
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE HOUSING INSPECTION Shift Housing, Gear and GEARCASE HOUSING Propeller Shaft Removal INSPECTION Push down on the shif t rod. This will move the detent lever downward to clear the inside of the Thoroughly clean gearcase housing to remove all gearcase when t he sh aft assembly is pulled o ut.
Page 331: Shifter, Bearing And Seal Service
GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE SHIFTER, BEARING AND “O” Type Gearcases Use a 7/8 in. wrench to hold the remover in place. SEAL SERVICE Use a 3/4 in. wrench to turn flange nut clockwise. Draw the bearing up from the housing.
Page 332 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Place a new O-ring on the pinion bearing retaining “O” Type Gearcases screw. Appl y G asket Sealing Compound to O- ring. Apply Nut Lock to screw thre ads. Install the screw and tighten to a torque of 60 to 84 in.
Page 333 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Push the pin o ut of the clutch dog . Remove all shifter detent as needed to help ease re moval of parts. parts. DSC02449 1. Shift lever pin DSC02489 2.
Page 334 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Thoroughly grease 25 needle bearings wit h Nee- Shift Housing Assembly dle Bearing grease and place in the bearing case (“O” Type gearcases). Clean and inspect all parts before IMPORTANT: beginning assembly p rocedures.
Page 335 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro- shift cradle. Pull shifter dete nt back up to NEU- peller shaft.
Page 336 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear- Service ing housing’s bottom groove. The bottom groove is an oil passage. Gearcase damage The driveshaft bearing is not serviceable. Replace could result.
Page 337 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Inspect th e b earing h ousing anode. Replace Propeller Shaft Bearing Housing anode if it is reduced to two-thirds of original size. Service Tighten screws to a torque of 108 to 13 2 in . lbs. (12 to 15 N·m).
Page 338 GEARCASE SERVICE, 75 – 90 HP MODELS SHIFTER, BEARING AND SEAL SERVICE Bearing Installation Rear Seal Installation Oil, then install new bearings in bearing housing. Apply Gasket Sealing Compound to metal casings of the seals before installing. Place the lettered end of the bearing case on the bearing inst aller, then press th e bea ring into the Use Seal Installation Tool to install new seals back housing u ntil the too l seat s.
Page 339: Driveshaft Shimming
GEARCASE SERVICE, 75 – 90 HP MODELS DRIVESHAFT SHIMMING Select correct collar and shim gauge bar: DRIVESHAFT SHIMMING Collar: P/N 341440 • Shim gauge bar: P/N 328367 • NOTICE If a new pinion gear is needed, Slide the collar o nto the driveshaft with large en d replace gear set before shimming.
Page 340: Gearcase Assembly
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY between the gauge bar and the bea ring h ousing GEARCASE ASSEMBLY between each pair of scre w holes. Replace the bearing housing and re peat check if va riance is Water Intake Screens greater than 0.004 in.
Page 341: Shift Rod Housing Installation
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY Apply Gasket Sealing Compound to both sides of Shift Rod Housing Installation a new shift rod cover gasket. Place the gasket on Lubricate a new shif t rod cover O-ring with Triple- the gearcase.
Page 342: Pinion Gear And Driveshaft Installation
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY The inside t aper of the p inion Pinion Gear and Driveshaft IMPORTANT: gear and the driveshaft taper MUST be com- Installation pletely free of grease. Clean the t apers with Refer to DRIVESHAFT SHIMMING on p.
Page 343: Propeller Shaft Bearing Housing And Gear Installation
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY Use Driveshaft Holding Socket, P/N 311875, Pin- Lightly apply Gasket Sealing Compound to a new ion Nut Hold er, P/N 334455, and W rench bearing housing O-ring. Install O-ring in groove in Retainer, P/N 341438, to tigh ten the pinion nut to the housing.
Page 344: Final Assembly And Adjustment
GEARCASE SERVICE, 75 – 90 HP MODELS GEARCASE ASSEMBLY Re-tighten two re tainer screws to 18 to 20 f t. lbs. “O” Type Gearcases (24 to 27 N·m). Loosen retainer screws 1/4 turn. Confirm that torque on the wedge screw is 15 to Install wed ge, screw , and wa sher.
Page 345 TRIM AND TILT TRIM AND TILT TABLE OF CONTENTS SERVICE CHART ..............344 SYSTEM DESCRIPTION .
Page 346: Service Chart
TRIM AND TILT SERVICE CHART SERVICE CHART 40 - 60 HP M ODELS 30 to 50 in. lbs. (4 to 5.6 N·m) 45 to 55 in. lbs. (5 to 6 N·m) 45 to 55 in. lbs. (5 to 6 N·m) Triple-Guard Grease 007632 Biodegradable TNT Fluid...
