BRP Evinrude E-Tec Series Service Manual

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115,150,175,200 hp, 60 v models

Manuals Content

BRP US Inc. Technical Publications 250 Sea Horse Drive Waukegan, Illinois 60085 United States † 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. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Corporation. † Fluke is a registered trademark of The Fluke Corporation † Frahm is a registered trademark of James G. Biddle Co. † Gasoila is a registered trademark of The Federal Process Corporation. † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † Plastigage is a registered trademark of The Dana Corporation. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. † ThreeBond is a registered trademark of Three Bond Co., Ltd.

Bombardier logo is a registered trademark of Bombardier, Inc., used under license.

The following trademarks are the property of BRP US Inc. or its affiliates: Carbon Guard™

Nut Lock™

DPL™ Lubricant

QuikStart™

Evinrude ®

S.A.F.E.™

Evinrude ® E-TEC ®

S.L.O.W.™

Evinrude ® / Johnson ® XD30™ Outboard Oil

Screw Lock™

Evinrude ® / Johnson ® XD50™ Outboard Oil

SystemCheck™

Evinrude ® / Johnson ® XD100™ Outboard Oil

Triple-Guard ® Grease

FasTrak™

Twist-Grip™

Gel-Seal II™

2+4 ® Fuel Conditioner

Hi-Vis™ Gearcase Lubricant

Ultra™ 4-Stroke Outboard Oil

I-Command™

HPF XR™ Gearcase Lubricant

Johnson ®

Ultra Lock™

Moly Lube™

Printed in the United States. © 2006 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

SAFETY INFORMATION Before working on any part of the outboard, read the SAFETY section at the end of this manual. This manual is written for qualified, factory-trained technicians who are already familiar with the use of Evinrude®/Johnson® Special Tools. This manual is not a substitute for work experience. It is an organized guide for reference, repair, and maintenance of the outboard(s). This manual uses the following signal words identifying important safety messages.

DANGER Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.

CAUTION Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.

IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product. These safety alert signal words mean: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you. It is understood that this manual may be translated into other languages. In the event of any discrepancy, the English version shall prevail. To reduce the risk of personal injury, safety warnings are provided at appropriate times throughout the manual. DO NOT make any repairs until you have read the instructions and checked the pictures relating to the repairs. Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect. When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction. Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts. If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.

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. Remove propeller before servicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). The motor cover and flywheel cover are machinery guards. Use caution when conducting tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads. The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning. Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and causing an explosion. Always work in a well ventilated area. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

TABLE OF CONTENTS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . . 17 2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 33 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 4 ENGINE MANAGEMENT MODULE (EMM) . . . . . . . . . . 95 5 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 6 ELECTRICAL AND IGNITION . . . . . . . . . . . . . . . . . . . . 135 7 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 8 OILING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 10 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 11 MIDSECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 12 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 13 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–1 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index–1 TROUBLE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . T–1 DIAGRAMS EMM SERVICE CODE CHART

4

INTRODUCTION

INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TYPICAL PAGE – A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TYPICAL PAGE – B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TYPICAL PAGE – C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TYPICAL PAGE – D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5

INTRODUCTION MODELS COVERED IN THIS MANUAL

MODELS COVERED IN THIS MANUAL This manual covers service information on all 60° Evinrude E-TEC ® models.

6

Model Number

Shaft

Paint

HP

E115DPLSUC

20”

BL

115

E115DPXSUC

25”

WH

115

E115DBXSUC

25”

BL

115

E115DSLSUC

20”

WH

115

E150DPLSUC

20”

BL

150

E150DPLSUF

20”

BL

150

E150DPXSUC

25”

WH

150

E150DPXSUF

25”

WH

150

E150DBXSUF

25”

BL

150

E150DSLSUC

20”

WH

150

E150DSLSUF

20”

WH

150

E150DHLSUC

20”

BL

150

E150DHLSUF

20”

BL

150

E150DCXSUC

25”

WH

150

E150DCXSUF

25”

WH

150

E175DPLSUF

20”

BL

175

E175DPXSUF

25”

WH

175

E175DSLSUF

20”

WH

175

E175DCXSUF

25”

WH

175

E200DPLSUR

20”

BL

200

E200DPLSUF

20”

BL

200

E200DPXSUR

25”

WH

200

E200DPXSUF

25”

WH

200

E200DSLSUR

20”

WH

200

E200DSLSUF

20”

WH

200

E200DCXSUR

25”

WH

200

E200DCXSUF

25”

WH

200

Identifying Model and Serial Numbers Outboard model and serial numbers are located on the swivel bracket and on the powerhead.

1

Swivel Bracket 1. Model and serial number

005231

1

1. Serial number

005232

INTRODUCTION MODEL DESIGNATION

MODEL DESIGNATION

PREFIX

STYLE:

LENGTH:

J = Johnson E = Evinrude

= 15” L = 20” Y = 22.5” X = 25” Z = 30”

HORSEPOWER

Std. Long Special X-long XX-long

MODEL RUN or SUFFIX

B E 200 DP X SU F DESIGN FEATURES:

MODEL YR:

AP = Advanced Propulsion B = Blue Paint C = Counter Rotation D = Evinrude E-TEC™ E = Electric Start w/Remote Steering F = Direct-Injection G = Graphite Paint H = High Output J = Jet Drive M = Military P = Power Trim and Tilt R = Rope Start w/Tiller Steering S = Saltwater Edition T = Tiller Steering TE = Tiller Electric V = White Paint W = Commercial Model

I =1 N=2 T =3 R=4 O=5 D=6 U=7 C=8 E=9 S=0 Ex: SU = 2007

7

INTRODUCTION TYPICAL PAGE – A

TYPICAL PAGE – A

Subsection title indicates beginning of the subsection.

Italic subheading above Service Chart indicates pertaining models.

Bold letter indicates liquid product to be applied to a surface

Pay attention to torque specifications. Some units appear as in. lbs. Use appropriate torque.

Exploded view of Service Chart assists in identifying parts and positions

Tightening torque for a fastener.

Indicates list corresponding to applicable letter in exploded view of the Service Chart.

Page Number

8

INTRODUCTION TYPICAL PAGE – B

TYPICAL PAGE – B Section Title

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING PROCEDURE

Subsection Section Title Title

Cable, Hose, and Wire Routing Route all hoses, control cables, and wiring through a protective sleeve or conduit into the boat and through the grommet. Refer to the following diagram to ensure proper positioning of rigging components in grommet.

If a water pressure gauge is to be used, install the water pressure hose fitting in the cylinder block. Use Pipe Sealant with Teflon (P/N 910048) on the threads of the hose fitting. Refer to installation instructions supplied with gauge. Route the water pressure hose through cover grommet with oil tank sending unit harness. Route hose along battery cables toward the back of the powerhead. Use tie straps to fasten in place.

2

1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Fuel supply hose Oil return hose Oil supply hose Battery cables Main wire harness (MWS) Throttle cable Shift cable Oil tank sending unit harness Water pressure hose Accessory charge wire

000084 V4 Models 1. Water pressure fitting location: top, starboard side of cylinder/crankcase assembly, below throttle position sensor.

Model specific illustrations designated with image captions

Connect outboard main wire harness to boat main wire harness.

DP0827

1

Before installing electrical connectors, check that the seal is in place. Clean off any dirt from connectors. Apply a light coat of Electrical Grease™ to the seal. Push connectors together until latched. Products and lubricants italicized

V6 Models 1. Water pressure fitting location: rear of cylinder/crankcase assembly

1

1. Seal

DP0828

If temperature gauge is to be used, route sending unit wire through grommet with hose for water pressure gauge. Follow the path of battery cables. Provide adequate length to reach cylinder head. Refer to installation instructions supplied with gauge.

DP0824

47

9

INTRODUCTION TYPICAL PAGE – C

TYPICAL PAGE – C POWERHEAD INSTALLATION IMPORTANT: The motor mount, washer, and screw are serviced as an assembly. Do not disassemble.

INSTALLATION Title in italics indicates V4 MODELS

a procedure

V6 MODELS

Title indicates the

concerning a Install base gasket dry. Do not use Permatex particular model No. 2 or Gasket Sealing Compound.

Denotes necessary step or information to prevent damage or control correct procedure

specific toto inner Apply Permatex No. 2 procedure gasket sealant V4both Models is of a new exhaust housing flange. Coat sides finished. From this base gasket with Gasket Sealing Compound. point, this particular procedure concerns V6 Models.

39820

Installation Place mount assemblies in position, with flats facing away from each other.

ALL MODELS

Title indicates from this point, All Models gasketare onconcerned adapter.

23079

Install a new base To ensure proper sealing, mating surfaces must be clean and free of oil, grease, and foreign matter.

49557

Apply Extreme Pressure Grease to all sides of retainer and install between mounts. Apply Nut Lock to retainer screw, install the screw, and torque to 15 to 20 ft. lbs. (20 to 27 N·m).

23497

Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.

1

1. Mount retainer screw

272

10

49556

INTRODUCTION TYPICAL PAGE – D

TYPICAL PAGE – D OILING SYSTEM COMPONENTS Two pulse hoses connect the pump to pulse fittings on the front of the cylinder/crankcase. • V4 Models – cylinders 1 and 3 • V6 Models – cylinders 1 and 4

Oil Pressure Switch The oil pressure switch is located in the oil injector-manifold and reacts to changes in oil manifold pressure. The EMM supplies and monitors electrical current to the switch.

1 1 TYPICAL 1. Lower pulse hose

000721

Oil Injector-Manifold

Typical illustration for lower pulse of The hose oil injector-manifold V4 or V6 Models

distributes the oil supplied by the oil lift pump. A pressure-sensing switch monitors oil injection pressure.

Oil Injector-Manifold Components Cross references • 40 V oil injector • Oil distribution manifold direct readers to related topics • Oil pressure switch • Pressure regulator (oil return hose) • Oil distribution hoses • Oil to fuel check valve

following

53 psi (365 kPa) (nominal) to close 43 psi (296 kPa) (nominal) to reopen

Service Code 38 A faulty electrical circuit or an inoperative pressure switch activates service code 38 (no oil sensor feedback or lack of oil pressure) and the EMM:

3 2

TYPICAL 1. Oil injector 2. Oil distribution manifold 3. Oil distribution hoses 4. Oil to fuel check valve

000723

Refer to Oil Pressure Switch Test on p. 224.

3

1

Illustration components numbered to The switch opens or closescorrespond based on tothe image oil manifold pressures:

TYPICAL 1. Oil pressure switch

4

000722

8

Activates the System Check "NO OIL" light Section tabs allow for Stores a service code quicker reference Initiates S.L.O.W.

Service Code 39

when thumbing through manual

If no oil pressure is detected during startup, the EMM initiates an oil injector “recovery mode” to pressurize the system. If inadequate oil pressure is still detected after the recovery mode is completed, the EMM: Activates the System Check "NO OIL" light Stores a service code Initiates S.L.O.W.

209

11

INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN THIS MANUAL Units of Measurement

List of Abbreviations

A

Amperes

ABYC

American Boat & Yacht Council

amp-hr

Ampere hour

ATDC

after top dead center

fl. oz.

fluid ounce

AT

air temperature sensor

ft. lbs.

foot pounds

BPS

barometric pressure sensor

HP

horsepower

BTDC

before top dead center

in.

inch

CCA

cold cranking amps

in. Hg

inches of mercury

CPS

crankshaft position sensor

in. lbs.

inch pounds

DI

Direct-Injection

kPa

kilopascals

ECU

electronic control unit

ml

milliliter

EMM

engine management module

mm

millimeter

ICOMIA

N·m

Newton meter

International Council of Marine Industry Associations

P/N

part number

MCA

marine cranking amps

psi

pounds per square inch

MWS

modular wiring system

RPM

revolutions per minute

NMEA

National Marine Electronics Assoc.

°C

degrees Celsius

NTC

negative temperature coefficient

°F

degrees Fahrenheit

PDP

power distribution panel

ms

milliseconds

PTC

positive temperature coefficient

µs

microseconds

ROM

read only memory

Ω

Ohms

S.A.F.E.™ speed adjusting failsafe electronics

V

Volts

SAC

start assist circuit

VAC

Volts Alternating Current

SAE

Society of Automotive Engineers

VDC

Volts Direct Current

S.L.O.W.™ speed limiting operational warning

12

SYNC

synchronization

TDC

top dead center

TPS

throttle position sensor

WOT

wide open throttle

WTS

water temperature sensor

INTRODUCTION ENGINE EMISSIONS INFORMATION

ENGINE EMISSIONS INFORMATION Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine SI (spark ignition) engine repair establishment or individual.

Manufacturer’s Responsibility Beginning with 1999 model year outboards, manufacturers of marine outboards must determine the exhaust emission levels for each outboard horsepower family and certify these outboards with the United States of America Environmental Protection Agency (EPA). An emissions control information label, showing emission levels and outboard specifications, must be placed on each outboard at the time of manufacture.

Dealer’s Responsibility When performing service on all 1999 and more recent Evinrude/Johnson outboards that carry an emissions control information label, adjustments must be kept within published factory specifications. Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within the prescribed certification standards. Dealers are not to modify the outboard in any manner that would alter the horsepower or allow emission levels to exceed their predetermined factory specifications. Exceptions include manufacturer’s prescribed changes, such as altitude adjustments, for example.

Owner’s Responsibility The owner/operator is required to have outboard maintenance performed to maintain emission levels within prescribed certification standards.

The owner/operator is not to, and should not allow anyone to, modify the outboard in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications. Tampering with the fuel system to change horsepower or modify emission levels beyond factory settings or specifications will void the product warranty.

EPA Emission Regulations All new 1999 and more recent Evinrude/Johnson outboards are certified to the EPA as conforming to the requirements of the regulations for the control of air pollution from new watercraft marine spark ignition outboards. This certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for servicing the product must be strictly followed and, whenever practical, returned to the original intent of the design. The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA requirements on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following locations:

VIA U.S. POSTAL SERVICE: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 401 M St. NW Washington, DC 20460

VIA EXPRESS or COURIER MAIL: Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J) 501 3rd St. NW Washington, DC 20001

EPA INTERNET WEB SITE: www.epa.gov

13

INTRODUCTION PRODUCT REFERENCE AND ILLUSTRATIONS

PRODUCT REFERENCE AND ILLUSTRATIONS BRP US Inc. reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. Specifications used are based on the latest product information available at the time of publication.

SYMBOLS Throughout this service manual, symbols are used to interpret electrical troubleshooting results or to assign values in drawings.

Electrical When “∞” shows on the meter face, no continuity, or very high resistance, is indicated. The symbol is referred to as infinity.

The continuing accuracy of this manual cannot be guaranteed. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only. Certain features or systems discussed in this manual might not be found on all models in all marketing areas. All service technicians must be familiar with nautical orientation. This manual often identifies parts and procedures using these terms.

Nautical Orientation

14

DR4203

When “V” follows a value on the meter face, the procedure is measuring voltage.

DR4204

INTRODUCTION SYMBOLS When “Ω” follows a value on the meter face, the procedure is measuring resistance. Ω is the symbol for ohm, the unit of measurement for resistance.

When “≥” precedes a value on the meter face, the reading should be greater than, or equal to, the value shown.

DR4207 DR4205

Values When “≤” precedes a value on the meter face, the reading should be less than, or equal to, the value shown.

DR4206

15

INTRODUCTION NOTES

NOTES Technician’s Notes

Related Documents Bulletins

Instruction Sheets

Other

16

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

SERVICE SPECIFICATIONS AND SPECIAL TOOLS

1

TABLE OF CONTENTS TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ELECTRICAL / IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FUEL/OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 POWERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

17

SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA

TECHNICAL DATA HP

115

150, 175, 200

Full Throttle Operating Range

5500–6000 RPM

4850–5850 RPM

Power

115 HP: (85.8 kw) @ 5750 RPM

150 HP: (111.9 kw) @ 5350 RPM 175 HP: (130.5 kw) @ 5350 RPM 200 HP: (149.1 kw) @ 5350 RPM

Idle RPM in Gear

550 ± 50

500 ± 50

Test Propeller

FUEL

ENGINE

Weight (may vary depending on model)

Lubrication

V4 20 in. (L) Models: P/N 386246 or P/N 433068 V4 25 in. (X) and V6 Standard Rotation Models: P/N 387388 V6 Counter Rotation Models: P/N 398673 20 in. (L) Models: 375 lbs. (170 kg) 25 in. (X) Models: 390 lbs. (177 kg)

20 in. (L) Models: 418 lbs. (190 kg) 25 in. (X) Models: 433 lbs. (196 kg)

Evinrude/Johnson XD50 Oil or Evinrude/Johnson XD100 Oil Refer to Oil Requirements on p. 66

Engine Type

60° V 4-Cylinder Loop-Charged

60° V 6-Cylinder Loop-Charged

Displacement

105.4 cu. in. (1727 cm3)

158.2 cu. in. (2592 cm3)

Bore

3.601 in (91.47 mm)

Stroke

2.588 in. (65.74 mm)

Standard Bore

3.6005 to 3.6015 in. (91.45 to 91.48 mm) To bore oversize, add piston oversize dimension to standard bore

Top Crankshaft Journal

2.1870 to 2.1875 in. (55.55 to 55.56 mm)

Center Crankshaft Journals

2.1870 to 2.1875 in. (55.55 to 55.56 mm)

Bottom Crankshaft Journal

1.5747 to 1.5752 in. (40.0 to 40.01 mm)

Rod Crankpin

1.3757 to 1.3762 in. (34.94 to 34.96 mm)

Piston Ring End Gap, Both

0.011 to 0.023 in. (0.28 to 0.58 mm)

Fuel/Oil Ratio

EMM Controlled

Starting Enrichment

EMM Controlled

Preferred Fuel

Regular unleaded gasoline

Acceptable Fuel

See Fuel Requirements on p. 65 for additional information.

Minimum (High) Fuel Pressure @ IDLE RPM – 500 ± 50

22 to 28 psi (152 to 193 kPa)

Minimum Fuel Lift Pump Pressure @ IDLE RPM – 500 ± 50

3 to 4 psi (21 to 28 kPa)

Maximum Fuel Inlet Vacuum

4 in. Hg. (13.5 kPa)

Minimum Octane

87 AKI (R+M)/2 or 90 RON ®

Additives

2+4 Fuel Conditioner, Fuel System Cleaner Use of other additives may result in engine damage. See Fuel Requirements on p. 65 for additional information.

18

SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA

COOLING

ELECTRICAL

HP

115

150, 175, 200

Minimum Battery Requirements

675 CCA (845 MCA); or 750 CCA (940 MCA) below 32°F (0°C) (Use a 107 amp-hr battery for extreme applications.)

Alternator

Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation

Tachometer Setting

6 pulse (12 pole)

Charging Isolator

Integral, Terminal on Engine Harness

Engine Fuses

P/N 967545 – 10 A

Thermostat

143°F (62°C)

Maximum Temperature

230°F (110°C) Below 3000 RPM and 194°F (90°C) Above 3000 RPM

Water pressure

21 psi minimum @ 3000 RPM

Type

IGNITION

Firing Order

GEARCASE

Capacitor Discharge 1-2-3-4

1-2-3-4-5-6

Ignition Features

EMM Controlled

RPM Limit

6250

Crankshaft Position Sensor Air Gap

Fixed Refer to Emission Control Information Label

Spark Plug

Champion † QC10PEPB @ 0.028 ± .003 in. (0.76 mm) Refer to Emission Control Information Label

Gear Ratio

V4 “S” Type Gearcase: 13:26 (.500) (2:1) V4 “O” Type Gearcase: 12:27 (.444) (2.25:1) V6 “M” Type Gearcase: 13:24 (.542) (1.85:1) V6 “O” Type Gearcase: 14:26 (.538) (1.86:1) V6 “L” Type Gearcase: 14:26 (.538) (1.86:1) Refer to GEARCASE TYPES on p. 305

Lubricant

HPF XR Gearcase Lubricant

Capacity

“S” Type Gearcase: 31.6 fl. oz. (935 ml) V4 “M” Type Gearcase: 43.0 fl. oz. (1270 ml) V6 “M” Type Gearcase: 44.0 fl. oz. (1300 ml) “M” Type – Counter Rotation: 41 fl. oz. (1220 ml) “O” Type Gearcase: 33.1 fl. oz. (980 ml) “L” Type Gearcase: 33.1 fl. oz. (980 ml) Refer to GEARCASE TYPES on p. 305

Shift Rod Height

20 in. (L) Models: 20.945 (532 mm) ± one-half turn 25 in. (X) Models: 25.945 (659 mm) ± one-half turn

Shift Cable Stroke

POWER TRIM/TILT

1

Lubrication

1.125 to 1.330 in. (28.6 to 33.8 mm) measured between NEUTRAL and FORWARD 115 (Single Piston style): Evinrude/Johnson Biodegradeable TNT Fluid 115-200 (Three Piston style): Evinrude/Johnson Power Trim/Tilt & Power Steering Fluid or GM Dextron † II Automatic Transmission Fluid

Fluid Capacity

21 fl. oz. (622ml)

Trim Range

0° to 21°

Tilt Range

22° to 75°

19

SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS

STANDARD TORQUE SPECIFICATIONS Standard Torque Chart Size

In. Lbs.

Ft. Lbs.

N·m

No. 6

7–10

0.58–0.83

0.8–1.1

No. 8

15–22

1.25–1.83

1.7–2.5

No. 10

24–36

2–3

2.7–4.0

No. 12

36–48

3–4

4.0–5.4

1/4 in.

60–84

5–7

6.7-9.4

5/16 in.

120–144

10–12

13.5–16.2

3/8 in.

216–240

18–20

24.4–27.1

7/16 in.

336–384

28–32

37.9–43.4

IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the appropriate section. When tightening two or more screws on the same part, DO NOT tighten screws completely, one at a time.

WARNING Torque wrench tightening specifications must be strictly adhered to. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/ Johnson Genuine Parts.