Page 347 TRIM AND TILT SERVICE CHART 75 - 90 HP M ODELS 30 to 50 In. lbs. (4 to 5.6 N·m) 45 to 55 In. lbs. (5 to 6 N·m) 45 to 55 In. lbs. (5 to 6 N·m) Triple-Guard Grease 005002 Biodegradable TNT Fluid...
Page 348: System Description
TRIM AND TILT SYSTEM DESCRIPTION SYSTEM DESCRIPTION The power tr im/tilt hydraulic system is completely contained between the outboard's stern brackets. The system consists of: Electric motor • Oil reservoir • Pump manifold assembly • Cylinder body assembly • Optimal boat and outboa rd performance can be achieved by adjusting (trimming) the angle of out- 008018 1.
Page 349 TRIM AND TILT SYSTEM DESCRIPTION For mooring or storing the boa t with the outboard 75 – 90 HP M ODELS tilted, a tilt suppo rt is provided to support the o ut- Use the trailering bracke t to su pport the outboard board.
Page 350: Routine Inspections
Pump coupler 75 - 90 HP: 21 fl. oz. (620 ml) • • Hydraulic pump • Use only Evinrude/Johnson Bi o- IMPORTANT: degradable TNT Fluid to fill the hydraulic system. No tilt down: Manual release valve • Refer to Trim and Tilt on p. 41 for filling proce- Fluid level •...
Page 351: Electrical Circuit Tests
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Connect a 0 to 100 A DC ammete r in series ELECTRICAL CIRCUIT between the ba ttery side of the st arter solenoid and the red lead to the trim/tilt relay module. TESTS Relay Testing When the trim-UP button is pressed, the UP relay is energized and connects the blue trim motor wire to the battery positive (+) terminal.
Page 352: Trim And Tilt Motor No Load Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Test results include three basic possibilities: Monitor motor RPM and current draw. A. Low current draw – Check for: Valves leaking • Pump damaged • O-rings leaking • Manual release valve damaged • B. High current draw – Check for: Valves sticking •...
Page 353: Trim Gauge Test
TRIM AND TILT ELECTRICAL CIRCUIT TESTS Trim Gauge Test Trim Sender Test To avoid immedia te me ter dam- STEP 1 IMPORTANT: age, never apply an ohmmeter to an electrical cir- Turn key switch ON. Using a voltmeter, check for cuit where voltage is present.
Page 354: Trim And Tilt Replacement
TRIM AND TILT TRIM AND TILT REPLACEMENT Separate the trim/tilt unit wires in the braided tube TRIM AND TILT to p ermit remo val t hrough the hole in t he ste rn bracket. REPLACEMENT Removal Raise the outboard and engage the tilt support. Remove the rubber grommet from the blue/green trim/tilt cable connector.
Page 355 TRIM AND TILT TRIM AND TILT REPLACEMENT Remove one of the locknuts from the angle adjust- Use a punch to remove the upper pin. ment ro d. Remove the rod from the stern brack- ets. 25065 Retract the tilt cylinder rod. 18941 Remove t he external s nap ri ngs f rom t he lower pin.
Page 356: Installation
TRIM AND TILT TRIM AND TILT REPLACEMENT Remove the un it fro m th e ste rn bracket s far Lubricate th e an gle adjustment ro d with Triple- enough to remove the ground lead from the pump Guard grease. Install the rod. Tighten the locknuts motor mounting screw.
Page 357 TRIM AND TILT TRIM AND TILT REPLACEMENT 75 – 90 HP M ODELS ODELS Install the ground lead. Place trim/tilt wires in br aided tub e an d inst all through hole in the stern bracket. Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin.
Page 358: Trim And Tilt Service
TRIM AND TILT TRIM AND TILT SERVICE Screw the man ual relea se valve in. Remove the TRIM AND TILT SERVICE retaining ring using a small pick or screwdriver. Discard the retaining ring. Disassembly Thoroughly clean the unit before disassembling. Scrub a ll outside surfaces with a stif f brush a nd hot, soapy water to prevent surface dirt from con- taminating internal parts.
Page 359 TRIM AND TILT TRIM AND TILT SERVICE Slowly remove the man ual release valve. Th ere Remove t he fou r larg e mo tor flange retaining may be pressure be hind the valve—wear safety screws. Remove the motor and discard O-rin g, glasses.
Page 360: Assembly
Assembly valve. Oil and inst all th e ma nual release valve. Tighten the valve to a torque of 45 to 55 in. lbs. (5 Use only Evinrude/Johnson Bi o- IMPORTANT: to 6 N·m). degradable TNT Fluid to fill the hydraulic system.
Page 361 TRIM AND TILT TRIM AND TILT SERVICE Fill the oil reservoir up to the fill plug with Evinrude/Johnson Biodegr adable TNT Fluid. Install the fill plug. 007646 40 - 60 HP Models 004278 75 - 90 HP Models Run the motor, t hen re check o il leve l. Cycle the unit several times and check the oil level when the cylinder is fully e xtended.
Page 362 TRIM AND TILT NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 363 MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS SERVICE CHART ..............362 RECOIL STARTER REMOVAL .