20

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

SPECIAL TOOLS

1

Diagnostics

Diagnostic Software P/N 763724

005444

Bootstrap tool P/N 586551

002276

Interface cable P/N 437955

45583

Flywheel puller adapter kit P/N 5007181

005314

Universal

Lifting tool P/N 342672

44686

Flywheel service kit P/N 434649 Includes P/N 5007181 adapter

46215

Universal Puller Set P/N 378103

32885

Large puller jaws P/N 432129

23148

Puller Bridge – 432127

Flywheel holder P/N 771311

42938

Small puller jaws P/N 432131

23150

Slide hammer P/N 391008

23146

CO1577

21

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

15345

Slide hammer P/N 432128

Temperature gun P/N 772018

45240

Tilt tube nut wrench P/N 342680

46879

Tilt tube service kit P/N 434523

33249

Electrical / Ignition

Digital multimeter Ohms resolution 0.01 Purchase through local supplier

DRC7265

Stator Test Adapter P/N 5006211

004222

22

Peak reading voltmeter P/N 507972

49799

Analog multimeter P/N 501873

49793

Test probe kit P/N 342677

45241

Connector tool P/N 342667

42004

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

1

Crimping pliers P/N 322696

30387

Tachometer/timing light P/N 507980

49789

AMP† connector tools Primary Lock Tool P/N 777077 Secondary Lock Tool P/N 777078 Release Tool P/N 351413 Lock Installer P/N 777079

002277

Injector test fitting kit P/N 5005844

002465

Oetiker† pincers, P/N 787145

001081

Fuel/Oil Systems

Fuel pressure gauge (60 PSI) P/N 5007100 90° fitting, P/N 353322

005339

Fuel pressure gauge (15 PSI) P/N 5006397 90° fitting, P/N 353322

004560

23

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

Powerhead

Alignment pin kit P/N 5007167

Cylinder bore gauge P/N 771310

005279

45303

Rod cap alignment fixture P/N 396749

Torquing socket P/N 331638

21596

000797

Wrist pin bearing installer P/N 336660

41029

Wrist pin pressing tool P/N 326356

23668

1 Piston stop tool P/N 342679 Replacement tip P/N 5006098

24

46543

Crankshaft bearing and sleeve installer P/N 338647

21953B

2

1. Wrist pin retaining ring driver P/N 318599 2. Wrist pin cone P/N 318600

DR1641

Ring compressor – standard ·P/N 336314 Ring compressor – oversize ·P/N 336313

CO3768

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

Gearcase

1

1

Universal Driveshaft Shimming Tool 002601 P/N 5005925 1. Lower Driveshaft Shimming Bolt (S2 gearcase) P/N352878

Universal Pinion Bearing Remover and installer kit P/N 5005927

002805

Gearcase Alignment Gauge Kit P/N 5006349

004315

Driveshaft Puller P/N 390706

Gauging Head, “S” Type Gearcases, P/N 352879

005072

Lower DriveshaftSpline Tool P/N 5007052

Lower Driveshaft Puller P/N 342681

47257

Driveshaft seal protector P/N 31867

23692

Universal shift rod height gauge P/N 389997

32872

Piinion/Driveshaft Wrench P/N 352877

005073

Alignment pin kit, P/N 5007231

005401

Backing plate P/N 325867

23621

32884

005074

25

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

Driveshaft socket P/N 311875

23261

Pinion nut starting tool P/N 342216

Prop shaft adapter P/N 432398

15356

Pinion bearing installer P/N 350958

Spanner wrench P/N 432400

15358

Bearing Installation Tool P/N 339778

40371

Prop shaft bearing installer P/N 339750

1

Prop shaft bearing installer P/N 432401

15355

000818

Prop shaft housing seal installer P/N 336311

32973

32519

Seal installation tool P/N 330268

32924

Gearcase pressure tester P/N 507977 (Stevens P/N S-34) Gearcase vacuum tester P/N 507982 (Stevens P/N V-34)

49794

2

1. Pinion nut holder P/N 334455 2. Wrench retainer P/N 341438

26

40372

32880

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS

Trim and Tilt

1

Gauge and collar assembly P/N 983975

33023

Hydraulic cylinder rod holder P/N 983213

23665

Tilt cylinder end cap remover P/N 326485, for three-piston tilt systems

33741

Trim/tilt service kit P/N 390010

2

33013

Tilt cylinder seal protector P/N 326005

27340

1. Trim cylinder end cap remover/installer P/N 436710 2. Replacement tip for 436710

1

1

1. Trim/tilt service kit P/N 434524 2. Replacement o-ring kit for adapter tips P/N 434729

Tilt cylinder end cap remover P/N 352932, for single-piston tilt systems

23694

2 33742A

005340

27

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS

SHOP AIDS

Cleaning Solvent P/N 771087

Engine Tuner P/N 777185

Anti-Corrosion Spray P/N 777193

“6 in 1” Multi-Purpose Lubricant P/N 777192

D.P.L. Spray P/N 777183

Silicone spray P/N 775630

Oil - XD100™ P/N 777118

Oil - XD50™ P/N 777225

Oil - XD30™ P/N 777219

Ultra 4-Stroke Outboard Oil, P/N 775594

4-Stroke Outboard Oil, P/N 775597

HPF XR™ Gear Lube P/N 778747

28

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS

1

HI-VIS™ Gearcase Lube P/N 775605

Triple-Guard® Grease P/N 508298

Extreme Pressure Grease™ P/N 508303

Moly Lube P/N 175356

Needle Bearing Grease, P/N 378642

Starter Bendix Lube P/N 337016

Storage Fogging Oil P/N 777186

Power Trim/Tilt and Power Steering Fluid P/N 775612

Biodegradeable TNT Fluid P/N 763439

Lubriplate† 777 P/N 317619

Black Neoprene Dip P/N 909570

Electrical Grease P/N 503243

29

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS

2 + 4™ Fuel conditioner P/N 775613

Fuel System Cleaner P/N 777184

Carbon Guard™ P/N 775629

Gel-Seal and Gasket Remover P/N 771050

Gel·Seal II P/N 327361

Gasket Sealing Compound P/N 317201

Permatex† No. 2, P/N 910032

ThreeBond† 1104, P/N 351052 ThreeBond 1207B, P/N 351053

Pipe Sealant with Teflon P/N 910048

GE† RTV Silicone Sealant P/N 263753

Gasoila† Thread Sealant P/N 200763

1

2

1. Screw Lock P/N 500417 (Loctite† Purple 222 equivalent 2. Nut Lock P/N 500421 (Loctite Blue 242 Equivalent) 3. Ultra Lock P/N 500423 (Loctite Red 271 Equivalent)

30

3

SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS

1

Locquic Primer P/N 772032

Adhesive 847 P/N 776964

GM† Gear Mark Compound P/N 772666

Thermal Joint Compound P/N 322170

Instant Bonding Adhesive P/N 509955

31

SERVICE SPECIFICATIONS AND SPECIAL TOOLS NOTES

NOTES Technician’s Notes

Related Documents Bulletins

Instruction Sheets

Other

32

INSTALLATION AND PREDELIVERY

INSTALLATION AND PREDELIVERY TABLE OF CONTENTS

2

BOAT RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REMOTE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 BATTERY SWITCHES AND MULTIPLE BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 AUXILIARY BATTERY CHARGE ISOLATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 OILING SYSTEM SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 CABLE AND HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 OUTBOARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 HULL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 TRANSOM MEASURING AND DRILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 OUTBOARD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 OUTBOARD RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 CABLE, HOSE, AND WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ELECTRICAL HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 CANBUS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FUEL AND OIL PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SYSTEMCHECK LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 BEFORE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 RUNNING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SYSTEMCHECK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 EMERGENCY STOP / KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 START-IN-GEAR PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 TACHOMETER PULSE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 WATER PUMP OVERBOARD INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 PROPELLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 PROPELLER SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 PROPELLER HARDWARE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TILT LIMIT SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TRIM SENDING UNIT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

33

INSTALLATION AND PREDELIVERY BOAT RIGGING Additional remote control information:

BOAT RIGGING

• Power trim/tilt switch(s) can be integral to the

Remote Controls Control Selection WARNING The remote control used must have startin-gear prevention. This feature can prevent injuries resulting from unexpected boat movement when the outboard starts.

remote control for outboards with power tilt and trim. • Side-mount controls require a neutral lock feature. • Single-outboard binnacle remote controls are offered with or without an integrated key switch. • Dual-outboard binnacle remote controls require separate key switches and a single emergency stop switch.

Remote control styles and applications are described in the Evinrude/Johnson Genuine Parts and Accessories Catalog. Plan the installation of all remote controls carefully. Read the outboard's Operator's Guide and the remote control's installation instructions prior to installation. The remote control and wiring harness used must have the following features: • Start-in-gear prevention • Emergency stop / key switch • Shift stroke must measure 1.125 to 1.330 in. (28.6 to 33.8 mm) between NEUTRAL and FORWARD • Throttle stroke must PUSH for open • All wiring must be compatible with Modular Wiring System (MWS) components

3 1. Emergency stop clip 2. Safety lanyard 3. Key switch with emergency stop feature

34

002817

Dual-outboard key switches with emergency stop switch

DRC40118

WARNING Always install and recommend use of an emergency stop/key switch. Doing so will reduce the risk of personal injury or death should the operator fall away from the controls or out of the boat.

INSTALLATION AND PREDELIVERY BOAT RIGGING Installation Guidelines

SystemCheck™ Monitor

Install the appropriate remote control following all instructions provided with the remote control.

The SystemCheck engine monitor alerts the operator of certain engine problems. Refer to the Operator’s Guide for detailed information related to the various warning signals.

Make sure the following items are checked: • Correct length control cables and wiring harnesses • Proper type and quality of cables and wiring harnesses • Correct routing of cables and harnesses • Appropriate slack in front of the outboard for remote control cables • Proper routing of cables to prevent kinking • Positioning and securing of cables and harnesses along their lengths to prevent movement or damage

IMPORTANT: Outboards with remote controls must be equipped with a SystemCheck gauge, ICommand system, or equivalent engine monitor. Operating the outboard without an engine monitor will void the warranty for failures related to monitored functions.

Typical transom-mounted outboard installations require a 12 in. (30 cm) cable loop at the front of the outboard when the cables are routed from the side of the splash well.

1

2

1. Surface side-mount remote control 2. Cable support 3. 12 in. (30 cm) cable loop at front of outboard

Typical MWS SystemCheck gauges

005329

Typical I-Command gauge

005330

3 DR4277

IMPORTANT: Cables of the proper length, style, and quality that are correctly installed and adjusted will eliminate most control-related operational problems.

35

2

INSTALLATION AND PREDELIVERY BOAT RIGGING

Battery Installation

Connections

Each outboard requires its own starting battery. Select a battery that meets or exceeds the minimum requirements.

IMPORTANT: Connect the battery positive (+)

Minimum 12 Volt Battery Recommendations Outboard Model

Battery Rating

Evinrude E-TEC 60° V 675 CCA (845 MCA), or 750 CCA (940 MCA) below 32°F (0°C) 107 amp-hr in extreme applications

cable to the battery positive (+) post FIRST. Connect the battery negative (–) cable to the battery negative (–) post LAST. Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from accessories. Finish this connection with a hex nut.

3

2

Location and Preparation Proper installation will prevent battery movement while underway. • Secure all batteries in protected locations. • Position battery as close to the outboard as possible. • Battery location must provide access for periodic maintenance. • Use battery mounting trays or battery boxes on all battery installations. • Connections and terminals must be covered with an insulator. • Battery connections must be clean and free from corrosion. • Read and understand the safety information supplied with the battery before installation.

WARNING Keep the battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion. If the battery mounting system does not cover the connections, install protective covers. Check often to see that connections stay clean and tight.

36

1 Marine Style Battery Post 1. Starwasher 2. Hex nut 3. Terminal Insulator

DR5103

IMPORTANT: Do not use wing nuts to fasten ANY battery cables. Wing nuts can loosen and cause electrical system damage not covered under warranty. Tighten all connections securely. Apply TripleGuard grease to prevent corrosion.

INSTALLATION AND PREDELIVERY BOAT RIGGING Battery Cable Requirements Evinrude/Johnson outboards are shipped with stranded copper battery cables for typical installations in which the starting battery is positioned close to the transom.

IMPORTANT: Inadequate battery cables can affect the performance of an outboard’s high amperage start circuit and the cranking speed of the outboard. DO NOT use aluminum wire cables. Use ONLY AWG stranded copper wire cables.

Specialized outboard installations with extended length battery cables require an increased wire size. Refer to the following table. Models

1 to 10 Ft. (.3 to 3 m)

11 to 15 Ft. (3.4 to 4.6 m)

16 to 20 Ft. (4.9 to 6.1 m)

Evinrude E-TEC 60° V

4 Gauge

2 Gauge

1 Gauge

Battery Switches and Multiple Batteries A multiple battery setup, including marine battery selector switches, can provide flexibility in single and dual outboard installations. Refer to Battery and Switch Wiring Diagrams on p. 39 for various battery connection options. The battery selection function can be used for emergency starting if a primary battery becomes discharged. The OFF position of the battery selector switch can be used to minimize battery discharge during periods of non-use.

Typical battery functions Primary • Used as starting battery under normal operating conditions. • Red (+) cable connected to battery selector switch. • Primary battery is charged by connection to main red (+) outboard battery cable. Dual outboard installations can utilize the opposing outboard's primary battery as a secondary battery for emergency starting only.

Secondary

• Used as back-up starting battery under abnormal operating conditions.

• Red (+) cable connected to battery selector switch.

• Secondary battery is charged independently from primary battery.

The secondary battery is often charged by a battery charge isolator. Refer to Auxiliary Battery Charge Isolator on p. 38. Accessory

• Not used as starting battery. • Isolated from outboard start function. • No red (+) cable connected to battery selector switch.

The accessory battery is often charged by a battery charge isolator. Refer to Auxiliary Battery Charge Isolator on p. 38.

Battery Switch Requirements Battery switches must meet the following requirements. • The switch must be approved for marine use. • The switch should be a “make before break” design to protect the charging system from a no-load condition. • Switch amperage rating should be adequate for the outboard it will be used on.

37

2

INSTALLATION AND PREDELIVERY BOAT RIGGING • Use one battery switch for each outboard

3

installed. • Use the appropriate sized wire and terminals for all connections. • Use AWG stranded copper wire.

Battery Switch Location • Always locate battery switch(s) as close to the battery(s) as possible.

• Locate switch so that it cannot be accidently bumped or switched.

• Refer to the battery switch manufacturer’s • • • • •

installation instructions for specific information related to the installation of switch. Fasten all battery switches to solid surfaces. Route wiring as directly as possible. Support the battery switch as needed to prevent abrasion. Use appropriate wiring and connectors. Seal all connections and terminals with liquid neoprene or electrical sealer to prevent corrosion.

IMPORTANT: Insulate all battery positive (+) terminals to prevent shorting.

Battery Switch Operation • Select the primary battery for normal operation. • Secondary batteries should only be selected for emergency starting.

• ALL or BOTH switch position is for emergency starting only.

Provide operator with the documentation supplied by the battery switch manufacturer. Make sure that the operator is informed of proper battery switch operation.

1

2

1. Starting battery (primary) 2. Accessory battery (secondary) 3. Cable connecting negative (–) battery terminals

DRC7284

Auxiliary Battery Charge Isolator Evinrude E-TEC 60° V outboards are equipped with isolated battery charging capability. The isolated charge connection must only be used to charge a single 12-volt battery or two 12-volt batteries wired in parallel.

IMPORTANT: Never connect an external battery isolator to the stator of an Evinrude E-TEC outboard. Accessory Charge Lead Kit, P/N 5006253, is routed from a connector on the outboard’s electrical harness to the accessory battery.

1

IMPORTANT: The negative (–) terminals of a multiple 12-volt battery installation must be connected together.

1. Accessory battery charge connector

004944

IMPORTANT: The accessory charging kit must never be connected to any battery of a 24-volt electrical system.

38

INSTALLATION AND PREDELIVERY BOAT RIGGING

Battery and Switch Wiring Diagrams One outboard: Battery disconnect

One outboard: One primary starting battery; one secondary battery

2 S

S

BOTH ON

2

1 OFF

OFF

+ #1

+ #1

PRIMARY

+ #2

PRIMARY

SECONDARY

000135rev1

Two outboards: Two starting batteries for each outboard

#1

#2

S S

BOTH

1

1

BOTH

2

1

OFF

+

#1

PRIMARY

2

2

OFF

+ #1

+ #2

SECONDARY

SECONDARY

Positive (+) Battery cables Negative (–) Battery cables Accessory charge wires, P/N 5006253 50 amp Fuse

+ #2 PRIMARY

000134N

39

INSTALLATION AND PREDELIVERY BOAT RIGGING

Two outboards: One primary starting battery for each outboard; one isolated accessory battery

#1

#2 S

S

BOTH

BOTH

2

1

2

1

OFF

OFF

+ #1

+ #2

+

PRIMARY

PRIMARY

ACCESSORY

Two outboards: One primary starting battery for each outboard; two isolated accessory batteries

#1

#2 S

S

BOTH

BOTH

OFF

OFF

+ #1 PRIMARY

+ #1

+ #2

ACCESSORY

ACCESSORY

Positive (+) Battery cables Negative (–) Battery cables Accessory charge wire, P/N 5006253 50 AMP Fuse

40

2

1

2

1

+ #2 PRIMARY

000086N

INSTALLATION AND PREDELIVERY BOAT RIGGING

Fuel System Requirements

Fuel System Primer

Overview

Outboards require a priming system capable of refilling the fuel system after periods of non-use.

Fuel systems must meet minimum specifications to insure the proper delivery of fuel to the outboard. The guidelines established by the ABYC and U.S. Coast Guard should always be followed. • Permanent fuel tanks must be properly vented outside of the hull. • Remote fuel tank gas fills must be grounded. • Permanent fuel tank pickups should have the correct anti-siphon valve installed to prevent fuel flow if a leak occurs in the fuel distribution system. Refer to ABYC Standard H-24.

Fuel Hose All fuel hoses must be designated as fuel hose and approved for marine use. • Use only fuel lines (or copper tubing) that meet the outboard minimum I.D. requirement. • “USCG Type A1” fuel hose must be used between permanent fuel tanks and motor well fittings on inaccessible routings. • Use “USCG Type B1” for fuel hose routings in motor well areas. • Permanently installed fuel hoses should be as short and horizontal as possible. • Use corrosion-resistant metal clamps on permanently installed fuel hoses. • Multi-outboard applications require separate fuel tank pickups and hoses. (A fuel selector switch may be used for “kicker” motors as long as it has enough flow capacity for the larger outboard.)

Primer Bulbs Primer bulbs that meet the outboard's minimum inside diameter fuel line requirements are used on most outboards. Install the primer bulb in the fuel supply hose as follows: • The primer bulb should be installed in an accessible location. • The arrow on the primer bulb must point in the direction of fuel flow. • The fuel primer bulb must be positioned in the fuel supply hose so the primer bulb can be held with the arrow pointing “up” during priming.

1

1. Arrow indicates direction of fuel flow

000124

Marine Primer Pump The alternative to a primer bulb is a U.S. Coast Guard approved marine primer pump. Electric primer pumps offer the convenience of outboard priming from a dash-mounted momentary switch.

41

2

INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter. 1

2

3

Typical Fuel Supply Configuration 1. Primer bulb 2. Water separating fuel filter 3. Anti-siphon valve, in fuel pick-up of tank

DRC6797

IMPORTANT: Avoid using “in-line” fuel filters. The filter area and flow characteristics may not be adequate for high horsepower outboards. Portable Fuel Tanks

0070

Do not use portable fuel tanks for outboards larger than 115 HP. Inadequate fuel flow to high horsepower outboards can result in serious powerhead damage.

Outboard Fuel System Recommendations Component

25 HP – 130 HP Models

135 HP – 250 HP Models

Fuel tank pickup tube

5/16 in. (7.9 mm) min. I.D.

3/8 in. (9.5 mm) min. I.D.

Fuel fittings

1/4 in. (6.4 mm) min. I.D.

9/32 in. (7.1 mm) min. I.D.

Fuel supply hoses

5/16 in. (7.9 mm) min. I.D.

3/8 in. (9.5 mm) min. I.D.

ALL MODELS Fuel tank pickup screen

100 mesh, 304 grade stainless steel wire, 0.0045 in. wire diameter, 1 in. (25 mm) long

Antisiphon valve

2.5 in. (63.5 mm) Hg maximum pressure drop at 20 gph (76 l/hr) flow

Remote fuel filter

0.4 in. Hg maximum pressure drop at 20 gph (76 l/hr) flow, 150 in.2 (1290 cm2) of filter area

Maximum fuel pump lift height

Fuel pump should not be located more than 30 in. (76.2 cm) above bottom of fuel tank

42

INSTALLATION AND PREDELIVERY BOAT RIGGING

Oiling System Set-Up

• Replacement hose must be designated for fuel

Location

• Extend wiring harness with 16 gauge AWG

IMPORTANT: Consider the installation location

• Protect connections with heat shrink tube. • Maintain wire color and polarity when extending

of the oil tank carefully. The oil tank is vented to the atmosphere. To avoid serious powerhead damage, be sure the oil tank is installed in a location that does not allow constant exposure to sunlight, rain, bilge water or spray. Select a mounting location that provides: • A solid place to mount the tank; • A dry location that prevents exposure to rain or spraying water; • Access for adding oil; • Access to oil-primer bulb; and • Interference-free hose and wire routing to outboard.

or oil use and approved for marine use. wire.

harness.

An appropriately sized battery box may be used to conceal and protect the oil tank, if desired.

IMPORTANT: Be sure box includes drain holes so it does not fill with water and contaminate oil.

Each oil tank is originally fitted with a single oil pickup assembly with 15 ft. (4.5 m) of oil supply hose and 17 ft. (5.2 m) of sending unit wiring harness. If necessary, the oil tank can be mounted further from the outboard than the supplied hoses and harness allow. The maximum length of oil supply hose that can be fitted to the oil tank is 25 ft. (7.6 m).