Page 364: Service Chart
MANUAL STARTER SERVICE CHART SERVICE CHART 60 to 84 in lbs. (7 to 9.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) 96 to 120 in lbs. (11 to 13.5 N·m) 120 to 144 in lbs. (13.5 to 16 N·m) Red Ultra Lock Blue Nut Lock 003724...
Page 365: Recoil Starter Removal
MANUAL STARTER RECOIL STARTER REMOVAL RECOIL STARTER RECOIL STARTER REMOVAL DISASSEMBLY WARNING WARNING To prevent accidental starting while ser- Wear safety glasses while disassembling vicing, twist and remove all spark plug and assembling manual starters because leads. of rewind spring tension. Remove the clamp holding the oiling system wir- Pull the st arter rope out far enough to tie a slip ing harness.
Page 366 MANUAL STARTER RECOIL STARTER DISASSEMBLY Remove the nut from the starter pawl ret aining Use a screwdriver to pry open the pulley lock ring, screw. and remove ring from the starter. COA1368 1. Lock ring 007855 1. Nut Remove the friction plates and friction plate spring washer.
Page 367: Recoil Starter Cleaning And Inspection
MANUAL STARTER RECOIL STARTER CLEANING AND INSPECTION RECOIL STARTER RECOIL STARTER CLEANING AND ASSEMBLY INSPECTION WARNING Wash met al components in solvent and dry with Wear safety glasses while disassembling compressed air. and assembling manual starters because of rewind spring tension. Inspect the rewind sp ring for broken end lo ops and weak tension.
Page 368 MANUAL STARTER RECOIL STARTER ASSEMBLY Apply Triple-Guard grease or Lubriplate 777 to the Install t he rewin d sp ring into the st arter hou sing. rewind sp ring. Install the re wind spring into the Locate the out er loop of the rewin d spring on the spring winder base with open loop of spring facing pin in the starter housing.
Page 369 MANUAL STARTER RECOIL STARTER ASSEMBLY inner loop of t he spring in the slot of the pulley, Place th e st arter hou sing sp ring in t he st arter and install the pulley in the starter housing. housing. COA1365 COA1361 1.
Page 370 MANUAL STARTER RECOIL STARTER ASSEMBLY Install the starter p awl plate ret aining screw a nd If removed, install the starter handle bracket to the washer into t he starter housing. Tighten screw to starter housing. Tighten screws securely. a torque of 96 to 120 in. lbs. (11 to 13.5 N·m). 002517 1.
Page 371: Recoil Starter Installation
MANUAL STARTER RECOIL STARTER INSTALLATION Press the starter rope into the channel of the rope RECOIL STARTER anchor, with end of starter rope firmly against end of channel. Press the anchor into the handle. INSTALLATION Apply Nut Lock to the thre ads of st arter ratch et screws.
Page 372 MANUAL STARTER NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
Page 373 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 374 S–2...
Page 375: 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 376: 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 377: 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 378: 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 379: Safety
SAFETY How can loss of steering control be minimized? Use a steer ing syst em recommende d by th e outbo ard ma nufacturer which me ets • Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions • When Follow warnings marked “...
Page 380: 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 381 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 382 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 383: 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 384 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 385: 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 386: 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 387 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 388: 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 389: 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 390 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 391 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 eng ine speed below 200 0 RPM. With no load, outboard will run too fa st very easily.
Page 392 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 393: 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 394: 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 395: 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 396: Safety Awareness Test
7) When replacement p arts are required, will you use /Johnson ® ® Evinrude Genuine Parts or parts with equivalent characteristics, including type, strength and material? 8) Are you ready to follow the rec ommendations in this service m anual before you s er-...
Page 397: Index