IMPORTANT: Do not add hose to an existing oil supply hose. If the oil tank requires more than 15 ft. (4.5 m) of oil supply hose: • Oil supply hose between the primer bulb and outboard must be replaced with one continuous length of 1/4 in. (6.4 mm) hose. • Maximum length of hose is 25 ft. (7.6 m).

000074

Mounting Place tank in selected position. Mark one line under groove in tank bottom and lines at each end of tank.

1

2 1. Center line of oil tank 2. Ends of tank

2 44737

Make sure hole locations provide enough clearance for fastening screws. Screws should not contact or penetrate hull.

43

2

INSTALLATION AND PREDELIVERY BOAT RIGGING Place floor bracket on center line between end lines. Use the inner bracket holes as guides to drill two 5/32 in. (4 mm) pilot holes.

1.8 GALLON TANK Place rods into floor bracket and secure floor bracket with lag bolts.

1

1

2

2

COB5381 1. Rods 2. Lag bolts

3 GALLON (11.4 L) TANK Place rods into floor bracket and secure floor bracket with lag bolts.

1

1

2

2

1. Rods 2. Lag bolts

1

44

Place oil tank onto floor bracket. If cover is not pre-assembled, route oil supply hose and harness through the cover and position cover on the oil tank. Attach spring-loaded rods to cover.

22241B

Place oil tank onto floor bracket. Assemble crossbar onto hook rods, install flat washers and locknuts. Tighten locknuts to securely hold tank.

1. Crossbar

22149A

DRC7418

48704

INSTALLATION AND PREDELIVERY BOAT RIGGING Oil Tank Profiles 1.8 Gallon Tank P/N 176995

3 Gallon Tank P/N 176996

2

Remote Oil Fill Kit (Optional) The remote oil fill kit (P/N 176461) provides a deck-mounted fill tube, cap, a tank-mounted tube, and nut that replace the original oil tank cap assembly. Installation Recommendations • Select a location on the deck of the boat that is above the oil tank fill cap. • Select a deck location which allows the required length of 1½ in. I.D. fill hose to route as directly and as vertically as possible. • Avoid inappropriate hose routings that could distort the fill tube or tank tube. • Refer to installation instructions provided with remote oil fill kit. A slanted area of the deck will allow water to drain away from the fill and is best suited for the installation.

DRC8123

Additional Items Required • 1½ in. I.D. fill hose cut to required length. Fill hose (P/N 123956) is available in 25 ft. (7.6 m) lengths. • Two corrosion resistant 2 in. (50 mm) hose clamps.

45

INSTALLATION AND PREDELIVERY BOAT RIGGING

Cable and Hose Installation

Cable and Wire Harness Routing

Before installation, identify all required wiring, cables, and hoses: • Throttle and shift cables • Modular Wiring System (MWS) harness • Battery cables and switches • Fuel supply hose • Primer bulb or primer pump • Oil supply hose • Oil tank sender harness Determine whether any additional wiring or hoses will be needed for accessory gauges or batteries: • Speedometer pick-up hose • Mechanical water pressure gauge hose • Accessory battery charging kit • CANbus adapter harnesses • CANbus water pressure sensor kit • CANbus oil level sensor kit 1

6

2

7

Typical outboard installation 1. Oil tank 2. Anti-siphon valve 3. Water separating fuel filter 4. Starting battery 5. Accessory battery 6. Flexweave protective sleeve 7. Access cover 8. Primer bulb 9. Battery switch

46

3

4

8

WARNING Improper installation and routing of outboard controls could wear, bind, and damage components, causing loss of control. Remote control cables, wiring, and hoses must follow a similar path into the lower motor covers. Select the best routing possible for the specific application. Proper remote control cable lengths are essential. Installations must provide adequate slack for all cables, wiring, and hoses. Check clearances of routings at all trim angles, at all steering positions, and at all possible combinations of outboard positioning.

5

Typical Small Splash Well

DRC7799

Typical Large Splash Well

DRC7797

9 DRC6487

INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Hose Route the fuel supply hose with adequate slack to allow for the primer bulb to be held with the arrow pointing “up” during use.

Typical Engine Bracket

DRC7798A

Protective Sleeve/Conduit Make sure all cables, wiring, and hoses have been identified and fitted to the appropriate lengths. Next, locate appropriate shielding to protect the components that route to the outboard. An expandable “flexweave” sleeve or a flexible conduit may be used to bundle the cables together as they enter the lower motor cover.

The fuel hose could be the only hose routed outside of the protective sleeve or conduit. Electric primers or manual primers may not require this consideration. • Route fuel hoses from boat fuel system to outboard with adequate slack. • Install the primer bulb with the arrow pointing in the direction of fuel flow to the outboard. • Connect the fuel supply hose from the fuel tank to the fuel supply line at the outboard.

IMPORTANT: Do not permanently fasten this connection until the boat's fuel system has been primed. Oil Supply Hose Evinrude E-TEC 60° V outboards use a single oil supply hose connected to the outboard and to the boat-mounted oil tank. • Route the hose from the oil tank to the ¼ in. (6.4 mm) fitting of the oil supply line at the lower motor cover grommet. • Install the hose on the fitting using the proper size Oetiker † clamp.

1

Flexible conduit installation

2

005138

Battery Cables Evinrude/Johnson outboards are equipped with premium quality battery cables that should be long enough for most installations.

1. Fuel supply hose and fuel fitting - 3/8 in. (9 mm) 2. Oil supply hose and fitting - 1/4 in. (6 mm)

003963

When routing battery cables, be sure to: • Route cables through the protective sleeve and to the appropriate location; and • Use the most direct path to route the battery cables to the battery or battery switch.

47

2

INSTALLATION AND PREDELIVERY BOAT RIGGING Oetiker Clamp Servicing

1

Use Oetiker† clamps for making hose connections. These clamps provide corrosion resistance, minimize the potential for abrasion of rigging components, and provide solid, permanent connections. The selection and installation of an Oetiker clamp is essential in the proper sealing of hose connections. The clamp identification numbers appear in millimeters on the side of the clamp, near the top of the ear. Refer to Oetiker Stainless Steel Stepless Clamps chart for actual dimensions.

WARNING

000093

1. Clamp identification numbers

DO NOT re-use Oetiker clamps. Fuel leakage could contribute to a fire or explosion.

The nominal size of the clamp should be chosen so that, when it is assembled on the connecting part, the outside diameter of the hose lies approximately in the middle of the clamping range of the clamp.

Oetiker Stainless Steel Stepless Clamps CLAMP NO. Replacement 346930 348838 349516 347107 347108 346931 346785 346786 348839 346150 346151 346152 346153 349759 349729

48

Clamp I.D. 95 105 113 133 138 140 145 157 170 185 210 256 301 316 410

NOMINAL O.D. Inches 3/8 13/32 7/16 1/2 17/32 34/64 9/16 5/8 11/16 23/32 13/16 1 1 3/16 1 1/4 1 5/8

MM 9.5 10.5 11.3 13.3 13.8 14 14.5 15.7 17 18.5 21 25.6 30.1 31.6 41

INCHES Open 0.374 0.413 0.445 0.524 0.543 0.551 0.571 0.618 0.669 0.728 0.827 1.008 1.185 1.244 1.614

Closed 0.307 0.346 0.378 0.425 0.449 0.453 0.472 0.52 0.571 0.602 0.701 0.882 1.063 1.122 1.492

MILLIMETERS Open 9.5 10.5 11.3 13.3 13.8 14 14.5 15.7 17 18.5 21 25.6 30.1 31.6 41

Closed 7.8 8.8 9.6 10.8 11.3 11.5 12 13.2 14.5 15.3 17.8 22.4 26.9 28.4 37.9

INSTALLATION AND PREDELIVERY BOAT RIGGING Clamp Installation

Clamp Removal

A constant stress should be applied to close the ear clamps. This method ensures a positive stress on the hose and does not result in excessive compression or expansion of the band material.

Method 1: Position Oetiker pincers across clamp ear and cut clamp.

2

IMPORTANT: Use only Oetiker recommended tools to close Oetiker stepless clamps. Oetiker pincers are available in the Evinrude/Johnson Genuine Parts and Accessories Catalog (P/N 787145).

000108

Method 2: Lift end of stepless clamp with screwdriver.

DP0886

• Position correct size clamp over hose. • Install hose on fitting. • Close clamp ear fully with Oetiker pincers (pliers).

000090

Method 3: Use Oetiker pincers (pliers) to grip clamp. Pull clamp off of connection and discard.

1 1. Open clamp 2. Closed clamp

2 000092 000091

49

INSTALLATION AND PREDELIVERY BOAT RIGGING Control Cable Identification IMPORTANT: Control cable function must be

Extend the control cables and lubricate them with Triple-Guard grease.

identified before rigging outboard. Identify each control cable: • Put the control handle into NEUTRAL position. The throttle cable casing guide will retract completely and the shift cable casing guide will go to the midpoint of its travel.

1 30501

2 1. Shift cable casing guide extended to midpoint 2. Throttle cable casing guide retracted

50

DP0811

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION • Check transom strength and height.

OUTBOARD INSTALLATION

WARNING DO NOT install an outboard on a curved or irregular surface. Doing so can wear, bind, and damage components, causing loss of control.

Hull Preparation Maximum Capacity WARNING Do not overpower the boat by installing an outboard that exceeds the horsepower indicated on the boat’s capacity plate. Overpowering could result in loss of control. Before installing outboard: • Refer to the boat manufacturer's certification label for maximum horsepower rating. • Refer to ABYC Standards to determine the maximum horsepower capacity for boats without certification labeling.

Top Edge of Transom or Bracket Transom thickness or off-sets must also be considered. The top edge of the transom or bracket must provide a proper surface for stern brackets. The stern brackets must contact the flat surface of the transom or bracket. Modify moldings or components that prevent the stern brackets from resting against the transom surface. Do not modify transom brackets.

Transom Clearances Make sure the transom and splash well area provide adequate clearances. • The top edge of the transom should be wide enough to allow full steering travel. The ABYC standard for most single outboard installations is 33 in. (84 cm). • Check cable and hose routing clearances. • Make sure there is clearance for mounting bolts and washers. Check the inside area of the transom for obstructions prior to drilling holes.

Water Flow 1029A

Mounting Surface Inspect transom surface prior to drilling mounting holes. • The transom should meet ABYC Standards. • The transom must be flat and cannot have any protrusions. • The transom angle should be approximately 14 degrees.

Inspect the hull area directly in front of the mounting location. • Boat-mounted equipment should not create turbulence in the water flow directly in front of the outboard's gearcase. Turbulence or disruptions in the water flow directly in front of the gearcase will affect engine cooling and propeller performance. • Avoid locating outboard centerlines within 3 in. (76 mm) of bottom strakes on dual-outboard installations.

51

2

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION

Transom Measuring and Drilling

Transom Brackets and Jack Plates When mounting an outboard on boats equipped with transom brackets or jack plates, refer to the manufacturer's recommendations. • Confirm maximum weight and horsepower capacities. • Jack plate assemblies must provide a one-piece mounting surface to support the outboard, hydraulic unit, and steering system.

Hull Centerline Locate the centerline of the boat transom as it relates to the hull (bottom) of the boat. Use a straightedge to draw a line connecting the port and starboard chines. The chines should be used as reference points for determining the centerline of the hull. Use a framing square to accurately place a line on the transom. The centerline of the hull should be in line with the keel of the hull and perpendicular to the midpoint of the line connecting the port and starboard chines.

DR5704

Mounting Hardware WARNING Use all mounting hardware supplied with the outboard to help ensure a secure installation. Substituting inferior hardware can result in loss of control. 1 The required outboard mounting bolts, aluminum backing plates, washers, and nuts are used to attach the outboard to the frame of the shipping palette. Refer to the outboard's parts catalog for alternate length mounting bolts or replacement components. • Use only Evinrude/Johnson Genuine Parts or parts of equivalent type, strength, and material. • Use the mounting hardware provided with outboard whenever possible.

52

1. 2. 3. 4.

2

3

4 DR5568

Chine Strake Keel Hull centerline

Dual-Outboard Centerlines The following table lists standard ABYC centerline spacing between outboards in dual installations: V4 and V6

26 in. (660 mm)

Some applications may require changes in this dimension to avoid strakes, to adjust for transom height, or for performance reasons. Best performance can be determined only through testing. Refer to boat manufacturer for recommendations.

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION If the standard spacing does not allow full steering travel in a particular installation, it may be necessary to increase the spacing.

IMPORTANT: Some steering systems may require additional spacing. Refer to steering system manufacturer for recommendations. The width of the top edge of the transom should be more than twice the dual-outboard centerline spacing dimension. Bracket installations may not require this consideration. Measure the transom for dual-outboard spacing after the centerline of the hull is established. Divide the spacing dimension by two. Use the resulting number to space the outboard centerlines from the hull centerline. EXAMPLE: A 26 in. (660 mm) dual-outboard spacing would result in two outboard centerlines, each 13 in. (330 mm) from the hull centerline.

Transom Heights Make sure the transom height is consistent with the height of the outboard to be installed. • A 19 to 21 in. (48.3 to 53.3 cm) transom height uses a 20 in. (50.8 cm) shaft outboard. • The shaft length of the outboard being installed should come close to matching the transom height of the boat. Determine transom height by measuring from the top edge of the transom, along the centerline. For dual-outboard installations, transom height should be measured at the outboard centerlines. Use a straightedge as a reference to extend the bottom of the boat. Position the straightedge along centerline. The distance from the top edge of the straightedge to the top edge of the transom is the actual transom height. 1

2

1. Top edge of transom 2. Actual transom height

1 1. Port centerline 2. Hull centerline 3. Starboard centerline

2

DR5541

3 DRC5527B

53

2

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Drilling Locations All models use the standard ABYC 4-Bolt mounting pattern. Transom drill fixture, P/N 434367 or P/N 385368, may be used as a guide for correct hole placement. If drill fixture is unavailable, refer to Drilling and Hardware Diagrams on p. 55 for measurements. Position drill fixture on top of transom or bracket and align indicator points with centerline.

IMPORTANT: DO NOT assume that the top edge of the transom is straight. Position the drill fixture based on measurements aligning it to the bottom of the hull. IMPORTANT: Maintain at least 1.75 in. (45 mm) of transom surface above the top mounting bolts. Make sure that the proposed mounting hole locations will provide adequate clearance for mounting bolts and washers. Check the inside area of the transom for obstructions prior to drilling mounting holes. Check transom height(s) at centerlines prior to drilling any mounting holes. Drill four ½ in. (13 mm) mounting holes in the appropriate locations.

IMPORTANT: Be sure to drill the required holes perpendicular to transom surface. Transom drill fixture P/N 434367 (heavy duty)

24496

The indicators are affected by the squareness of the top edge of the transom. If either side of the fixture must be raised more than ¼ in. (6 mm) above the transom's top surface to make both indicators align, the transom must be modified.

54

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION

Drilling and Hardware Diagrams IMPORTANT: This is not a template. 2 2'' (50.8mm)

1

6 7/16" (136.5mm)

2

6 7/16" (136.5mm)

2" (50.8mm)

3

3

90˚

9 10 11 12

5 8" (203.2mm)

90˚

8" (203.2mm)

6

7

8

4 3

4 15/16" (125.4mm)

4 15/16" (125.4mm)

3

1

000133m

Quantity 4

* Choose from the following bolt sizes:

1. Center of Transom

5. Bolt *

2. Top of Transom

6. 318272 Plate

2

327053 3 in. (76 mm)

3. 1/2” Bolt Hole Locations

7. 318273 Retainer

2

318573 3 1/2 in. (89 mm)

4. Outside of Transom

8. 319886 Screw

4

313327 4 in. (102 mm)

9. 307238 Washer

2

336676 4 1/2 in. (114 mm)

10. 320248 Washer

4

331578 5 in. (127 mm)

11. 313623 Nut

4

321577 6 in. (152 mm)

12. 318572 Cap

4

55

2

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION

Lifting the Outboard

Before Mounting Outboard to Transom

Lifting Fixtures WARNING To avoid personal injury, make sure the lifting capacity of the hoist is at least twice the weight of the outboard. DO NOT allow the lift hook or chain from the hoist to come in contact with any part of the engine during lifting. Remove shipping carton. Remove any banding material used to secure outboard to shipping palette. The mounting hardware used to attach the outboard to the shipping frame is reused to fasten outboard to boat transom. Use correct Lifting Fixture to lift outboard: Model Evinrude E-TEC 60° V

Some rigging components that attach directly to the outboard should be assembled before the outboard is mounted to the boat's transom. Steering system components and gearcase speedometer pickup hoses are the most common. Determine what equipment will be installed prior to mounting the outboard to the transom or bracket.

Steering Systems Mechanical Cables All Evinrude/Johnson outboards equipped with tilt tubes are designed to be compatible with mechanical steering systems that meet ABYC Standard P-17. Single-cable mechanical steering systems can be used on single or dual-outboard installations if an ABYC-approved steering link is used. Dual-cable mechanical steering helps provide firm steering control at high speeds.

Lifting Fixture P/N 342672

Position lifting tool on crankshaft and tighten the center retaining screw securely using a 1/4 in. Allen wrench.

Extend the output end of the steering cable and lubricate the inner core of cable prior to installation.

1

ABYC-approved Mechanical Steering Cable 1. Center retaining screw

004945

Fasten appropriate chain hook to eye of tool. Carefully hoist outboard with chain and unbolt outboard mounting brackets from frame.

5873

IMPORTANT: Install steering cable through tilt tube before mounting outboard on transom. Tighten nut securely. WARNING DO NOT use cable over pulley steering on 40 HP and larger outboards.

56

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Manual Hydraulic Steering

Drag Links

Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard. Hydraulic steering systems offer certain design advantages that can be beneficial in some applications.

Install cable wiper nut on tilt tube and connect drag link to the correct location on the steering arm. For single motor, single cable applications, the drag link should be installed in the rear hole.

Use only a hydraulic steering system designed for the specific application. Refer to the steering system manufacturer’s specifications for recommended applications.

1

2

002097

1. Drag link connection 2. Wiper nut

1 TYPICAL Manual Hydraulic Steering

004948

2 IMPORTANT: Some hydraulic steering systems require additional centerline spacing in dual-outboard installations. Refer to steering system manufacturer’s recommendations and to DualOutboard Centerlines on p. 52.

3

1. Rear Location (D)–Steering drag link connection 2. Middle Location (P)–Power steering connection (Refer to manufacturer’s instructions for hydraulic steering systems.) 3. Front Location (T)–Bar connection (multiple outboard installations)

DRC7162

Use the correct drag link to allow full steering travel: Model

Drag Link

Evinrude E-TEC 60° V

P/N 175125

57

2

INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Assemble transom mounting plates on mounting bolts.

Outboard Mounting Mounting Height Boat performance depends on outboard mounting height.

Apply sealant around the mounting bolt holes on the outer surface of the transom.

Generally, the anti-ventilation plate of the gearcase should be in alignment with the bottom of the hull. Conventional V-hulls often perform well with the anti-ventilation plate approximately 1 in. (25 mm) above the bottom of the hull.

Install the mounting bolts through the transom from the inside of the boat.

Boats that exceed 50 MPH may benefit from higher outboard heights. Consult the boat manufacturer for specific outboard mounting height information for a particular hull. Test outboard and boat performance at different heights until the best performance is achieved.

IMPORTANT: Be sure that outboard water pressure is not adversely affected by the mounting height of the outboard. DR5536

IMPORTANT: Use a marine sealant rated for above or below waterline use. RTV silicone is not approved for below waterline use. Polyurethane sealants are not easily removed and may damage outboard or boat mounting surfaces when removed. Apply marine sealer under hex heads of bolts, on the mounting plates, and to the bolt shanks.

Position the square aluminum transom mounting plates (when applicable) so the retainer holes are horizontal. Position hex head of bolt with flats toward holes in the mounting plates. Install retainer over hex head of the bolt and secure it with screws provided. Install all washers and nuts. Torque nuts and bolts to 40 ft. lbs. (54 N·m).

WARNING

0078A

58

If either side of the transom deforms or cracks when the bolts are tightened to their recommended torque, the transom construction may not be adequate or may be deteriorated. Structural failure of the transom could result in loss of boat control and injury to the occupants.

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Refer to the following diagram to ensure proper positioning of rigging components in grommet.

OUTBOARD RIGGING CAUTION To prevent accidental starting while servicing, disconnect the battery cables at the battery. Twist and remove all spark plug leads.

12

9

8

4 7

3

5

Cable, Hose, and Wire Routing

1

Remove two screws and bracket that fasten the grommet to lower motor cover.

1

1. Grommet retaining bracket

2

11

6

10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Fuel supply hose Fuel supply hose--alternate location Oil supply hose Oil tank sending unit harness Battery cables Main wire harness (MWS) Shift cable Throttle cable Accessory charge wires CANbus harness Water pressure hose Speedometer hose

2

000095c

1

003964

Route all hoses, control cables, and wiring through a protective sleeve or conduit into the boat and through the grommet. The fuel hose may be routed through the protective sleeve or through an alternate hole in the lower motor cover grommet. To route the fuel hose outside the sleeve, trim the material covering the alternate fuel hose slot in the grommet.

1. Alternate fuel hose location

004946

The main wiring harness, battery cables, oil tank sending unit harness, and any CANbus cables should be routed along the same path to the star-

1

1. Alternate fuel hose location

003970

59

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING board side of the powerhead. Secure all cables to anchor points with tie-straps.

• Use long nose pliers to insert straight section of clip into linkage pin hole.

1

1 2 DP0818 DP0817

1. Straight section 2. Angled section

1. Anchor points

004949

• Push the clip towards the hole while lifting on the curved end with the pliers.

Control Cable Installation Remove remote control cable trunnion covers and cable attachment hardware.

• Be sure retainer clip fully engages the pin. • Lock the retainer by moving the angled section behind the straight section.

1

1 Locked Retainer Clip 1. Angled section behind straight section

DP0817A

Shift Cable Installation and Adjustment Position the shift cable on the shift lever pin and install the washer and retainer clip. 1. Trunnion covers

004955

IMPORTANT: Do not bend or deform clip. Cable Retainer Clip Installation When installing retainer clips on control arm linkage pins, clips should be locked and must not be bent or deformed. For proper installation, review the following steps: • Place washer on pin. • Position retainer clip with straight section on the bottom and angled section on the top.

Confirm that the remote control, gearcase, shift linkage, and shift cable are in NEUTRAL. Hold the shift linkage in NEUTRAL and grab the shift cable firmly. Push and pull on the shift cable and observe the cable slack. Position the casing guide in the center of the slack. Adjust shift cable trunnion to align with center of the trunnion block. Place cable trunnion in trunnion block.

60

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Install trunnion cover and screw. Tighten retaining screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m).

1

With throttle cable attached to the throttle linkage, pull cable to remove slack and ensure that idle stop of the throttle linkage is against the crankcase.

2

2

1 1. Shift cable retainer clip and washer 2. Shift cable trunnion

004956 1. Throttle linkage, idle stop against crankcase

004947

Throttle Cable Installation and Adjustment Rotate the propeller shaft and shift control lever to FORWARD, then pull control lever half-way back to NEUTRAL.

Adjust the throttle cable trunnion to align with the trunnion block. Place the cable trunnion in the trunnion block.

Position throttle cable on throttle lever pin and install washer and retainer clip.

IMPORTANT: Make sure that the idle stop on the throttle linkage firmly contacts the crankcase when the remote control is in the IDLE position. The roller on the cam follower should spin freely.

1

Install the trunnion cover and screw. Tighten the retaining screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m).

1

1. Throttle cable retainer clip and washer

004957

1. Trunnion cover and screw, throttle cable

004958

61

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Route oil tank sending unit harness around the front to the port side. Secure all cables with tie straps.

Electrical Harness Connections Remove flywheel/harness connector cover.

1

2

004954

Before installing electrical connectors, check that the seal is in place. Clean off any dirt from connectors. Apply a light coat of Electrical Grease™ to the seal.

1. Low oil sender connection 2. Tie straps

004952

Install battery cables on starter solenoid and main ground stud.

1 2

1 1. Seal

42079A

Connect outboard main wire harness to boat wire harness. Secure connectors in brackets.

1. Positive (+) battery connection 2. Ground (–) connection

Replace flywheel/harness connector cover.

1

1. Harness connections

62

004951

004953

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING

Water Pressure Gauge If a mechanical water pressure gauge is used, install the water pressure hose fitting in the cylinder block. Use Pipe Sealant with Teflon, P/N 910048, on the threads of the hose fitting. Refer to installation instructions supplied with gauge.

SystemCheck connector with 6-Pin Connector Seal, P/N 586076.

2 1 3

Route the water pressure hose around the starboard side of the powerhead along the same path as the battery cables.

1

1. CANbus Ignition connector 2. Trim/Tilt connector 3. SystemCheck connector (with seal)

005266

Connect the EMM CANbus connector to the CANbus Network Harness.

1 1. Water pressure hose fitting

004959

IMPORTANT: After installation, make sure there is enough clearance for all cables to avoid binding or chafing through all engine steering and tilting angles.

CANbus Connections If the outboard will be used with an I-Command † system, or other NMEA 2000 † compliant CANbus instruments, the following connections will supply information to the network: Use a CANbus Ignition Harness, in place of the standard MWS harness, to connect the outboard to the key switch and trim/tilt control. Seal unused

1. EMM CANbus connector

005267

Route the harness under the front of the EMM and around the port side of the powerhead. Secure with tie straps.

1 1 2

1. Harness routing 2. Tie straps

005268

63

2

INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Connect the purple wire from the CANbus Ignition Harness to the CANbus Network Harness. This connection supplies power to the network when the keyswitch is on.

install the transducer lead in the engine wiring harness connector and secure in bracket.

1 1

2

1. Water pressure transducer lead 2. Engine harness connector 1. CANbus power supply connector

005269

Secure all cables to anchor points with tie-straps.

1

004962

If a CANbus oil level gauge is used, an optional CANbus oil level sender must be installed in the oil tank. Connect the oil level sensor harness to the boat CANbus network. Use the Evinrude Diagnostics Software program to activate CANbus control functions in the EMM. From the Settings screen, select Engine Options.

1

005270

2

If a CANbus water pressure gauge is used, install Water Pressure Transducer Kit, P/N 5006214, in the cylinder block.

3

1. Anchor points

Engine Options Screen 1. Trim gauge calibration 2. Multi-engine setup 3. Water pressure gauge setup

1

1. Water pressure transducer

64

004961

005136

INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING

FUEL AND OIL PRIMING Fuel Requirements WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Improper handling of fuel could result in property damage, serious injury or death. Always turn off the outboard before fueling. Never permit anyone other than an adult to refill the fuel tank. Do not fill the fuel tank all the way to the top or fuel may overflow when it expands due to heating by the sun. Remove portable fuel tanks from the boat before fueling.

When using alcohol-extended fuels, be aware of the following: • The boat’s fuel system may have different requirements regarding the use of alcohol fuels. Refer to the boat’s owner guide. • Alcohol attracts and holds moisture that can cause corrosion of metallic parts in the fuel system. • Alcohol blended fuel can cause engine performance problems. • All parts of the fuel system should be inspected frequently and replaced if signs of deterioration or fuel leakage are found. Inspect at least annually.

IMPORTANT: Always use fresh gasoline. Gasoline will oxidize, resulting in loss of octane and volatile compounds, as well as the production of gum and varnish deposits which can damage the outboard. Additives

Always wipe off any fuel spillage.

IMPORTANT: The only fuel additives approved

Do not smoke, allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

for use in Evinrude outboards are 2+4 ® fuel conditioner and Evinrude/Johnson Fuel System Cleaner. Use of other fuel additives can result in poor performance or engine damage.

Minimum Octane Evinrude/Johnson outboards are certified to operate on unleaded automotive gasoline with an octane rating equal to or higher than: • 87 (R+M)/2 AKI, or • 90 RON Use unleaded gasoline that contains methyl tertiary butyl ether (MTBE) ONLY if the MTBE content does not exceed 15% by volume. Use alcohol-extended fuels ONLY if the alcohol content does not exceed: • 10% ethanol by volume • 5% methanol with 5% cosolvents by volume

Evinrude/Johnson 2+4 Fuel Conditioner will help prevent gum and varnish deposits from forming in fuel system components and will remove moisture from the fuel system. It can be used continuously and should be used during any period when the outboard is not being operated on a regular basis. Its use will reduce spark plug fouling, fuel system icing, and fuel system component deterioration. Evinrude/Johnson Fuel System Cleaner will help keep fuel injectors in optimal operating condition.

65

2

INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe all fuel lines, both in the boat and on the outboard. Repair any fuel leaks.

Fuel System Priming Vent Line Clamp In compliance with Code of Federal Regulations, 49 CFR §173.220, all outboards using a fuel vapor separator must be shipped with a vent line clamp installed. This clamp must be removed before priming the fuel system or starting the outboard for the first time.

WARNING Failure to check for fuel leaks could allow a leak to go undetected, resulting in fire or explosion and may cause personal injury or property damage. The high-pressure fuel circuits and injectors will prime as the outboard is cranked with the starter.

Oil Requirements IMPORTANT: Failure to follow these recommendations could void the outboard warranty if a lubrication-related failure occurs.

004963

IMPORTANT: Failure to remove the clamp may cause fuel starvation and poor running qualities.

Priming the Fuel System WARNING Fuel vapors are highly flammable. Perform the following procedure in a well ventilated area. Extinguish all smoking materials and make certain no ignition sources are present. Insert the fuel supply hose from the fuel tank into a suitable container. Squeeze the fuel primer bulb or activate the boat-mounted electric fuel primer until fuel flows from the fuel hose. Once fuel flow is observed, connect fuel supply hose from fuel tank to hose fitting on outboard. Secure hose with Oetiker clamp. Use the primer to fill the outboard’s fuel system.

66

Evinrude/Johnson XD100, XD50, or XD30 outboard oil is recommended for use in Evinrude ETEC outboards. Evinrude/Johnson XD100 outboard oil is preferred for use in Evinrude E-TEC models. If these oils are not available, you must use an oil that meets NMMA TC-W3 certification.

Engine Lubricant Below 32°F (0°C) If the outboard will be operated in temperatures below freezing (32°F, 0°C), use Evinrude/Johnson XD100.

INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING

Oil Injection Rate If the owner desires, the Engine Management Module (EMM) on Evinrude E-TEC models can be programmed for the exclusive use of XD100, which will significantly reduce oil consumption.

Use the XD100 Outboard Oil Decal, P/N 352369, to accurately inform the boat operator of the XD100 outboard oil requirement.

2

CAUTION Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil ratio will result in increased engine wear and shortened outboard life. The TC-W3 OIL control setting allows the outboard to be run on TC-W3 outboard lubricant. Changing to the optional XD100 OIL CONTROL setting requires the use of Evinrude XD100 outboard lubricant. Running the outboard in XD100 OIL mode can reduce oil consumption by approximately one third. Refer to Oil Control on p. 109. Powerhead oil programming labels are provided to identify EMM oil programming. Install the correct label to alert user to specific oil requirements.

IMPORTANT: Make sure the engine label and boat decal match EMM programming. 2 1

XD100 Outboard Oil Decal

004522

Install decal(s) in one or more of the highly visible recommended locations to alert the outboard operator(s). Recommended Locations: Dashboard/deck of boat, adjacent to key switch Deck of boat, adjacent to the remote oil fill Deck of boat, adjacent to oil tank assembly Oil tank cover Cover of oil tank compartment Attach to oil tank or oil fill cap

• • • • • •

Break-In Oiling IMPORTANT: DO NOT add oil in the fuel tank on Evinrude E-TEC models. The Engine Management Module (EMM) will automatically supply extra oil to the engine during the first two hours of operation above 2000 RPM.

004964 1. Evinrude/Johnson XD30 outboard lubricant (TC-W3) YELLOW label 2. Evinrude/Johnson XD100 outboard lubricant (Premium) BLUE label (Installed)

XD100 Outboard Oil Decal Evinrude/Johnson XD100 oil decals are available to label boats equipped with Evinrude E-TEC outboards that have been programmed for the XD100 oil injection ratio.

Follow these steps for initial outboard set-up: • Use the Evinrude Diagnostics Software program to confirm that the break-in program has been initiated. Refer to Oil Control on p. 109. • The oil tank should be filled and the oil level accurately marked for reference. • Fill the fuel tank with the recommended fuel.

IMPORTANT: The operator must monitor the oil tank level to confirm oil consumption. This may require several hours of operation above idle speed.

67

INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING

SystemCheck Low Oil Warning IMPORTANT: Leave oil tank empty until low oil warning has been tested. Turn key switch to ON. The SystemCheck gauge should initiate a test mode, momentarily sound the warning horn, and illuminate all four indicator lights. The “LOW OIL” light should remain illuminated. Fill the oil tank with the recommended oil. The “LOW OIL” light should turn off. Turn key switch to OFF and install oil fill cap.

Oil Supply Priming

Oil Distribution Manifold Priming Follow these steps for initial outboard set-up: • Squeeze the oil primer bulb to flow oil from the hose connection, through the filter, to the oil pump. • Visually inspect filter to ensure that all air has been purged. • Continue squeezing the primer until oil flows through the distribution manifold into the oil distribution hoses and to the crankcase fittings. All air must be eliminated from oil lines. • Use the Evinrude Diagnostics Software program to confirm that the EMM is programmed for the type of oil being used. • Start the outboard and use the oil priming function in the software for a minimum of 90 seconds to make sure the system is completely primed.

Oil Hose Connections WARNING Always use caution while working around machinery with moving parts. The following set-up procedures require running tests that are performed with the outboard’s motor cover removed.

1

Insert the end of the oil supply hose (from the oil tank) into a suitable container. Squeeze the oil primer bulb to flow oil from the oil tank. Once oil flow is observed, connect the oil tank hose to the outboard’s oil supply hose and secure with 14.5 mm Oetiker clamp.

68

Dynamic Tests Screen 1. Prime Oil button

005137

INSTALLATION AND PREDELIVERY FUEL AND OIL PRIMING Observe oil flow through the oil distribution hoses.

Small bubbles are acceptable. Large bubbles must be eliminated through a continued priming process.

1 1

2 3

1. Oil distribution hoses (7)

004965

Make sure that oil flows through the rear oil distribution manifold to the cylinder block fittings.

2

1. Oil distribution hose 2. Small bubbles 3. Large bubbles

004398

IMPORTANT: All clear “blue” oil distribution hoses on the powerhead should fill with oil as the air is purged from the lines. Repair any fuel or oil leaks.

1

1. Rear oil distribution manifold

The oiling system can also be primed using the Self-Winterizing feature if diagnostic software is not available. Refer to STORAGE on p. 91.

005271

69

INSTALLATION AND PREDELIVERY BEFORE START-UP

BEFORE START-UP

Trim and Tilt Fluid

Gearcase Lubricant With outboard in vertical position, check the gearcase lubricant level: • Remove the lubricant level plug. Lubricant must be even with the bottom of the threaded hole. • A clean tie strap can be used as a “dip stick” if the lubricant level is not obvious. • Add HPF XR gearcase lubricant as needed.

Make sure trim and tilt reservoir is full before running outboard: • Tilt the motor up and engage the tilt support. • Remove filler cap and check fluid level.

1

1 Single Piston Trim System 1. Fill cap

1. Gearcase lubricant level

000072

004278

1

Oil Level Make sure oil tank contains an adequate supply of the correct lubricant for the outboard and that the SystemCheck Low Oil Warning test has been performed. When starting the outboard for the first time, refer to Oil Supply Priming on p. 68.

DR22834

1. Filler cap

• Single Piston System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. • Three Piston System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads. Install the fill plug and torque 45 to 55 in. lbs. (5 to 6 N·m).

WARNING Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

70

INSTALLATION AND PREDELIVERY RUNNING CHECKS

RUNNING CHECKS WARNING DO NOT run outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.

DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

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.

SystemCheck Operation Attach emergency stop lanyard. Turn key switch to ON. Observe the SystemCheck self-test function. Warning horn should sound for 1/2 second and all warning indicator lights should turn on at the same time, then turn off one at a time.

Fuel System Perform running checks of the fuel system by following these steps: • Squeeze fuel primer bulb until hard or activate electric primer. Observe all fuel hoses and connections. Repair any leaks. • Start outboard. Inspect all hoses and connections. Repair any leaks or misrouted hoses immediately.

Emergency Stop / Key Switch Check emergency stop function. With outboard running at IDLE, pull safety lanyard from emergency stop switch. Outboard must stop immediately.

Remote Control Operation Make sure that control can be easily moved into all gear and throttle settings. Do not shift remote control when outboard is not running.

Start-In-Gear Prevention WARNING Make certain that the starter will not operate when the outboard is in gear. The startin-gear prevention feature is required by the United States Coast Guard to help prevent personal injuries. Start outboard and shift remote control lever to FORWARD. Turn outboard OFF while remote control is in FORWARD. Attempt restarting the outboard. Outboard should not start. Pull remote control lever back to NEUTRAL and restart outboard. Shift remote control lever to REVERSE. Turn outboard OFF while remote control is in REVERSE. Attempt restarting the outboard. Outboard should not start.

71

2

INSTALLATION AND PREDELIVERY RUNNING CHECKS

Tachometer Pulse Setting

Operating Temperature

Confirm accuracy of tachometer reading. • Adjust dial on back of tachometer to required setting (the outboard should not be running).

An outboard run at idle speed should achieve a temperature based on the engine’s thermostatic control. In general, the powerhead temperature should reach at least 104°F (40°C) after five minutes of idling. Check that the powerhead reaches idle temperature. Refer to TECHNICAL DATA on p. 18.

Outboard Model Evinrude E-TEC 60° V

Tachometer Setting 6 Pulse or 12 Pole

Water Pump Overboard Indicator

Idle Speed

A steady stream of water should flow from the overboard indicator.

Outboard idle speed is essential for proper outboard control and shift function. Make certain the outboard idles within the specified idle RPM range. If the outboard is run on a flushing device, the idle speed and quality may not be representative of actual “in water” use.

Break-In When the outboard is delivered, the customer should be referred to the correct break-in procedure in the Operator’s Guide. The Engine Management Module (EMM) on new Evinrude E-TEC models is programmed to automatically supply extra oil to the engine during the first few hours of operation above 2000 RPM. 1 1. Water pump overboard indicator

72

DRC4952

Use the Diagnostic Software program to confirm that the break-in program has been initiated. Refer to Oil Control on p. 109.

INSTALLATION AND PREDELIVERY PROPELLERS

PROPELLERS Propeller Selection CAUTION Selection of the wrong propeller could reduce engine service life, affect boat performance, or cause serious damage to the powerhead. Water testing with various propeller designs and sizes is the best method of propeller selection. The correct propeller, under normal load conditions, will allow the engine to run near the midpoint of the RPM operating range at full throttle. Refer to TECHNICAL DATA on p. 18.

5 1

When selecting a propeller, consider the following: • Use an accurate tachometer to determine the engine’s full-throttle RPM. • The outboard should be trimmed for top speed. • Select a propeller that suits the customer’s application and allows the engine to run near the midpoint of the full-throttle operating range when the boat has a normal load. • Occasionally, one propeller will not cover a wide range of boat applications — water skiing to high speed performance boating. In such cases, it might be necessary to have a propeller for each situation. • Refer to the Evinrude/Johnson Genuine Parts and Accessories Catalog for propeller styles and sizes. • Right-hand propellers are considered standard rotation propellers. When propelling a boat forward, the propeller rotates in a right-hand (clockwise) direction as viewed from the rear. • Left-hand propellers are considered counterrotation propellers. When propelling a boat forward, the propeller rotates in a left-hand (counterclockwise) direction as viewed from the rear.

3

6 2 1. 2. 3. 4. 5.

7 4

Percentage of horsepower (kw) Engine RPM Horsepower curve Full throttle operating range Midpoint of full throttle operating range, horsepower rating in kilowatts (kw) 6. Engine is overloaded at full throttle 7. Engine is overspeeding at full throttle

DR1261

IMPORTANT: If the propeller blades have too much pitch, the engine will operate below its normal range at full throttle. Power will be lost, and powerhead damage could occur. If the propeller blades have too little pitch, the engine will operate above its normal range and damage from overspeeding could occur.

2

1

1. Right-hand rotation (clockwise) 2. Left-hand rotation (counterclockwise)

000033

WARNING For dual-outboard installations, always check to be sure propellers are installed on the correct engines before aggressively operating the boat.

73

2

INSTALLATION AND PREDELIVERY PROPELLERS

Propeller Hardware Installation 1

WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally.

2

Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.

4

Install thrust bushing onto propeller shaft with shoulder of thrust bushing facing aft. Taper of bushing must match taper of propshaft. Install propeller on propeller shaft by aligning splines and pushing until seated on the thrust bushing.

3

Models without cotter pin “keeper” 1. Thrust bushing 2. Spacer 3. Cotter pin 4. Propeller Nut

CO2917

Wedge a block of wood between propeller blade and the anti-ventilation plate.

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

1 2 3 4 5 Models with cotter pin “keeper” 1. Thrust Bushing 2. Spacer 3. Propeller Nut 4. Cotter Pin 5. Keeper

DR4028

001992

Install the propeller nut and torque to: • With Keeper – 70 to 80 ft. lbs. (95 to 109 N·m) • Without Keeper – 120 to 144 in. lbs. (13.6 to 16.3 N·m) If cotter pin holes in the propeller nut (Without Keeper) and propeller shaft are not aligned, tighten the nut until they are in line. Do not loosen. Insert a new cotter pin through the propeller nut and shaft, or propeller nut keeper and shaft. Bend its ends over the nut to secure the assembly.

IMPORTANT: After fastening propeller nut, make sure outboard is in NEUTRAL and carefully spin propeller. Propeller must turn freely and should not spin off center. If propeller appears to wobble, check for possible bent propeller shaft.

74

INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS

FINAL ADJUSTMENTS Tilt Limit Switch Adjustment

Use the trim/tilt switch and trim the outboard IN all the way. Rotate the LOWER adjustment tab UP to reduce the maximum tilt. Rotate the UPPER adjustment tab DOWN to increase the maximum tilt position.

WARNING If the outboard does not clear all boat parts when tilted fully or turned side to side, safety related parts could be damaged in the course of such outboard movement. Injuries could result from loss of boat control. Adjust the tilt limit switch on all new outboard installations. Check the clearance between outboard(s) and the boat’s motor well and transom area. Tilt outboard(s) to highest point of clearance and turn the steering system lock to lock. If the outboard contacts the boat's motor well when fully tilted, adjust the tilt limit cam to reduce full-tilt position.

IMPORTANT: The tilt limit cam will not prevent the outboard from overriding the adjustment if the outboard is tilted manually.

2

1 DR4268

1. Lower adjustment tab 2. Upper adjustment tab

Confirm the adjustment by tilting the outboard fully, using the trim/tilt switch. Repeat this procedure until the tilt limit switch stops the outboard's upward travel before it contacts the motor well. To prevent damage to equipment, provide additional motor well clearance when it is needed. Consider either changing the outboard mounting position or modifying the boat if the possibility for interference and damage exists.

WARNING

DR3916

Adjusting the tilt limit cam will NOT prevent the outboard from tilting fully and contacting the motor well if the gearcase hits an object at high speed. Such contact could damage the outboard and boat and injure boat occupants.

75

2

INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS Observe the trim gauge. If the needle does not show center position, tilt the outboard up and adjust the sending unit by pivoting it up or down.