INDEX INDEX Pinion Gear 305, 329 Propeller Shaft 310, 335, 336 Abbreviations 6 Wrist Pin 197, 205 Accessories Battery Cable, P/N 584348 64 Break-In EMM Programming 165, 220 XD100 Outboard Oil Decal, P/N 352369 Gearcase 298, 317, 320, 342 Oiling 165 Adjustments Procedure 67 Control Cable 19, 276, 286...
Page 398 INDEX Anodes 44, 252, 254, 257, 301, 310, 324, 335 Oiling Rate 66, 164 Cylinder walls 200 Reports 69 Long Term Storage 45 Sensor Monitoring 95 Metal components 44 Service Codes 65 Steering Cable 37 Static Ignition Test 81 Timing Verification 67, 114 Cover Service 50 TPS Calibration 68, 114 Crankcase...
Page 399 INDEX TPS Calibration 114 Pressure Tests 137 Transfer 70 Priming 136 Relieving Pressure 142 Engine Monitor Description 61 Requirements 130 Low Oil Warning 58, 162, 168 Troubleshooting 76, 84, 137 No Oil Warning 162 Vapor Separator 132, 144 Operation Check 33 Fuse 94 Engine Temperature Check 180 Engine Temperature Sensor...
Page 400 INDEX Intake Manifold Muffler Assembly 150 Installation 219 Disassembly 150 Removal 192 Inspection 150 Servicing 244 Installation 151 Removal 149 New Engines Outboard Rigging Procedure 17 Key Switch Operation Check 33 Start Circuit 102 Oetiker Clamp Servicing 25 Oil Injector Electrical Circuit (55 V) 161 Electrical Tests 166 LED Indicators 77...
Page 401 INDEX Piston Rings RPM Limit 11, 13, 59, 60 End Gap 202, 206 Installation 206 Removal 197 S.A.F.E. Description 62 Pistons Assembly 205 Low Oil 58 Inspection 202 No Oil 162 Installation 206 Temperature 56, 57 Removal 196 Safety 1 Powerhead Sensor Tests 95 Assembly 203...
Page 402 INDEX Replacement 42 Tests 107, 108, 109 Service 42 Winterization Procedure 45 Specifications 10 Starter Assembly 365 Tachometer Circuit Description 100 Pulse Setting 33 Current Draw Test 103 Technical Data 10 Installation 115, 369 Temperature Removal 115 Operating 34, 180 Rope Replacement 368 Operation below freezing 160 Solenoid Test 102...
Page 403 INDEX Backing Plate, P/N 325867 304, 326 Key Switch Assembly, P/N 176408 64 Ball Socket Installer tool, P/N 342225 276, Large Puller Jaws, P/N 432129 199, 309, 310, 334, 335 Ball Socket Remover tool, P/N 342226 149, Lifting Fixture, P/N 396748 191, 192, 216, 271, 277 Battery Cable, P/N 584348 64 Lower Driveshaft Puller, P/N 342681 326...
Page 404 INDEX Tilt Tube Service Kit, P/N 434523 241 Strategy 75 Torquing Socket, P/N 331638 196, 210 Trim and Tilt 348, 349 Twist-Grip Remover, P/N 390767 272, 279 Universal Puller Set, P/N 378103 111, 302, Upper Mount Servicing 215 Universal Shift Rod Height Gauge, P/N 389997 300, 323 Wrench Retainer, P/N 341438 325, 341 Vapor Separator...
Page 405: 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 406 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 407 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 408 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 409 TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION POSSIBLE CAUSE PROCEDURE SystemCheck light Outboard is in S.A.F.E. Check Service Codes and SystemCheck warning Refer to specifications, check recommended WOT Incorrect propeller RPM; water test and install correct pitch propeller Setup or rigging change Incorrect outboard mounting...
Page 410 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 411 Hose Routing and Water Flow Diagram 40 – 65 E-TEC Inline 2 Cylinder 60, 65 HP 1. Intake water screens 2. Water pump 3. Water tube 4. Cylinder block 5. Pressure valve 6. Thermostat 7. Water supply to EMM 8. Water supply, EMM to vapor separator 9.
Page 412 Hose Routing and Water Flow Diagram 75-90 HP EVINRUDE ETEC 1. Intake water screens 2. Water pump 3. Water tube 4. Adaptor housing 5. Cylinder block 6. Pressure valve 7. Thermostat 8. Water supply to EMM 9. Water supply, EMM to vapor separator 10.
Page 418 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 419 40 – 65 HP E-TEC 1. Air Temperature Sensor 2. Throttle Position Sensor 3. Neutral Switch 4. Stator 1 2 3 4 5. Crankshaft Position Sensor B A C 6. Trim/Tilt Connector 7. SystemCheck Connector 8. Key Switch Connector 9. High Pressure Fuel Pump FUSE 10.
Page 421 75 – 90 HP E-TEC 1. Air Temperature Sensor 2. Throttle Position Sensor 3. Neutral Switch 4. Stator 5. Crankshaft Position Sensor 1 2 3 4 B A C 6. Trim/Tilt Connector 7. SystemCheck Connector 8. Key Switch Connector 9. High Pressure Fuel Pump 10.
Page 423 EVINRUDE 40 – 90 HP EMM SERVICE CODE CHART DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Throttle Position Sensor TPS Voltage > 0.78 V with key ON (or cranking). Becomes stored fault when outboard starts.
Page 424 DASHBOARD TIME TO EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION ACTIVATE DISPLAY Air temperature < -58° F (-49.9° C), or > 218° F (103.2° C). 47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω...

This manual is also suitable for:

E-tec 65 hp E-tec 90 hp E-tec 50 hp E-tec 60 hp E-tec 75 hp

Evinrude E-Tec 40 HP Service Manual

S M Ervice Anual

Table of Contents

Inspection and Maintenance Schedule

Lifting the Outboard

Outboard Rigging Connections

Battery and Battery Connections

Oetiker Clamp Servicing

Adjustments

Operational Checks

Cooling System

Lubrication

Spark Plugs

Fuel and Oil Systems

Anti-Corrosion Protection

Storage

Pre-Season Service

Submerged Engines

Engine Cover Service

Table of Contents

Engine Management Module (Emm) Notes Notes

Diagnostic Procedures

Dynamic Tests

Emm Led Indicators

Ignition Output Tests

Fuel Delivery Tests

Exhaust Water Valve (60-65Hp)

Table of Contents

Electrical and Ignition Notes Notes

Service Chart

Fuel System Hose Routing

Fuel System Circuit Diagrams

Fuel System Requirements

Components

Fuel System Priming

Fuel System Tests

Fuel Component Servicing

Fuel System Notes Notes

Table of Contents

Hose Routing and Water Flow Diagrams

Components

Operation

Engine Temperature Check

Thermostat Servicing

Temperature Sender Servicing

Pressure Relief Valve Servicing

Powerhead

Service Chart

Powerhead Removal

Compression Testing

Powerhead Disassembly

Powerhead

Cylinder Block Cleaning

Powerhead Inspection

Powerhead Assembly

Upper Mount Servicing (3-Cylinder)

Powerhead Installation

Powerhead Views

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Evinrude E-Tec 40 HP