Trim Sending Unit Adjustment Tilt the outboard and engage the tilt support. Temporarily install a thrust rod, P/N 436541, in the number 3 hole.

1

1. Needle at center position

29072

Loosen the sending unit screws, to allow the sending unit to pivot.

000662

Lower the outboard against the thrust rod to check adjustment. Repeat adjustment, if necessary. After adjustment is correct, tilt the outboard up, tighten the two sending unit screws, and remove the thrust rod.

WARNING 1

1. Screws

27339

Disengage the tilt support. Lower the outboard against the thrust rod.

76

When the outboard is returned to the customer, the trim limiter rod must be installed and in the same location as it was when the motor was brought in for service. Leaving the trim limiter rod out, or changing the adjustment, could allow the motor to unexpectedly trim in too far and cause loss of control.

INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS

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

IMPORTANT: A single trim tab adjustment will relieve steering effort under only one set of speed, outboard angle and load conditions. No single adjustment can relieve steering effort under all conditions. WARNING To prevent accidental starting while servicing, twist and remove all spark plug leads. If the boat pulls to the left or right when its load is evenly distributed, adjust the trim tab as follows: • With the remote control in NEUTRAL and the engine OFF, loosen the trim tab screw. If the boat pulled to the right, move rear of the trim tab slightly to the right. If the boat pulled to the left, move rear of the trim tab slightly to the left. • Tighten the trim tab screw to a torque of 35 to 40 ft. lbs. (47 to 54 N·m).

1

2 1. Trim tab screw

COA3663

Test the boat and, if needed, repeat the procedure until steering effort is as equal as possible.

Outboards with High Transom Heights The trim tab may be above the surface of the water when the outboard is trimmed out. Steering effort might increase. Lower the trim setting to submerge the trim tab and to reduce steering effort.

Dual Standard Rotation Outboards Move both trim tabs equally and in the same direction.

Dual Outboards, One Counter and One Standard Rotation Set both trim tabs to the center position.

77

INSTALLATION AND PREDELIVERY FINAL ADJUSTMENTS

Dual-Outboard Alignment

Alignment Adjustment

Dual outboards must be connected with a tie bar and adjusted to align the outboards for correct water flow to the gearcases and propellers. Incorrect outboard alignment could cause one or more of the following: • Propeller ventilation • Reduction of top speed • Improper boat tracking • Engine overheat and powerhead damage Follow the instructions provided by the tie-bar manufacturer for tie bar installation and adjustment.

Measure Alignment The “toe-in” (gearcase leading edges closer together than propeller shaft centers) or “toe-out” (gearcase leading edges farther apart than propeller shaft centers) is determined as follows: • Position outboards straight with the anti-ventilation plates parallel with the bottom of the boat. • Measure between propeller shaft centers.

Various boat/motor combinations respond differently to dual-outboard alignments. Each application must be thoroughly tested until the ideal combination of performance, steering, and cooling is found. A common practice is to set-up the outboards parallel, or with a small amount of “toe-out,” and adjust inward until best results are achieved. • A typical set-up with 2-stroke outboards mounted directly on the transom often runs best with a slight amount of “toe-in.” • Outboards mounted behind the transom on motor brackets usually require “parallel” alignment or “toe-out.” Adjust the outboard alignments by adjusting tie bar. Follow the tie bar manufacturer’s adjustment procedures. Check steering operation. Make sure that the steering system operates properly at various trim angles.

Confirm Alignment To confirm proper alignment, perform the following steps: • Water test the boat. • Monitor the water pressure for both outboards. • Run the boat at various trim angles. • Perform steering maneuvers and vary the throttle settings. • Monitor boat and outboard performance.

6365

• Measure between leading edges of gearcase.

6340

78

A sudden loss of water pressure or excessive propeller ventilation on one or both outboards may indicate a misalignment of the gearcases. Reset the outboard alignment and retest.

MAINTENANCE

MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 ADDITIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 OUTBOARD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 BATTERY(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 POWER TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 ENGINE DROPPED OVERBOARD (NOT RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 ENGINE DROPPED OVERBOARD (RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 ENGINE DROPPED OVERBOARD (IN SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 PROLONGED SUBMERSION (FRESH OR SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

79

3

MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE

INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer.

IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance. Inspection and maintenance should be adjusted according to operating conditions and use; and environmental conditions. Engine Care Product

Description

Routine Inspection

SystemCheck self-test and warning horn, check

3

Emergency stop circuit and lanyard, check operation

3

Controls, steering and tilting; check operation, lubricate

3

Engine to transom mounting hardware, re-torque (40 ft. lbs.)

3

Fasteners, tighten any loosened components

3

Water intake screens, check condition

3

Cooling system; check water pump indicator / water pressure

3

Anticorrosion anodes, check condition

3

Gearcase, check condition

3

Propeller, check condition Fuel and oil system components, inspect and repair leaks

Every 300 hours or every three years (1)

3 (2)

3

Check battery connections and condition

3

Access EMM information, resolve any service codes

3

Electrical and ignition wires, inspect for wear or chafing

3

Fuel filter, replace

3

Oil filters, replace Gearcase lubricant, replace

3 A

Spark plugs, inspect or replace (2)

3 3

Thermostats, inspect and check operation (2)

3

Grease fittings, lubricate (3)

C

3

Power trim/tilt and fluid level, inspect

B

3

Propeller shaft splines, inspect and lubricate (3)

C

3

Starter pinion shaft, inspect and lubricate (3)

D

3

Control cables, inspect and adjust

3

Water pump, inspect / replace (more often if water pressure loss or overheating occurs)

3

(1) Frequency for average recreational use. Commercial use, heavy use or use in salt, brackish or polluted water requires more frequent inspection and maintenance. (2) Emission-related component (3) Annually in salt water applications

80

A

HPF XR Gearcase Lubricant

B

Power Trim/Tilt Fluid

C

Triple-Guard Grease

D

Starter Lube Only P/N 337016

MAINTENANCE ANTI-CORROSION PROTECTION

ANTI-CORROSION PROTECTION

Testing Procedure – Continuity Connect meter leads between engine ground and anode surface.

Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to protect the underwater metal components of the outboard from galvanic corrosion. Outboards are equipped with three sacrificial anodes.

3 1 1. Meter lead to anode

1

3

000677

The multimeter should indicate little or no resistance. If resistance is high, check the following: • Remove the anode and clean the area where the anode is installed. • Clean the mounting screws. • Install the anode and do the test again.

Metallic Component Protection 2

1. Stern bracket anode 2. Propeller shaft bearing housing anode (inside of gearcase housing) 3. Gearcase housing anode

DR5082

Visually inspect anodes and metal components below water level. Erosion of anodes is normal and indicates the anodes are functioning properly.

IMPORTANT: Anodes that are not eroding may indicate that the anodes are not properly grounded. Anodes and the mounting screws must be clean and tight for effective corrosion protection. For best anode performance: • Replace all anodes that have eroded or disintegrated to two-thirds of their original size. • Do not paint or apply protective coatings to anodes or anode fasteners. • Avoid using metal-based antifouling paint on the boat or outboard.

Protect metal components on outboards from corrosion. Use the following products to minimize corrosion. • Anti-Corrosion Spray provides a heavy, waxy coating to protect components. • “6 in 1” Multi-Purpose Lubricant provides a thin film of anti-corrosion protection.

Exterior Finishes Maintain the outboard’s exterior finish to prevent corrosion and reduce oxidation. • Use automotive wax to protect the outboard’s exterior finish from oxidation. • Clean regularly using clean water and mild detergent soap. • Touch-up damage to painted surfaces promptly. • Protect moving components with appropriate lubricants.

81

MAINTENANCE COOLING SYSTEM

COOLING SYSTEM

Thread garden hose into flushing port.

Check the condition of cooling system components regularly. The outboard cooling system consists of: • water intake screens; • water pump; • all internal water passages; • thermostats; • all external water hoses and fittings; • vapor separator cooling passages and fittings; • EMM cooling passages and fittings; • overboard water pressure indicator.

Flushing Flush the outboard with fresh water following each use in brackish, salt, or polluted water to minimize the accumulation of scale and silt deposits in cooling system passages.

004264

Shift the outboard to NEUTRAL with the propeller removed. Turn water supply on. START outboard. Run it at IDLE only.

The outboard can be flushed on the trailer or at dockside; running or not running.

Shut OFF the outboard. Turn off water supply and remove garden hose.

IMPORTANT: The outboard must be located in a well ventilated area with appropriate ground drainage during the flushing procedures.

Leave the outboard in VERTICAL (DOWN) position long enough for the powerhead to drain completely.

Keep water inlet pressure between 20 to 40 psi (140 to 275 kPa).

Reinstall propeller.

Flushing — Outboard Running WARNING To prevent injury from contact with rotating propeller, remove the propeller before flushing.

Flushing — Outboard Not Running Outboard can be in VERTICAL (DOWN) or TILTED (UP) position. Thread garden hose into flushing port. Turn water supply ON. Flush outboard for at least five minutes.

Refer to Propeller Hardware Installation on p. 74.

Turn off water supply and remove garden hose.

Place outboard in VERTICAL (DOWN) position in a well ventilated area.

Position outboard in VERTICAL position (DOWN) long enough to allow the powerhead to drain completely.

82

MAINTENANCE LUBRICATION

Water Intake Screens Inspect condition of water intake screens. Clean or replace as needed. Confirm function of overboard water pressure indicator.

2

Steering System WARNING Failure to regrease as recommended could result in steering system corrosion. Corrosion can affect steering effort, making operator control difficult. Grease the stainless steel output end of the steering cable with Triple-Guard grease.

1

1. Water intake screen 2. Overboard water pressure

LUBRICATION

drc4952arev

Use an appropriate cleaning solvent to remove corrosion and dirt from output end of cable prior to coating it with grease. Make sure wiper nut is installed and not damaged.

Additional Maintenance • Confirm function of SystemCheck engine monitor.

• Check operation or visually inspect thermostats and pressure relief valve. Clean or replace as needed. • Check that all water passages, hoses, and fittings for both the EMM and the vapor separator flow water freely. • Replace water pump.

2 1

1. Steering cable 2. Wiper nut

DR29546

83

3

MAINTENANCE LUBRICATION

Swivel Bracket and Trailering Bracket

Throttle and Shift Linkage

Lubricate the swivel bracket with Triple-Guard grease.

Remove cable trunnion cover. Carefully, remove throttle and shift cables from trunnion block.

Apply grease until the grease begins to flow from the upper or lower swivel bracket areas.

IMPORTANT: DO NOT disturb cable trunnion

Disconnect the battery cables at the battery.

Coat the pivot points of the trailering bracket with Triple-Guard grease.

1

2

3

adjustments. Shift remote control into FULL THROTTLE/ REVERSE position to fully extend the plastic casing guides. Apply Triple-Guard grease to: • Pivot and slide area of the shift interrupt switch bracket • Cable attachment pins of both the throttle and shift levers • Brass inner casings of both the throttle and shift cables

DR5073

1. Grease fitting 2. Pivot points 3. Lower swivel bracket area

3

Tilt Tube Lubricate the tilt tube grease fittings with TripleGuard grease.

1 2

1. Attachment pins, throttle and shift cables 2. Shift shaft grease fitting 3. Brass inner casings, throttle and shift cables

DRC6500R

Shift the remote control to the NEUTRAL/IDLE position. 1 1. Tilt tube fittings

84

Install control cables in trunnion block(s) and install trunnion cover(s) and screw(s) securely.

1 DR38798

Check proper throttle and shift function.

MAINTENANCE LUBRICATION

Propeller Shaft Debris from the water can become lodged around propeller shaft. Frequent inspection can minimize potential gearcase damage.

WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery cables at the battery.

Examine drained lubricant for excessive metal fragments and for any indication of water in oil (cloudy or milky appearance). Lubricant that is black in color with a burnt odor indicates worn, overheated oil. Pressure and vacuum check gearcases with apparent leaks. Repair all leaks. Refer to the INSPECTION AND MAINTENANCE SCHEDULE on p. 80 for service frequency and recommended lubricants. Refer to LUBRICANT on p. 307 for complete gearcase lubricant filling procedures.

Remove propeller. Refer to Propeller Hardware Installation on p. 74. Inspect bushing and blade surfaces. Replace damaged or worn propellers.

3 1

Clean propeller shaft. Inspect propeller shaft seals. Replace damaged or worn seals.

2

Apply Triple-Guard grease to entire length of propeller shaft prior to installing propeller. 1. Magnetic level and drain/fill plugs 2. Drain/fill hole 3. Lubricant level hole

Reinstall propeller hardware and propeller.

Gearcase Lubricant IMPORTANT: Always check the fill level of the gearcase lubricant prior to removing drain/fill plug. A tie strap can be used to check lubricant level.

Refill the gearcase with HPF XR Gearcase Lubricant. If HPF XR Gearcase Lubricant is not available, HiVis gearcase lubricant can be used as an alternative; however, long term durability may be affected with continued use.

IMPORTANT: The recommended gear lubricants include special additives for marine applications. Do not use any automotive gear lubricants, 2-stroke or 4-stroke engine oil, or any other oil or grease for gearcase applications.

1

1. Tie strap

DR33681

000072

85

3

MAINTENANCE LUBRICATION

Trim and Tilt Position outboard in FULL TILT (UP) position. Engage the tilt support bracket.

1

Three Piston Trim System 1. Fill cap

1

DR22834

• Single Piston System–Add Evinrude/Johnson 1. Tilt support bracket

DR5071

Inspect for fluid leaks. Repair all leaks. Remove the fill plug and check fluid level. The fluid level must be even with bottom of the reservoir fill cap hole.

Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. • Three Piston System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads. Install the fill plug and torque 45 to 55 in. lbs. (5 to 6 N·m).

WARNING Correct fluid level must be maintained to ensure operation of the impact protection built into the unit.

1

Single Piston Trim System 1. Fill cap

86

004278

MAINTENANCE BATTERY AND BATTERY CONNECTIONS

BATTERY AND BATTERY CONNECTIONS Check battery connections frequently. Periodically remove battery to clean and service connections.

WARNING Battery electrolyte is acidic—handle with care. If electrolyte contacts any part of the body, immediately flush with water and seek medical attention.

FUEL AND OIL SYSTEMS Routine replacement of filters reduces the possibility of foreign material restricting the incoming fuel or oil supplies. Replacement filter elements are available through Evinrude/Johnson Genuine Parts.

3

Fuel Filter Evinrude E-TEC 60° V outboards are equipped with an in-line fuel filter. Refer to FUEL COMPONENT SERVICING on p. 189.

• Confirm that battery meets the minimum engine requirements.

• Connections must be clean and tight. • Observe all wiring connections prior to disassembly.

1

Disconnect battery negative (–) cable first and the battery positive (+) cable last. Clean all terminals, battery posts, and connectors with a solution of baking soda and water. Use a wire brush or battery terminal tool to remove corrosion buildup. Rinse and clean all surfaces. Reinstall battery and tighten all connections securely. Refer to Battery Installation on p. 36.

1. In-line fuel filter

005234

Accessory kit, P/N 5007045, is available to add a water-separating cannister fuel filter to Evinrude E-TEC 60° V outboards.

IMPORTANT: DO NOT secure battery cables with wing nuts. Coat all connections with Triple-Guard grease and insulate to prevent shorts or spark arcing.

WARNING Keep battery connections clean, tight, and insulated to prevent their shorting or arcing and causing an explosion. If the battery mounting system does not cover the connections, install covers.

1

1. Water-separating fuel filter

005237

87

MAINTENANCE FUEL AND OIL SYSTEMS

Oil Filters and Oil Reservoir

Air Silencer

Evinrude E-TEC 60° V outboards are equipped with two serviceable oil filters: one is located in the oil injection tank, and one is located in the oil supply line before the oil lift pump.

The air silencer on Evinrude outboards minimizes audible noise related to air flow into the engine.

Sample oil from bottom of oil injection tank. Confirm that oil is free of water or other contaminants.

1

005238

2

Routine cleaning of the air silencer is recommended to remove any accumulation of debris. 1. Filter, oil supply line 2. Filter, oil injection tank

005233 42785

Hoses and Connections Check condition of all hoses and connections related to both the fuel and oil systems. • Visually inspect all components. • Observe all clamps, hoses, and connections while outboard is running. • Replace all damaged components. • Repair all leaks.

WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

88

MAINTENANCE SPARK PLUGS

SPARK PLUGS Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs.

Apply Triple-Guard grease to the gasket surface of the spark plugs. Install all spark plugs and tighten them to a torque of 15 ft. lbs. (20 N·m). If the mark is in unshaded area do not tighten anymore.

Use only recommended spark plugs with the correct gap setting. Spark Plug, Champion QC10PEPB @ 0.028 ± 0.003 in. (0.71 mm)

1

2

• Remove spark plugs and inspect condition. • Set spark plug gap on new, replacement spark plugs.

• Mark spark plugs for ground electrode orientation.

• Apply Electrical Grease to the ribbed portion of the spark plug ceramic and to the opening of the spark plug cover to prevent corrosion. • Install spark plugs using “indexing” procedure.

Indexing Spark plug indexing positions the ground electrode of the spark plug opposite the fuel injector nozzle. Put an ink mark on the ceramic of the spark plug that is in line with the OPEN side of the ground electrode. This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector.

2 1. Ink mark 2. Open side

Spark Plug Indexing Diagram 1. Unshaded area 2. Shaded area

004294

If the mark is in the shaded area, reset torque wrench to 30 ft. lbs. (41 N·m) and continue to turn until the mark is in the unshaded area. If the mark does not reach the unshaded area before the torque of 30 ft. lbs. (41 N·m) is reached, the spark plug cannot be indexed for that cylinder. Try another spark plug and repeat the steps above.

1 000758

89

3

MAINTENANCE EXHAUST PRESSURE FITTING

EXHAUST PRESSURE FITTING The exhaust pressure fitting is threaded into the cylinder/crankcase assembly and protrudes into the inner exhaust.

1

1. Exhaust pressure fitting

With key ON, outboard NOT running, the exhaust pressure sensor reading should be close to zero. With the outboard running, make sure the exhaust pressure reading changes with throttle setting. This reading will vary, based on actual outboard exhaust pressure conditions. If the exhaust pressure readings are not as described, clean or replace exhaust pressure fittings.

1

005236

A hose is routed from this fitting to the EMM. Due to carbon accumulation in the exhaust, this fitting must be periodically de-carbonized or replaced.

Operation Test Use the engine Monitor screen of the Evinrude Diagnostics Software program to confirm: • barometric pressure reading; and • changes in exhaust pressure reading. With key ON, outboard NOT running, make sure the barometric pressure reading reflects actual atmospheric conditions. If barometric pressure reading is inaccurate, remove exhaust/barometric pressure hose from EMM. Retest and observe engine Monitor screen. If barometric pressure reading is accurate with hose removed, replace hose and diaphragm assembly. and inspect exhaust fitting for restriction.

2 Engine Monitor Screen 1. Barometric pressure reading 2. Exhaust pressure reading

005141

Cleaning Cleaning with Engine Tuner maintenance product can dissolve carbon build-up. Spray Engine Tuner through the fitting and allow it to soak for four to six hours.

WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa). Use compressed air to blow through the fitting. Limit the air pressure to 25 psi (170 kPa). Confirm movement of air through fitting.

IMPORTANT: Fitting does restrict air movement. Replace exhaust pressure fittings that are blocked and cannot be decarbonized.

90

MAINTENANCE STORAGE

STORAGE IMPORTANT: DO NOT start outboard without a water supply to the outboard’s cooling system. Cooling system and/or powerhead damage could occur.

Software Control Method Winterization can also be run using the Evinrude Diagnostics software program. With the outboard running, start the process at the Settings/Adjustments screen and follow the instructions.

Fuel System Treatment

3

Stabilize the boat’s fuel supply with Evinrude/ Johnson 2+4 Fuel Conditioner following the instructions on the container.

Internal Engine Treatment

1

Remove the propeller, attach garden hose to flushing port and turn on water. Evinrude E-TEC models are designed to be selfwinterizing using either of the following methods:

1. Winterization start button

005140

IMPORTANT: Engine MUST be in NEUTRAL throughout these procedures.

Remote Control Method • Advance throttle to full warm-up position and start the outboard. SystemCheck lights will illuminate and the outboard will run at idle speed. • After approximately 15 seconds, the SystemCheck lights will go off. Move throttle to IDLE position. SystemCheck lights will illuminate again. • Wait another 15 seconds. SystemCheck lights will go off. At this point, advance throttle to FULL (in neutral)—SystemCheck lights will flash. • Outboard will automatically go to fast idle and fog itself. Allow outboard to run until it shuts itself off (about one minute).

005149

After the outboard shuts itself off, turn key switch OFF, then detach garden hose.

IMPORTANT: When finished, leave the outboard in vertical position long enough to completely drain the powerhead.

IMPORTANT: If SystemCheck lights do not flash, or outboard runs above fast idle, immediately turn off outboard and start the procedure again.

91

MAINTENANCE PRE-SEASON SERVICE

Additional Recommendations • Top off oil reservoir. • inspect the fuel filter. If there is debris in the fuel • • • • • •

• •

• •

filter, it must be replaced. Replace gearcase lubricant. Remove and inspect propeller. Clean and grease propeller shaft. Blow water from gearcase speedometer pickup system (gearcase speedometer models only). Lubricate all grease fittings and linkages. Inspect outboard, steering system, and controls. Replace all damaged and worn components. Refer to manufacturer’s and lubrication recommendations. Touch up painted surfaces as needed. Coat outer painted surfaces with automotive wax. Remove battery(s) from boat. Store in a cool, dry location. Periodically charge battery(s) while stored. Refer to manufacturer’s maintenance recommendations when servicing batteries. Store outboard in upright (vertical) position. Check for fuel leakage.

WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

PRE-SEASON SERVICE If the outboard was removed from the boat for storage, make sure that it has been reinstalled with factory specified hardware. Refer to the INSTALLATION AND PREDELIVERY section for proper set-up procedures.

Outboard Mounting Bolts • Check and re-torque outboard mounting bolts to 40 ft. lbs. (54 N·m).

Gearcase Lubricant • Check the lubricant level. • Inspect gearcase for leaks. If leak is apparent, pressure and vacuum test gearcase.

• Repair gearcase as needed.

Battery(s) • Replace batteries that cannot be charged.

Power Trim and Tilt • Remove filler cap and check fluid level. • Inspect the power trim and tilt unit for leaks. Repair as needed.

Operational Checks • • • •

Steering system Remote controls SystemCheck gauge All other accessories and instrumentation

Check Oil Injection Tank • Inspect the oil tank for leaks. Check Fuel System • Inspect entire fuel system for leaks prior to starting outboard.

• Repair all leaks. Water Pump • Confirm that a steady stream of water flows from overboard indicator.

WARNING Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

92

MAINTENANCE SUBMERGED ENGINES

SUBMERGED ENGINES Once an outboard has been submerged in fresh or salt water, it must be serviced within three (3) hours of recovery. Immediate service can minimize the corrosive affect that air has on the polished surfaces of the crankshaft, connecting rods, and internal powerhead bearings.

IMPORTANT: If outboard cannot be started or serviced immediately, it should be resubmerged in fresh water to avoid exposure to the atmosphere.

Engine Dropped Overboard (Not Running) Disconnect the battery cables at the battery. Rinse powerhead with clean water. Remove spark plug leads and spark plugs. Place outboard in horizontal position (cylinder heads down). Slowly rotate flywheel in a clockwise rotation to work all water out of powerhead.

IMPORTANT: If sand or silt may have entered the outboard, DO NOT attempt to start the it. Disassemble and clean. Disassemble all electrical connectors. Clean connectors and terminals, and treat with water displacing electrical spray. Apply Electrical Grease to terminals prior to reassembly. Coat all exposed solenoid terminals and engine grounds with Black Neoprene Dip. Clean and inspect all electrical components. Replace damaged or corroded components prior to returning the outboard to service. Electric starters should be disassembled, cleaned, flushed with clean water, and treated with water displacing electrical spray prior to reassembly. Disconnect fuel supply hose from outboard. Drain and clean all fuel hoses, filters, and fuel tanks. Disconnect oil supply hose and oil return hose from outboard. Drain and clean all oil hoses, filters, and oil tank assemblies. Refill fuel tank with fresh fuel and oil tank with recommended oil.

Prime oil system and fuel system. Refer to FUEL AND OIL PRIMING on p. 65. Make sure all oil injection hoses are clean and filled with oil. Make sure high pressure fuel system does not contain water. Flush as needed. Inject a small amount of outboard lubricant into spark plug holes and install new spark plugs. Refer to Spark Plug Indexing on p. 160. Reinstall all removed or disconnected parts. Use the Evinrude Diagnostics Software program to: • Initiate Break-in • Check fuel pump operation • Check injector operation (fuel and oil) • Check timing (once outboard is running at full operating temperature) Run outboard below 1500 RPM for one-half hour.

Engine Dropped Overboard (Running) Follow the same procedures as Engine Dropped Overboard (Not Running). However, if there is any binding when the flywheel is rotated, it may indicate a bent connecting rod and no attempt should be made to start the outboard. Powerhead must be disassembled and serviced immediately.

Engine Dropped Overboard (In Salt Water) Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running). Disassemble and clean outboards that have been submerged in salt water for prolonged periods of time. Clean or replace electrical components as necessary.

Prolonged Submersion (Fresh or Salt Water) Outboards that have been dropped overboard and not recovered immediately, must be serviced within three hours of recovery. Follow the same procedures used for Engine Dropped Overboard (Not Running) and Engine Dropped Overboard (Running).

93

3

MAINTENANCE NOTES

NOTES Technician’s Notes

Related Documents Bulletins

Instruction Sheets

Other

94

ENGINE MANAGEMENT MODULE (EMM)

ENGINE MANAGEMENT MODULE (EMM) TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 EMM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 SENSORS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 INTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 EXTERNAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 INTERNAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 EMM INPUTS AND OUTPUTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 S.A.F.E. WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 INITIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 SHUTDOWN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 EMM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 DIAGNOSTIC SOFTWARE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 PROGRAM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SERVICE CODES (FAULTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 OIL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 TIMING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 FUEL INJECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 SOFTWARE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 EMM TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 SYSTEMCHECK ENGINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SYSTEM SELF-TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 ENGINE RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

95

4

ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION

DESCRIPTION

EMM Connections

The Engine Management Module (EMM) is a water-cooled engine controller. It controls numerous outboard systems including alternator output for the 12 V and 55 V circuits. The stator provides the EMM with voltage inputs that are essential to alternator output.

IMPORTANT: EMM connections and wiring

This section discusses the functions of the EMM and the various internal and external sensors. The process for retrieving service codes stored in the EMM during engine operation is also presented. The EMM Service Code Chart located at the back of this manual can be used to reference service code information.

must be clean and tight. Improper electrical connections can damage the EMM. DO NOT attempt to run the outboard with loose or disconnected wiring. Make sure EMM connections are clean and tight. • Engine wire harness to EMM connectors; J1-A, J1-B, J2 • Stator to EMM connections; one 6-pin AMP and J2 connector.

2

EMM Functions The EMM controls the following processes and functions: • Fuel and ignition timing and duration • Ignition system primary voltage output • Fuel injector activation • Oil injector pump activation • Electric fuel pump control • Alternator output; 55 V and 12 V • Idle speed control • RPM limiter • Electrical circuit monitoring • Service codes and warning system activation • ROM verification, self-test • Choke-less cold starting • Output of “real-time” diagnostic data • Tachometer signal • RPM profile and engine hours • Oiling ratios • Exhaust valve activation (V4 models)

96

3 1

1. J2 connector 2. J1-A connector 3. J1-B connector

005235

ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS

SENSORS AND FUNCTIONS Sensor inputs and internal EMM controllers are used to control outboard operation. Use the Evinrude Diagnostics Software program to troubleshoot the sensors. Refer to Evinrude EMM Service Code Chart at back of manual for complete list of al engine fault codes.

Internal Sensors Internal sensors are NOT serviceable. Reprogramming or replacement may be required to resolve EMM related issues.

EMM Temperature Sensor Monitors the temperature of the fuel injector driver circuits. If the EMM temperature exceeds 176°F (80°C) or the circuit fails, the EMM: Activates S.A.F.E. Stores a service code 25 Initiates EMM NO OIL/OVERHEAT LED Initiates the SystemCheck TEMP/HOT light If EMM temperature exceeds 212°F (100°C) or the circuit fails, the EMM: Activates SHUTDOWN Stores a service code 29 Flashes EMM NO OIL/OVERHEAT LED Flashes SystemCheck TEMP/HOT light

IMPORTANT: The outboard will not restart until the engine cools below 212°F (100°C )and the EMM temperature returns to normal. Refer to SHUTDOWN MODE on p. 103. If EMM temperature is less than -22°F (-30°C) or the circuit fails, the EMM:

Sensor indicates less than -71°F (-57.4°C) or greater than 314°F (156.9°C) a sensor circuit fault is detected and the EMM: Stores a service code 23 Initiates EMM NO OIL/OVERHEAT LED

55 V Circuit Sensor Monitors the EMM’s 55 V alternator circuit. If system voltage exceeds 57 volts, the EMM: Activates S.A.F.E. Stores a service code 18 Initiates EMM CHARGING FAULT LED Initiates the SystemCheck CHECK ENGINE light

4

If system voltage is below 45 volts with outboard running 500 to 1000 RPM or is below 52 volts with outboard running above 1000 RPM, the EMM: Activates S.A.F.E. Stores a service code 17 Initiates EMM CHARGING FAULT LED Initiates the SystemCheck CHECK ENGINE light

12 V Circuit Sensor Monitors the EMM’s 12 V alternator circuit. If battery voltage exceeds 15.5 volts, the EMM: Stores a service code 27 Initiates EMM CHARGING FAULT LED If battery voltage is below 12 volts with outboard running 500 to 2000 RPM OR is below 12.5 volts with outboard running above 2000 RPM, the EMM: Stores a service code 26 Initiates EMM CHARGING FAULT LED

Stores a service code 24 Initiates EMM NO OIL/OVERHEAT LED

97

ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Barometric Pressure Sensor

External Sensors

Supplies the EMM with barometric pressure reading to compensate for changes in altitude and air density.

The EMM provides a 5 V DC signal for sensor circuits. It monitors all sensor voltage inputs and compares them to predetermined acceptable ranges. Inputs that fall outside of the acceptable range initiate service codes.

If the BP sensor is out of the expected range (below 13.3 KPa or above 119.0 KPa), or the sensor or circuit fails, the EMM: Stores a service code 44 Initiates EMM SENSOR FAULT (LED 3) If the BP sensor is below expected range (below 70 KPa), the EMM: Stores a service code 45 Initiates EMM SENSOR FAULT (LED 3) If the BP sensor is above expected range (above 105 KPa), the EMM: Stores a service code 46 Initiates EMM SENSOR FAULT (LED 3)

Exhaust Pressure Sensor Monitors exhaust pressure during all running conditions to compensate for engine loads. If the exhaust pressure sensor is not in the expected range (< 0.12 V or > 4.88 V ), or the sensor or circuit fails, the EMM: Stores a service code 87 Initiates EMM SENSOR FAULT (LED 3) If the exhaust pressure is below expected range (below 40 in. water), the EMM: Stores a service code 88 Initiates EMM SENSOR FAULT (LED 3) If the exhaust pressure is above expected range (above 80 in. water), the EMM: Stores a service code 89 Initiates EMM SENSOR FAULT (LED 3)

98

Air Temperature Sensor Monitors the air temperature at the throttle body. The air temperature sensor is a negative temperature coefficient (NTC) thermistor. As temperature increases, the resistance of the sensor decreases resulting in a lower voltage reading at the EMM. Temperature decreases result in a resistance increase and a higher voltage reading at the EMM. If the AT sensor voltage is out of the expected range, or the sensor or circuit fails, the EMM: Stores a service code 47 Initiates EMM SENSOR FAULT (LED 3)

Engine Temperature Sensor(s) Monitor the temperature for each cylinder head. The sensor is a negative temperature coefficient thermistor (NTC). It provides engine temperature information to the EMM. The EMM uses this information to control engine operation and to activate the overheat warning system. If PORT cylinder head temperature exceeds 194°F (90°C), the EMM: Activates S.A.F.E. Stores a service code 43 (engine temperature above expected range PORT cylinder head) Initiates EMM NO OIL / OVERHEAT (LED 4) Initiates SystemCheck TEMP/HOT light If STARBOARD cylinder head exceeds 194°F (90°C), the EMM:

temperature

Activates S.A.F.E. Stores a service code 69 (engine temperature above expected range STARBOARD cylinder head) Initiates EMM NO OIL / OVERHEAT (LED 4) Initiates SystemCheck TEMP/HOT light

ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS If EITHER cylinder head temperature exceeds 248°F (120°C), the EMM Activates SHUTDOWN Stores a service code 31 Flashes EMM NO OIL / OVERHEAT (LED 4) Flashes SystemCheck TEMP/HOT light The outboard will not restart, after a temperature related SHUTDOWN, until the engine temperature is BELOW 120°C (returns to normal. Refer to SHUTDOWN MODE on p. 103. If sensor values are below -15°F (-26.1°C) or above 331°F (166.5°C), the EMM: Stores a service code 41 Initiates EMM SENSOR FAULT (LED 3) If sensor values are below -4°F (-20°C), the EMM: Stores a service code 42 (engine temperature below expected range) Initiates EMM SENSOR FAULT (LED 3) If engine does not reach operating temperature on PORT cylinder head (122°F / 50°C below 2300 RPM) in 10 minutes, the EMM: Stores a service code 58 (engine not reaching operating temperature) Initiates EMM SENSOR FAULT (LED 3) If engine does not reach operating temperature on STARBOARD cylinder head (122°F / 50°C below 2300 RPM) in 10 minutes, the EMM: Stores a service code 59 (engine not reaching operating temperature) Initiates EMM SENSOR FAULT (LED 3)

Oil Pressure Sensor The oil pressure sensor monitors oil pressure in the oil distribution manifold. If the sensor fails to indicate pressure in the oil distribution manifold, the EMM: Activates S.A.F.E. Stores a service code 38 Initiates EMM NO OIL / OVERHEAT (LED 4) Initiates the SystemCheck NO OIL light If outboard has been run for more than 5 hours with the existance of NO OIL faults (codes 34 & 38), the EMM Activates SHUTDOWN Stores a service code 33 Flashes EMM NO OIL / OVERHEAT (LED 4) Flashes SystemCheck NO OIL light

IMPORTANT: The outboard will restart for one minute intervals until problem is resolved and code is cleared. To clear code use the diagnostic software propram. If the sensor circuit fails to indicate within a specific range or fails, the EMM: Stores a service code 71 Initiates EMM SENSOR FAULT (LED 3) If the sensor circuit indicates below expected range (<.5 V), the EMM: Stores a service code 72 Initiates EMM SENSOR FAULT (LED 3) If the sensor circuit indicates above expected range (> 4.5 V), the EMM: Stores a service code73 Initiates EMM SENSOR FAULT (LED 3)

99

4

ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Throttle Position Sensor The throttle position sensor is a rotary potentiometer connected to the throttle plate shaft. The sensor receives a voltage signal from the EMM. As the throttle lever is rotated, the EMM receives a return voltage signal through a second wire. This signal increases as the TPS lever is advanced. A third wire provides a ground circuit back to the EMM. Refer to TPS CALIBRATION on p. 159. If the TPS sensor or circuit fails (below 0.15 volts or above 4.95 volts), the EMM: Stores a service code 12 Limits engine RPM to IDLE Initiates EMM SENSOR FAULT (LED 3) Initiates the SystemCheck CHECK ENGINE light

IMPORTANT: Once a TPS circuit fault has been detected, the outboard will not accelerate above idle speed. To reset, stop the outboard and correct the fault. If the TPS sensor circuit indicates below 0.2 volts, the EMM: Stores a service code 13 Initiates EMM SENSOR FAULT (LED 3) Initiates the SystemCheck CHECK ENGINE light If the TPS sensor circuit indicates above 4.85 volts, the EMM: Stores a service code 14 Initiates EMM SENSOR FAULT (LED 3) Initiates the SystemCheck CHECK ENGINE light If the TPS sensor circuit indicates above 0.65 volts when the key is turned to the ON position, the EMM: Initiates a service code 11 If the outboard is started, the code is stored.

100

If code 11 is present as both a Hard Fault and a Stored Fault, refer to Control Cable Installation on p. 60.

Crankshaft Position Sensor The CPS is a magnetic device. It is mounted on the reed plate, adjacent to the flywheel. Encoder rib spacing on the flywheel coincides with crankshaft position. As the encoder ribs of the flywheel pass the magnetic field of the CPS, an AC voltage signal is generated. The EMM uses this signal to identify crankshaft position and speed, generate a tachometer signal, and control fuel and ignition timing. If the sensor is damaged or the signal is intermittent (10 instances), the EMM: Stores a service code 16 Initiates EMM SENSOR FAULT (LED 3) Approximate air gap between CPS and flywheel encoder ribs is .073 (1.85 mm). Use the engine Monitor screen of the Evinrude Diagnostics Software program to check CPS operation. The outboard should indicate an RPM reading while cranking. If the CPS or its circuit fails, no RPM reading will be generated and the outboard cannot run.

Neutral Switch (V4 Models) The powerhead mounted neutral switch provides a ground signal for the EMM to indicate shift linkage position when a tiller kit has been installed. This allows the EMM to provide start in gear protection. Fuel and ignition functions are turned off on tiller models if the neutral switch is not activated. If the switch is not functioning properly, the EMM: Stores a service code 19 (tiller models only) Initiates EMM SENSOR FAULT LED (Starting Mode only) The engine Monitor screen of the diagnostic program displays switch position, NEUTRAL or IN GEAR. Make sure switch is operating properly.

ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS

Internal Functions ROM Verification The EMM runs through a self-test of programming every time it is turned ON. Service code 15 indicates a programming (software) issue. Reprogram the EMM with the correct software program to resolve.

Idle Controller The idle controller reacts to engine operating conditions. Fuel and ignition timings are altered to maintain a specific RPM when engine is cold or warm. The controller is inactive when TPS is advanced from idle position.

RPM Limiter This feature of EMM programming prevents engine damage due to excessive RPM. At 6250 RPM, fuel and ignition to the cylinders is shut off. Normal engine operation resumes when engine RPM returns to the specified range.

Exhaust Valve (V4 Models) The EMM controls a valve that switches between two exhaust paths to provide optimum exhaust tuning under various running conditions. At slower speeds and under acceleration, the system opens a longer path, allowing the engine to develop more midrange horsepower as the boat comes on plane. At higher RPMs, the path is shortened for maximum high speed performance.

Shutdown, Code 57 This feature of EMM programming monitors engine operation for abnormally high RPM with a low TPS position. If this condition is detected, the EMM: Activates SHUTDOWN Stores a service code 57 Flashes EMM SENSOR FAULT (LED 3) Flashes SystemCheck CHECK ENGINE light

IMPORTANT: The outboard will not restart until the stored service code is cleared; and the EMM is turned OFF and then ON again. Refer to SHUTDOWN MODE on p. 103.

Fault Codes Refer to Evinrude EMM Service Code Chart at back of manual for complete list of all engine fault codes.

101

4

ENGINE MANAGEMENT MODULE (EMM) EMM INPUTS AND OUTPUTS DIAGRAM

EMM INPUTS AND OUTPUTS DIAGRAM

1. Engine Management Module (EMM) 2. Battery (12 volt) 3. Key switch (switched B+, start signal) 4. Stator 5. Crankshaft Position Sensor (CPS) 6. Throttle Position Sensor (TPS) 7. Neutral Switch 8. Air Temperature Sensor (AT) 9. Oil Pressure Sensor (component of 17)

102

10. Engine Temperature Sensor(s) 11. Water in Fuel Sensor / Fuel Filter 12. Trim / Tilt Sending Unit 13. Water Pressure Sensor w/adaptor harness 14. LED indicators 15. Fuel Pump (high pressure) 16. Starter Solenoid 17. Oil Injection Pump and Manifold 18. Ignition Coil

19. Fuel Injector 20. Tachometer/SystemCheck Gauge 21. Diagnostic Connector 22. CANbus adaptor harness (NMEA 2000®) 23. Trim and Tilt Relay Module 24. Oil Level Switch 25. Exhaust Valve Relay Module (V4)

ENGINE MANAGEMENT MODULE (EMM) S.A.F.E. WARNING SYSTEM

S.A.F.E. WARNING SYSTEM The EMM activates S.A.F.E. (Speed Adjusting Failsafe Electronics) and the dash-mounted SystemCheck gauge and horn to alert the operator of abnormal operating conditions and to prevent engine damage that could result from: • Loss of oil flow • Engine overheat • Excessive EMM temperature • Excessive or reduced alternator output • LOW Oil, sender/switch

Initiation When a sensor or switch provides the EMM with a specific fault signal, it responds by interrupting fuel injector and ignition operation. This results in a gradual reduction in engine RPM until the engine speed reaches 1200 RPM. The dashmounted warning horn sounds and the appropriate SystemCheck light turns on. As long as S.A.F.E. is activated, the engine will run normally below 1200 RPM. Above 1200 RPM, the engine will vibrate excessively.

SHUTDOWN MODE Outboard “shutdown” will occur if specific faults are detected by the EMM.

Conditions that initiate shutdown Code 29 Code 31 Code 33 Code 57

Excessive EMM temperature Excessive engine temperature Excessive NO OIL condition High RPM with low TPS setting

To recover from shutdown mode, the EMM must not detect the related fault at start-up. The outboard will not restart until the cause for the stored service code is resolved (code 29 and 31) and the code is cleared using diagnostic software (code 33 and 57); and the EMM is turned OFF and then ON again.

WARNING If the engine shuts OFF and the “CHECK ENGINE” or “CHK ENG” or EMM SENSOR FAULT LED light is flashing, the engine cannot be restarted. A hazardous fuel condition may exist which could potentially result in a fire or explosion.

Conditions that initiate S.A.F.E. Code 17 Alternator 55 V below expected range Code 18 Alternator 55 V above expected range Code 25 EMM temperature above expected range Code 34 Oil injector open circuit Code 38 No oil pressure feedback Code 43 PORT cylinder head temperature sensor above expected range Code 69 STARBOARD cylinder head temperature sensor above expected range

Recovery The engine will operate in S.A.F.E. as long as the fault condition exists. To recover from S.A.F.E., two conditions must be satisfied: sensor or switch parameters must be back within limits; and engine RPM must be reduced to idle. The system will immediately recover and engine operation will return to normal.

IMPORTANT: Shutdown related to code 57 or 33 requires the removal of the stored service code. Use the Evinrude Diagnostics software program to erase a code 57 or 33. Code 57 occurs when the EMM detects abnormally high RPM relative to the TPS position. This condition could be caused by uncontrolled fuel entering the combustion cycle. Before removing the code and STARTING the outboard, seek out and repair the cause. • Perform Fuel System Pressure Test on p. 185. Seek out possible external fuel leakage that could allow fuel and/or vapor to enter the combustion cycle through the air intake (air silencer). • Seek out possible internal fuel leakage from a leaking injector and/or vapor separator vent hose.

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ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS

EMM DIAGNOSTICS

code 33 (engine shutdown, excessive no oil condition).

LED Indicators

Running Mode

The EMM has LED indicators located next to the electrical connectors that provide information related to various electrical circuits.

IMPORTANT: LED 1 is toward the rear of the outboard (Closest to EMM J2 connector).

1

1. LED indicators

005239

Starting Mode “Starting mode” occurs from EMM power ON until outboard is running for 2 seconds. LED 1 – Stator signal 30 V or higher, “CHARGING OKAY.” For NO LIGHT, investigate S.A.C. circuit operation. LED 2 – Crankshaft position sensor output, EMM powered (ON), “CRANK POSITION OKAY.” For NO LIGHT, investigate possible fault code 16. LED 3 – Sensor circuits (5 V), “SENSORS OKAY.” For NO LIGHT, investigate possible fault codes: 12, 13, 24, 16, 41, 42, 44, 45, 46, 47, 48, 49, 67, 68, 69. For FLASHING LIGHT ON, investigate code 57 (High RPM with low TPS setting) LED 4 – Lanyard/Stop circuit not grounded, “LANYARD/STOP OKAY.” For NO LIGHT, repair grounded stop circuit. For FLASHING LIGHT ON, investigate possible fault code 29 (engine shutdown, EMM overheat), code 31 (engine shutdown, engine overheat) or

104

LED 1 – Low charging output, “CHARGING FAULT.” For LIGHT ON, investigate possible fault codes: • Code 17 – system voltage (55 V) below range • Code 18 – system voltage (55 V) above range • Code 26 – low battery (12 V) voltage • Code 27 – high battery (12 V) voltage • Code 77 – S.A.C. overcurrent fault LED 2 – Damaged injector circuit, ignition primary circuit, or fuel pump circuit, “INJECTOR/IGNITION FAULT.” For LIGHT ON, investigate possible fault codes: • Code 51 – cylinder no. 1 injector circuit open • Code 52 – cylinder no. 2 injector circuit open • Code 53 – cylinder no. 3 injector circuit open • Code 54 – cylinder no. 4 injector circuit open • Code 55 – cylinder no. 5 injector circuit open • Code 56 – cylinder no. 6 injector circuit open • Code 61 – cylinder no. 1 injector circuit short • Code 62 – cylinder no. 2 injector circuit short • Code 63 – cylinder no. 3 injector circuit short • Code 64 – cylinder no. 4 injector circuit short • Code 65 – cylinder no. 5 injector circuit short • Code 66 – cylinder no. 6 injector circuit short • Code 81 – no. 1 ignition primary circuit open • Code 82 – no. 2 ignition primary circuit open • Code 83 – no. 3 ignition primary circuit open • Code 84 – no. 4 ignition primary circuit open • Code 85 – no. 5 ignition primary circuit open • Code 86 – no. 6 ignition primary circuit open • Code 91 – fuel pump circuit open • Code 94 – fuel pump circuit short LED 3 – Sensor circuits (5 V), “SENSOR FAULT.” For LIGHT ON, investigate possible fault codes: • Code 12 – TPS circuit fault • Code 13 – TPS below expected range • Code 14 – TPS above expected range • Code 16 – CPS, intermittent loss of sync • Code 28 – shift switch malfunction • Code 41 – PORT temp. sensor circuit fault • Code 42 – PORT temp. below expected range • Code 44 – BP sensor circuit fault

ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS • • • • • • • • • • • • • • • • • • • • •

Code 45 – BP below expected range Code 46 – BP above expected range Code 47 – AT sensor circuit fault Code 48 – AT sensor below expected range Code 49 – AT sensor above expected range Code 57 – High RPM with low TPS setting Code 58 – PORT operating temp. not reached Code 59 – STBD operating temp. not reached Code 67 – STBD temp. sensor circuit fault Code 68 – STBD temp. below expected range Code 71 – oil pressure circuit fault detected Code 72 – oil pressure below expected range Code 73 – oil pressure above expected range Code 74 – water pressure circuit fault detected Code 75 – water pressure below range Code 76 – water pressure above range Code 78 – analog 5V circuit overload detected Code 79 – starter solenoid circuit open Code 87 – exhaust pressure circuit fault Code 88 – exhaust pressure below range Code 89 – exhaust pressure above range

LED 4 – Engine overheat, EMM temperature or sensor, oil injection pump or sensor, “NO OIL / OVERHEAT.” For LIGHT ON, investigate possible fault codes: • Code 23 – EMM temperature sensor circuit fault • Code 24 – EMM temp. below expected range • Code 25 – EMM temp. above expected range • Code 29 – EMM temp. OVER range (flashing) • Code 31 – engine temp. OVER range (flashing) • Code 34 – oil injection pump circuit open • Code 38 – oil pressure feedback not detected • Code 43 – PORT temp. above expected range • Code 69 – STBD temp. above expected range

Diagnostic Software Program

Personal ComEvinrude Diagnostics Softputer (PC) based ware, software P/N 763724 (Windows)

IMPORTANT: For software help, refer to “Help Info” in the Evinrude Diagnostics software.

Communication Locate the diagnostic connector on the engine. Remove the cover and install the Diagnostic Interface Cable (P/N 437955).

2 3 1

1. Cover 2. Diagnostic interface cable 3. Engine harness diagnostic connector

005240

Connect the 9-pin connector of the interface cable directly to the computer’s serial port. The EMM must turn ON before it will communicate with any outside device. Power is normally supplied to the EMM when the key switch is ON. Switched B+ (12 V) is supplied to the engine wire harness. Current enters the EMM at pin 21 (purple) of the EMM J1-B connector. Pin 9 (black) of the EMM J1-B connector provides ground to the EMM.

The EMM stores valuable information about the outboard and its running history. This information can be used for troubleshooting and for checking outboard parts information. Program information is accessed through Diagnostic Software running on a laptop computer connected to the outboard.

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ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS

Program Information

Dynamic Information

Static Information Refers to information viewed when the outboard is NOT running. This includes manufacturing information. The outboard model and serial numbers displayed on the Identity screen must match the identification label on the outboard swivel bracket.

Refers to specific information viewed while the outboard is running. Dynamic information updates quickly and allows the viewer to monitor voltage changes. The displayed information can be used for troubleshooting and checking outboard information.

Engine Monitor Screen

Identity Screen

005399

The serial number and cylinder location displayed on the Injector Coefficients screen must indicate the correct cylinder placement for all injectors.

005141

Service Codes (Faults) Service codes are fault conditions the EMM has identified. A service code may be stored as a result of some unidentified problem or condition. If no codes are displayed, the engine has no stored service codes.

Stored Faults A stored service code represents a previous event or condition. Service codes are stored if they occur while the outboard is running. The Stored Faults screen of the diagnostic program shows the code number, the number of

Injector Coefficients Screen

106

005142

ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS times the event occurred, operating hours of first and last occurrence.

Static Tests Static Tests perform diagnostic testing of specified components.

4 Stored Faults Review Screen

005143 Static Tests Screen

Hard Faults A hard fault is a code that currently exists. Hard faults become stored faults only if the outboard is running.

005146

Ignition Test Use the diagnostic software to test each ignition circuit. Refer to Static Spark Test on p. 128. Check each ignition circuit for continuity between the EMM and individual coil. Check the resistance of the ignition coil windings. Refer to IGNITION COIL TESTS on p. 141.

Fuel Test

Hard Faults Review Screen

005145

Use the diagnostic software to test each fuel injector. The injector should make an audible click. Make sure the injector being monitored is wired correctly. If the injector activates, the EMM and injector circuits are not at fault. If the fuel injector(s) will not fire during the diagnostic tests, check the continuity of the injector circuit. Refer to Fuel Injector Resistance Test on p. 185.

Persistent Faults The Persistent Faults screen provides a history of all previously stored codes, including code number, the number of times the event occurred, and operating hours of the last occurrence. Persistent faults cannot be erased.

107

ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Oil Injector

Dynamic Tests

Use the diagnostic software to test the oil injection pump. Make sure the pump is wired correctly. If the pump activates, the EMM and oil injection circuit are not at fault. If the oil injection pump does not run during the static test, check voltage and continuity of pump circuit. Refer to OILING SYSTEM TESTS on p. 218. The resistance of the oil injection pump winding is approximately 22 Ω.

Dynamic tests are performed with the outboard running.

Fuel Pump Use the diagnostic software to test the fuel pump. Make sure the pump is wired correctly. If the pump activates, the EMM and fuel pump circuit are not at fault. If the pump does not run during the static test, check voltage and continuity of pump circuit. Refer to Circulation Pump Resistance Test on p. 187. Dynamic Tests Screen

005137

Overheat This test is used to simulate an overheat situation and is used to check the “ENG TEMP” or “HOT” circuit of the SystemCheck gauge.

Fuel Test

This test is used to check the “CHECK ENGINE” circuit of the SystemCheck gauge.

The Fuel Test is performed with the outboard running (600 RPM minimum). This test momentarily disables one fuel injector circuit. By dropping one cylinder, RPM and running quality changes can be observed. Refer to the diagnostic software User’s Guide and Dynamic Tests on p. 120.

Tachometer

Ignition Test

This test is used to check operation of the tachometer circuit.

The Ignition Test is performed with the outboard running (600 RPM minimum). This test momentarily disables the ignition circuit and fuel injection circuit to one cylinder. By dropping one cylinder, RPM and running quality changes can be observed. Refer to the diagnostic software User’s Guide and Dynamic Tests on p. 120.

Check Engine

Prime Oil This test is used to cycle the oil injection pump for priming the oiling system. Perform this test with outboard running to activate oil injection pump.

108

ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS

Oil Control

IMPORTANT: Initiate Break-in programming for

Oil Injection Ratio (Used with XD100 oil only)

Timing Verification

rebuilt powerheads.

Evinrude E-TEC outboards can be programmed to run a reduced oiling rate. This feature should only be used with Evinrude/Johnson XD100 oil.

1

Use the Ignition Timing screen of the diagnostic software to check and adjust EMM timing. EMM timing must be synchronized to crankshaft position. Refer to TIMING ADJUSTMENTS on p. 157.

4

005140

1. Oil control setting

CAUTION Running an Evinrude E-TEC outboard on other grades of oil while set to the XD100 oil ratio will result in increased engine wear and shortened outboard life.

Powerhead Break-In Use the diagnostic software to initiate break-in oiling. Break-in is a predetermined oiling program that runs for two hours of outboard operation, above 2000 RPM.

005148

Perform timing verification after any of the following procedures: • Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement • CPS replacement • EMM replacement • EMM software replacement

IMPORTANT: Make sure the timing pointer is set and the outboard reaches operating temperature before timing verification is performed.

1

1. Break-in oil setting

005140

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ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS

TPS Calibration

Fuel Control Adjustment

Use the diagnostic software Settings screen to tell the EMM what the throttle position sensor voltage level is when the throttle plates begin to open.

The purpose of this feature is to help troubleshoot cylinder combustion. The Evinrude Diagnostics Software program allows temporary adjustments to the fuel flow characteristics of the injectors. This feature should not be used by itself to identify a faulty injector. Adjustment can be made before the outboard is started or while it is running. Factory fuel flow settings are restored when the key switch is returned to the OFF position.

Refer to TPS CALIBRATION on p. 159.

1

1. TPS Calibration button

006311

Perform TPS Calibration after replacing or adjusting any throttle body or throttle linkage parts.

Fuel Injector Servicing All fuel injectors are “compensated” and require software programming. DO NOT install an injector without updating the compensation software. To install a service injector, click the “Replace” button on the Injector Coefficients screen and select the file for the replacement injector. Refer to Fuel Injector Installation on p. 194.

005157

110

005150

ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS

Reports

Software Replacement

Engine reports provide service records and can be used to document the running history of an outboard. Reviewing this information can help identify or resolve some service issues.

Software programs or “maps” are downloaded into the EMM prior to factory testing of the outboard. Periodically, a new map may be available to enhance the operation of an outboard. Refer to the installation instructions provided with the program.

Clicking the print button in several windows of the diagnostic software allows the user to print engine data, or to export the information to a variety of computer file types.

IMPORTANT: Software replacement requires the use of “Bootstrap” Tool, P/N 586551.

4

1

2

002383

EMM Transfer 1. Print button 2. Print/Export options

005158

EMM Transfer is a feature that allows EMM replacement. Use the diagnostic software program and follow the “help info” instructions provided in the program.

IMPORTANT: Whenever the EMM is replaced, timing verification must be performed. Refer to Timing Verification on p. 159.

Engine Report Data Files

005159

006310

111

ENGINE MANAGEMENT MODULE (EMM) SYSTEMCHECK ENGINE MONITOR

SystemCheck ENGINE MONITOR The SystemCheck engine monitor warns the operator of conditions that could damage the engine. The monitoring system consists of a dashmounted gauge, a warning horn, sensors on the engine and oil tank, and related wiring. The system is compatible with the Evinrude Modular Wiring System (MWS), I-Command system, or other NMEA 2000 compliant CANbus instruments.

Gauges Gauges are available in several styles, from a basic gauge with four LEDs to a CANbus gauge with LCD readout.

The EMM activates the warning horn and the appropriate gauge display as follows: • NO OIL indicates an oil delivery problem such as an empty oil tank or damaged oil system components. • WATER TEMP or HOT indicates an engine or EMM overheat condition. • CHECK ENGINE is used to indicate numerous fault conditions identified by EMM. Refer to the EMM Service Code Chart located at the back of this manual for a detailed list of service codes related to SystemCheck activation. The oil tank sending unit activates the warning horn and the LOW OIL light of the gauge. • LOW OIL indicates the oil level in the oil tank is down to the reserve level (about 1/4 full).

System Self-Test During engine start-up, pause with the key switch in the ON position. The horn self-tests by sounding a half-second beep. MWS gauges self-test by turning the indicator lights on simultaneously, then off in sequence.

Service Mode

Typical MWS SystemCheck gauges

005329

SystemCheck goes into a service mode if the key is left ON after self-test (engine NOT running). All light circuits and sensors are active, but the horn is not. Grounding the appropriate light circuit wire will turn the light on, but the horn will not sound.

Engine Running All warning light circuits are active when the engine is running. The horn circuit is active when engine speed exceeds 500 RPM. The gauge will continue monitoring until the engine stops.

Typical I-Command gauge

112

005330

SystemCheck warnings activate the horn for 10 seconds and the appropriate gauge light for a minimum of 30 seconds. If the failure is momentary (e.g., oil moving in the tank), the light will remain ON for the full 30 seconds before going out. If the fault continues, the light remains ON until the key is turned OFF or the failure is corrected. The warning will reoccur at the next startup if the problem is not corrected.

SYSTEM ANALYSIS

SYSTEM ANALYSIS TABLE OF CONTENTS ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 EMM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 SOFTWARE PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 SPECIALIZED TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 TESTING WITH TIMING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 ENGINE MONITORING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 VOLTAGE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 START CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 ELECTRIC STARTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 STARTER SOLENOID ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 START CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 IGNITION AND ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 IGNITION OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 IGNITION VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 SYSTEM VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 STATIC SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 IGNITION PRIMARY CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 MANIFOLD PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 VAPOR SEPARATOR CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 FUEL DELIVERY TO LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 FUEL INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 STATIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 EXHAUST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

113

5

SYSTEM ANALYSIS ELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONS

EMM J1-A Connector

Inspect wiring and electrical connections. Disassemble and clean all corroded connections. Replace damaged wiring, connectors, or terminals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference charts to identify specific wiring details.

IMPORTANT: The key to effective troubleshooting is confirming the proper operation of each engine system. Causes of electrical failures may be difficult to isolate. Check the integrity of all connections, grounds, and wiring prior to replacing a suspect component. Inspect the condition and positioning of the following components: • Engine Management Module (EMM): wiring to EMM connectors and pins • Stator: connections to EMM, wiring to connectors, and connector pins • Engine wiring harness and connectors Refer to AMP Connectors on p. 169 for AMP connector servicing procedures.

Engine Harness to Stator Connector

004050

Pin No.

Description of Circuit

1

Stator winding (1S)

Yellow

2

Stator winding (3S)

Orange

3

Stator winding (2S)

Brown

4

Stator winding (1F)

Yellow /White

5

Stator winding (3F)

Orange/White

6

Stator winding (2F)

Brown/White

114

Wire Color

001875

Pin No.

Description of Circuit

Wire Color

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Oil Pressure switch Diagnostic connector Diagnostic connector Ground, water in fuel (digital) Oil level switch Crankshaft position sensor (CPS) Ground, CPS (digital) Bootstrap connector (programming) Stop circuit Throttle position sensor (TPS) 5 V Ground (analog) Engine temperature sensor, port CANbus, NET-L CANbus, NET-H Water pressure Tachometer CHECK ENGINE signal, SystemCheck TPS Engine temperature sensor, starboard Air temperature sensor CANbus, NET-S CANbus, NET-C Water in fuel NO OIL signal, SystemCheck WATER TEMP signal, SystemCheck Start signal none none Shift switch (shift linkage) Trim relay, UP Trim relay, DOWN Trim sender, IN Trim sender, OUT LOW OIL signal, SystemCheck

Tan/White Red White Black Tan/Black Yellow White Blk/Orange Blk/Yellow Red Black Pink/Black Blue White Pink Gray Tan/Orange Green Pink/Black Pink/Blue Red Black Pink/Green Tan/Yellow Tan Yellow/Red N/A N/A Black/Yellow Blue/White Green/White White/Tan White/Tan Tan/Black

SYSTEM ANALYSIS ELECTRICAL CONNECTIONS EMM J1-B Connector

EMM J2 Connector

001876

004046

Pin No.

Description of Circuit

Wire Color

Pin No.

Description of Circuit

Wire Color

1

Injector, cylinder 1

Blue

1

B+

Red

2

Injector, cylinder 2

Blue

2

none

N/A

3

Injector, cylinder 3

Green V4 Purple V6

3

Isolated B+

Red/Black

4

Battery ground

Black Black

4

+55 V, in, ignition power

White/Red

5

Battery ground

5

Fuel pump

Purple/black

6

none

N/A

6

Ignition, cylinder 4

Orange/Purple

7

Winding 1S

Yellow

7

Ignition, cylinder 3

Orange/Purple

8

Winding 2S

Brown

8

Injector, cylinder 6 (none V4)

Green V6

9

Injector, generator ground

Black

9

Injector ground

Black

10

Winding 3S

Orange

10

Injector ground

Black

11

B+

Red

11

Starter solenoid OUT

Brown/White

12

B+

Red

12

Exhaust valve control (none V6)

Blue/Black V4

13

Isolated B+

Red/Black

13

Ignition, cylinder 5 (none V4)

Orange/Green V6

14

Battery ground

Black

15

Battery ground

Black

16

Battery ground

Black

17

Winding 1F

Yellow/White

18

Winding 3F

Orange/White

19

+55V

White/Red

20

B+

Red

21

Isolated B+

Red/Black

22

Isolated B+

Red/Black

23

Battery ground

Black

24

Battery ground

Black

25

Battery ground

Black

26

none

N/A

27

Injector, generator ground

Black

28

Winding 2F

Brown/White

29

+55V

White/Red

14

Injector, cylinder 5 (none V4)

Green V6

15

Injector ground

Black

16

Injector ground

Black

17

Ignition ground

Black

18

Ignition ground

Black

19

Ignition, cylinder 2

Orange/Blue

20

Injector, cylinder 4

Green V4 Purple V6

21

Switched B+ (12V)

Purple

22

Injector ground

Black

23

Oil solenoid

Blue

24

Ignition ground

Black

25

Ignition, cylinder 6 (none V4)

Orange/Green V6

26

Ignition, cylinder 1

Orange/Blue

115

5

SYSTEM ANALYSIS GROUND CIRCUITS • Ignition (pins 17, 18 and 24 of the EMM J1-B

GROUND CIRCUITS All ground circuits are essential to optimum outboard performance. Make certain all ground connections are clean and tight. Refer to wiring diagrams to identify specific wiring details.

connector), injector and EMM battery grounds on port and starboard cylinder head ground screws.

Test Procedure Disconnect the battery cables at the battery.

1

Use an ohmmeter to check grounds at the appropriate pin locations of the EMM. Calibrate the ohmmeter on the “high” ohms scale. Connect the ohmmeter red lead to the ground wire and the black meter lead main harness ground. Resistance readings for all ground circuits should be 0 Ω. Main engine harness grounds to: • Injector circuits: check continuity to terminal pins 9 and 27 of the EMM J2 connector and to terminal pins 9, 10, 15, 16 and 22 of the EMM J1-B connector. • Ignition circuit: check continuity to terminal pin 17, 18, 24 of the EMM J1-B connector. • Power supply / battery: check continuity to terminal pins 4, 5, 14, 15, 16, 23, 24 and 25 of EMM J2 connector. • Trim and Tilt module: check connection at main ground terminal.

1. Grounds, starboard cylinder head

005316

FUSE The engine harness 12 V (B+) circuit is protected by one automotive style 10 amp minifuse. The fuse is positioned on the starboard side of powerhead, and fastened to the capacitor.

1 2

1 1. Fuse 2. Spare fuse

2

1. Main engine harness ground 2. Ground stud (battery)

116

005315

005317

SYSTEM ANALYSIS EMM DIAGNOSTICS

EMM DIAGNOSTICS

Running Mode

Access EMM information using the EMM’s LED indicators and the diagnostic program. EMM turned ON is verified through LED display or communication with diagnostic software. To access EMM information using the diagnostic software, connect interface cable to diagnostic plug and turn key switch ON. Battery cables and battery must be connected to supply power to EMM.

LED Indicators Activation of LED indicators on the EMM correspond to specific EMM circuits.

1

Light ON indicates system is MALFUNCTIONING. • LED 1 – Light ON, charging output malfunction 12 V or 55 V circuit; or SAC overcurrent “CHARGING FAULT” • LED 2 – Light ON, Injector or ignition circuit malfunction, “INJECTOR/IGNITION FAULT” • LED 3 – Light ON, Sensor/5 V circuits, “SENSOR FAULT” • LED 4 – Light ON, “NO OIL /OVERHEAT FAULT” Refer to EMM DIAGNOSTICS on p. 104 for additional diagnostic information.

Software Programs The Evinrude Diagnostics Software program can be used to communicate with the EMM. Communication also requires a 12 V supply to power up the EMM. Refer to EMM DIAGNOSTICS on p. 104 for additional diagnostic information. Identify and resolve all problems related to Stored Faults/Codes. Note all Stored Faults/Codes prior to clearing the codes.

1. LED indicators

005239

IMPORTANT: LED 1 is toward the rear of the outboard (Closest to EMM J2 connector). Starting Mode Light ON indicates system is functioning properly. • LED 1 – Light ON, Stator signal 30 V or higher, “CHARGING OKAY” • LED 2 – Light ON, CPS output, “CRANK POSITION OKAY” • LED 3 – Light ON, Sensor/5 V circuits, “SENSORS OKAY” • LED 4 – Light ON, Lanyard/Stop circuit not grounded, “LANYARD/STOP OKAY”

Stored Faults Review Screen

005143

Refer to EMM DIAGNOSTICS on p. 104 for additional diagnostic information.

117

5

SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES

DIAGNOSTIC PROCEDURES The key to effective troubleshooting is confirming the proper operation of each engine system. Causes of electrical failures may be difficult to isolate. Check the integrity of all connections, grounds, and wiring prior to replacing a suspect component. Refer to GROUND CIRCUITS on p. 116. Observe and run the outboard prior to performing any unnecessary procedures. Initial inspection should include the following: • Observe the outboard and confirm the actual symptoms. Refer to TROUBLE CHECK CHART at the end of this manual. • Inspect spark plugs for indication of wear, oil fowling, or damage. A rich or lean running condition or evidence of internal engine damage could be identified by the appearance of the spark plugs. • Make sure the outboard can be turned over easily. There should not be any mechanical binding. • Check the Evinrude Diagnostics Software program Profiles screen, History screen, and Persistent Faults screen for evidence of prior abnormal operation. Refer to Diagnostic Software Program on p. 105.

118

Profiles Screen

005153

History Screen

005152

Persistent Faults Screen

005400

SYSTEM ANALYSIS DIAGNOSTIC PROCEDURES

Symptoms Outboard will not crank, starter does not operate: • Check condition of battery and cables (main battery switch and cables). Make sure battery cables are not reversed. • Confirm that B+ is present at “A” terminal (purple wire) of starter solenoid with key switch in the ON position. • Proceed to START CIRCUIT on p. 122. Repair starter or start circuit as needed.

Outboard runs: • Use Evinrude Diagnostics Software program to perform Dynamic Tests. See Dynamic Tests on p. 133. • Use the engine Monitor screen of the Evinrude Diagnostics Software program to observe circuit voltages. Refer to Engine Monitoring Information on p. 121. • Use the diagnostic software Logging function to record engine data as a runability problem is occurring.

Outboard cranks, will not start: • Use LED indicators of EMM for initial diagnostic information.

5

• Perform a spark test using the Evinrude Diagnostics Software program. Refer to IGNITION OUTPUT on p. 127. Results: Steady spark on all cylinders and proper ignition voltage: • Check operation of all fuel injectors. Refer to FUEL COMPONENT TESTS on p. 184. • Check fuel quality and that fuel is present at injectors. • Refer to FUEL COMPONENT TESTS on p. 184 for fuel system pressure tests. No spark on one or more cylinders: • Note cylinder with no ignition output. Refer to IGNITION OUTPUT on p. 127. • Monitor cranking RPM using the diagnostic program (approximately 175 RPM, minimum 75 RPM). • Check CPS operation (verify RPM reading.) • Perform ignition circuit resistance test(s). Refer to Ignition Primary Circuit Resistance Test on p. 130 and IGNITION COIL TESTS on p. 141.

Logging Screen

005154

• Use an inductive timing light to monitor the injector circuits and ignition primary circuits. Refer to Testing with Timing Light on p. 120, IGNITION OUTPUT on p. 127, FUEL DELIVERY on p. 131 and FUEL COMPONENT TESTS on p. 184. • Use an inductive amp meter to monitor injector circuit current. Compare readings of all circuits to identify possible failure.

119

SYSTEM ANALYSIS SPECIALIZED TEST PROCEDURES

SPECIALIZED TEST PROCEDURES DANGER

Dynamic Tests can be used in conjunction with: • A timing light to determine how other cylinders are affected by one cylinder being “dropped”; or • A voltmeter to check voltage changes on electrical circuits.

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. Remove propeller before servicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death. The following tests are performed with the outboard running. Observe the operation of each electrical circuit. Look for inconsistencies between similar circuits and variations in cylinder performance.

Dynamic Tests Use the diagnostic program to perform Dynamic Fuel and Ignition tests. These tests can be used to momentarily stop injector or ignition function for a selected cylinder while the outboard is running. This is an effective tool for checking the performance of each cylinder. Comparing one cylinder’s performance to others can frequently isolate a cylinder that is not operating properly.

IMPORTANT: DO NOT misinterpret tests run at IDLE. The idle speed controller in the EMM compensates to maintain a constant engine speed at IDLE. The Dynamic Tests screen of the diagnostic software includes a function to temporarily disable the idle controller.

120

005147

Dynamic Tests Screen

IMPORTANT: Test the outboard while the runability issue is present. Use the test procedures to identify inconsistencies in voltages and cylinder performance. Once a circuit has been identified as malfunctioning, a thorough inspection of all related wiring and connections must be performed. Check all voltage inputs and grounds; and perform resistance tests for all circuits prior to replacing any suspect components.

Testing with Timing Light WARNING The electrical system presents a serious shock hazard. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning. An inductive timing light can be used to monitor ignition system output and the activation of fuel injectors and the oil injection pump. DO NOT clamp timing light pick-up on more than one wire at a time. Avoid erratic timing light reading by isolating pick-up from other wires. Self powered timing lights offer the convenience of no power cables and can help eliminate false signals.

SYSTEM ANALYSIS SPECIALIZED TEST PROCEDURES Ignition System Output

Inductive Amp Meter Test

Use the timing light to monitor each ignition circuit for a consistent flash. Run outboard and observe strobe of the light. Connect the timing light pick-up to the ignition coil secondary, high tension wire and then the primary wire. The strobe should indicate one flash per revolution. Intermittent output or multiple flashes per revolution indicate improper ignition control.

Use an inductive amp meter to monitor battery charging and current flow. Identifying erratic amperage in a circuit can be used to isolate a problem component.

Test ignition system grounds, primary circuit resistance, coil resistances and EMM ignition voltage prior to replacing any components.

2

Engine Monitoring Information Use the Evinrude Diagnostics Software program to access the engine Monitor screen. This screen display provides engine information as it is occurring. Circuits are monitored for actual voltages or the condition of the circuit. Switch and sensor circuits, battery voltage (12 V), system voltage (55 V), and ignition voltage (200 V) are continuously monitored.

1

1. Timing light pick-up 2. Ignition coil primary wire

005318

1 2

Engine Monitor Screen

005141

IMPORTANT: The engine Monitor screen of the diagnostics program does not offer voltage information for all circuits.

1. Timing light pick-up 2. Secondary, high tension wire

005319

Fuel Injector/Oil Injection Pump Activation Use the timing light to monitor each fuel injector or the oil injection pump lead. The strobe of the light indicates current in the circuit. Test all grounds, circuit resistance(s), and circuit voltages prior to replacing EMM for faulty injector or pump control function.

121

5

SYSTEM ANALYSIS START CIRCUIT

Voltage Testing Use the engine Monitor screen of the Evinrude Diagnostics Software program or a digital multimeter to check voltages. Identify all wiring and circuits prior to performing any voltage tests. Refer to Wiring Diagrams and descriptions of the various systems for specific information on each circuit. Identify erratic or lower than expected voltage readings. Determine if the voltage source or the wiring and connections of the circuit are the problem.

IMPORTANT: Use a digital multimeter to perform voltage checks on external circuits only when necessary. All EMM output currents are DC current.

Battery Circuits (12 V) Battery and auxiliary battery voltage is displayed on the engine Monitor screen of the diagnostic software. Each of these circuits are supplied approximately 25 A of battery charging current as needed and voltage is limited to approximately 14.5 V when outboard is running.

System Circuits (55 V) 55 V circuits are supplied 30 V when the key switch is ON, the EMM is powered up, and the outboard is not running and 55 V when outboard is running.

START CIRCUIT The start circuit provides the required current to the starter motor and associated electrical circuits.

Electric Starter Operation The starter must engage and turn the flywheel. A cranking speed of approximately 100 RPM must be achieved for the outboard to start. Normal cranking speed is approximately 175 RPM. Optimum starter performance is achieved by providing: • Proper battery capacity (675CCA). Refer TECHNICAL DATA on p. 18 for battery recommendations • Cables capable of transferring the amperage • Low resistance battery and cable connections • A solenoid capable of switching the current These “high amperage” start circuit components provide the battery current required to crank and start the outboard (electric start models). Check the quality and condition of the following:

12 V Marine Battery • Battery type, capacity, and condition • Condition of battery posts, terminals, and connections • Battery switch type, capacity, and connections

1

Stator output supplies the rectifier circuits of EMM with approximately 40 VAC when outboard is cranking and approximately 55 VAC when outboard is running.

Ignition System Circuits Ignition voltage displayed on the engine Monitor screen of the diagnostic software will have approximately 125 ± 10 V when the key switch is ON, the EMM is powered up, and the outboard is not running and 200 ± 10 V when outboard is running. Cranking voltage is approximately 200 V.

122

3

2 1. Main battery cable 2. Star washer 3. Battery post

DR6495

Refer to Battery Installation on p. 36 for battery, terminal, and cable requirements.

SYSTEM ANALYSIS START CIRCUIT Starter Solenoid • Starter solenoid and connections • Starter solenoid switched ground (NEG), terminal “B”

• Starter cable (solenoid to starter motor) • 12 V from solenoid terminal (POS) and engine harness (red wire) to 10 A fuse

Starter Motor and Drive Gear • Starter motor operation, refer to ELECTRIC STARTER SERVICING on p. 161.

• Starter bendix operation. 2

Engine Wire Harness Contains the following circuits: • Red/purple output wire from fuse and provides 12 V to instrument harness • Purple wire provides switched 12 V to solenoid (terminal “A”) and EMM • Yellow/red wire provides switched 12 V to EMM • Brown/white wire from terminal 11 of EMM J1-B connector provides switched ground (NEG) to starter solenoid (terminal “B”)

Instrument Wire Harness 3

Contains the following circuits: • Red/purple wire provides 12 V to key switch terminal “B” • Purple wire provides switched 12 V to engine wire harness • Yellow/red wire from terminal “S” of key switch provides switched 12 V to EMM (key switch in START position)

1 Key Switch 1. Starter solenoid 2. Starter cable 3. POS battery cable

005320

Starter Solenoid Activation Solenoid Wiring

Terminal “B” of key switch receives 12 V input from 10 A fuse.

IMPORTANT: Repeat failures of fuse could be the result of faulty connections or accessories. The 12 V accessory circuit (purple wire from terminal “A” of key switch) is often used to power gauges.

The positive (B+) battery cable connects to the large lower terminal of the starter solenoid. This terminal also provides the 12 V power supply to the engine harness (red wire) and the 10 A fuse. The red/purple wire from the fuse holder (10 A) provides 12 V to terminal “B” of key switch. The negative (B–) battery cable connects to the main ground stud located next to starter solenoid.

123

5

SYSTEM ANALYSIS START CIRCUIT Key Switch, ON position

Key Switch, START Position

12 V is applied to the “accessory” circuit. Key switch ON: • Switches 12 V to terminal “A” of key switch and to the purple wires of the wire harnesses. • Provides 12 V input to terminal 21 of J1-B EMM connector and terminal “A” of starter solenoid.

Switches 12 V to terminal “S” of key switch and 12 V is applied to neutral safety switch.

1 B M C

A

S

B M

M A

C

S

B M

C

M

A

2

B M

1

S

M A

M B

C

M

C

S

M S A

B

M

C

4

5

6

3

2

1

M S A

4

5

6

2 3

2

1. Ignition switch, START position – Continuity between terminals “B” and “A”; “B” and “S” 2. Terminal “S”, 12 V 3. Neutral safety switch

1

3 1. Key switch, ON position – Continuity between terminals “B” and “A” 2. Terminal “B”, 12 V (Red/purple) 3. Terminal “A”, 12 V (Purple)

3

000691

000691R

Neutral Safety Switch (Remote Control) Terminal “S” of the key switch provides 12 V (yellow/red) to the neutral safety switch (key switch in START position). A depressed or activated neutral safety switch (in remote control) provides 12 V to the engine wire harness yellow/red wire (key switch in START position) and terminal 26 of EMM J-1A connector.

124

SYSTEM ANALYSIS START CIRCUIT

Start Circuit Diagram

5

1. Marine battery 2. RED wire (POS) 3. BLACK wire (NEG) 4. Starter solenoid 5. Fuse (10 amp) 6. RED/PURPLE wire 7. 6-pin connectors 8. Ignition switch 9. PURPLE wire (switched B+)

10. 26-pin J1-B EMM connector 11. 34-pin J1-A EMM connector 12. Engine Management Module (EMM) 13. YELLOW/RED wire, start 14. BROWN/WHITE wire, start signal 15. Neutral Safety Switch (remote control) 16. RED starter motor cable 17. Electric starter motor

125

SYSTEM ANALYSIS IGNITION AND ELECTRICAL CIRCUITS

IGNITION AND ELECTRICAL CIRCUITS Following is a complete list of circuits required for ignition output:

Stop Circuit • Outboard running: black/yellow wire NOT grounded (emergency stop switch lanyard in place).

Battery • Battery switched B+ input to power up EMM • Battery B+ input to Start Assist Circuit (SAC) of EMM

Alternator Output/System Voltage • System voltage from EMM (white/red) provides 55 VDC to the oil injection pump, the fuel injectors, and the ignition module of EMM.

Capacitor • Connected to 55 V circuit (white/red) to stabilize current on 55 V circuit. • Negative terminal of grounded.

capacitor

must

be

Ignition Primary Voltage • Output from EMM. • EMM provides -200 VDC ± 10 V output to orange ignition primary wires during cranking.

Stator Output Voltage • Provides EMM J2 connector with A/C voltage: Outboard cranking, typical range is 20-40 VAC (AC output voltage is related to cranking RPM); outboard running approximately 55 VAC.

EMM • Start Assist Circuit (SAC) of EMM converts battery voltage (12 V) to 30 V for system circuit (55 V). • Stator output to EMM provides voltage to EMM’s internal power supply. • EMM digital ground, battery grounds, ignition grounds, and injector grounds must be functional.

Crankshaft Position Sensor • Provides EMM with input. • Outboard cranking speed exceeds 75 RPM and a steady CPS signal is generated.

Engine Monitor Screen, Ignition Voltage

IMPORTANT: Peak reading voltmeters must be set to “NEG” and “500” settings to measure ignition voltage.

Ignition Coil • EMM provides input to primary winding of coil. • Output from ignition coil secondary winding and high tension spark plug wire.

126

005141

SYSTEM ANALYSIS IGNITION OUTPUT

IGNITION OUTPUT

Ignition Voltage

DANGER The electrical system presents a serious shock hazard. Allow outboard to sit for two minutes after running before handling capacitor or 55 V electrical components. Failure to handle capacitor properly can result in uncontrolled electrical discharge and possible electrical shock to humans. DO NOT handle primary or secondary ignition components while outboard is running or flywheel is turning.

Use the Evinrude Diagnostics Software program to check ignition voltage to the primary ignition circuit(s). Check the EMM’s ignition voltage to the primary circuits of the ignition coils on the engine Monitor screen.

5

Wiring Inspection Visually inspect all wiring, connections, and grounds. Use an ohmmeter and perform resistance tests on all ground circuits and connections. Ohmmeter readings should be approximately 0.0 Ω. Check that all engine wire harness grounds have continuity to the cylinder/crankcase.

1

1. Main engine harness ground

005315

Make sure battery is fully charged. Clean or repair all ground circuits, wiring, and connections as needed. Refer to ELECTRICAL CONNECTIONS on p. 114.

Engine Monitor Screen, Ignition Voltage

005141

Results: • “KEY ON” - 125 V ± 10, Ignition voltage is GOOD, check voltage with outboard “running”. Refer to Static Spark Test on p. 128. • “KEY ON” - less than 125 V ± 10, check system voltage to EMM. Refer to System Voltage on p. 128. Note: Key ON voltage will not be constant (fluctuates 125 - 200 V range) • “RUNNING” - 200 V ± 10, Ignition voltage is GOOD. Refer to Static Spark Test on p. 128 • “RUNNING” - less than 200 V ± 10, check stator output to EMM. Refer to System Voltage on p. 128 and STATOR TESTS on p. 141 Low or no voltage on EMM ignition circuit: • Check system voltage (55 V) input to ignition circuit on pin 4 of EMM J1-B connector.

127

SYSTEM ANALYSIS IGNITION OUTPUT

System Voltage

Static Spark Test

The ignition module of the EMM is powered by the 55 V system.

Perform the static spark test using the Evinrude Diagnostics Software program and timing light.

Use the engine Monitor screen of the Evinrude Diagnostics Software program to check system voltage.

IMPORTANT: DO NOT use a spark checker tool with E-TEC models. Radio Frequency Interference (RFI) generated by the arcing current can cause erratic behavior in the EMM. The outboard must NOT be running and the emergency stop switch lanyard must be installed.

Engine Monitor Screen, System Voltage

005141

Results: • “KEY ON” - 30 V ± 2, system voltage is GOOD • “KEY ON” - less than 30 V ± 2, check 12 V power to EMM. Repair connection or wiring. Possible faulty SAC circuit in EMM. • “RUNNING” - 55 V ± 2, system voltage is GOOD • “RUNNING” - less than 55 V ± 2, check stator output to EMM. Repair connection or wiring. Possible faulty stator or EMM. Refer to STATOR TESTS on p. 141.

IMPORTANT: EMM must be ON for voltage to be present on the system voltage (55 V) circuit. This output supplies all 55 V circuits on the engine, including the ignition module of the EMM. Power is normally supplied to the EMM when the key switch is ON. Switched B+ (12 V) is supplied to the engine wire harness. Voltage enters the EMM at pin 21 (purple) of the EMM J1-B connector. Pin 9 (black) of the EMM J1-B connector provides ground to the EMM.

128

Testing, Static Test Screen

005146

Connect timing light pickup to primary and then secondary circuit of the ignition circuit being activated. Activate one circuit at a time and observe timing light strobe for consistent flash.

2 1

1. Timing light pick-up 2. Ignition coil primary wire

005318

SYSTEM ANALYSIS IGNITION OUTPUT Results: • Spark control on all cylinders and outboard runs, Refer to Running Ignition Tests on p. 129 and Dynamic Tests on p. 120. • NO spark control on one or more cylinders, note cylinders. Refer to Ignition Primary Circuit Resistance Test on p. 130 and IGNITION COIL TESTS on p. 141.

Running Ignition Tests The purpose of this test is to isolate ignition system malfunction. This test should be used in conjunction with other ignition system tests to identify component failures. This test provides limited information. Use the findings of this test to eliminate ignition system components. A thorough understanding of the outboard’s ignition system is required.

Monitor Ignition Output with Timing Light Use a timing light to monitor the spark signal through each of the high tension spark plug wires. Start outboard and observe the timing light’s strobe. Look for a consistent flash and only one flash per revolution. The strobe of the timing light should be consistent or the same for each cylinder’s ignition output.

IMPORTANT: Test on primary circuit if strobe from secondary circuit appears faulty.

1 2

Monitor Voltage Outputs Use the Evinrude Diagnostics Software program to monitor system voltage (55 V) and ignition voltage (200 V). • Voltage readings at a specific speed (RPM) should be steady.

1. Timing light pick-up 2. Secondary, high tension wire

005319

Results: Steady voltage and strobe: • Inspect or replace spark plugs, check fuel system performance, and / or eliminate the possibility of internal engine damage. Voltages are steady, engine misfires: • Check CPS air gap and resistance, check ignition voltage while problem is occurring. See Ignition Primary Circuit Resistance Test on p. 130 and IGNITION COIL TESTS on p. 141. Voltages fluctuate, engine misfires:

• Inspect condition of battery and connections, Engine Monitor Screen, System and Ignition Voltage

005141

Results: Low voltages: refer to System Voltage on p. 128 and Ignition Voltage on p. 127.

test capacitor, and check all ground connections. See System Voltage on p. 128, Ignition Voltage on p. 127, Ignition Primary Circuit Resistance Test on p. 130 and IGNITION COIL TESTS on p. 141.

IMPORTANT: If a running problem occurs at about 1200 RPM, the outboard may be in S.A.F.E. Refer to Conditions that initiate S.A.F.E. on p. 103.

129

5

SYSTEM ANALYSIS IGNITION OUTPUT

Ignition Primary Circuit Resistance Test

Crankshaft Position Sensor (CPS) Test

Disconnect the battery cables at the battery.

Use the Evinrude Diagnostics Software program to check RPM reading. An RPM display higher than zero indicates a CPS signal to the EMM. Cranking RPM is typically 175 RPM.

Calibrate ohmmeter to low ohms scale. With key switch OFF, remove the EMM J1-B connector and measure resistance of each primary circuit. Note resistance reading between each primary wire and ground. Refer to engine wiring diagram. Ignition Coil Primary Circuit Resistance 0.090 ± 0.005 Ω.

Observe Engine RPM and Power ON Time display fields of the engine Monitor screen. “ON Time” should be continuous and should not reset unless the key switch is turned OFF or power to the EMM is interrupted.

IMPORTANT: A reading of less than 2 ohms is acceptable. Make sure meter is calibrated to read 1 ohm or less.

2

3 1 1. Ohmmeter, low ohms scale 2. Red meter lead, with pin adapter 3. Black meter lead to ground

005440

Results: Primary circuit (complete circuit) resistance reading is higher than 2 Ω: • Repair primary circuit wiring or coil grounds as needed and retest. • Replace faulty coils or wiring. Primary circuit resistance reading less than 2 Ω or within specification and EMM ignition output voltage is 130 V or higher: • Refer to Secondary Winding Resistance Test on p. 141. Repair high tension spark plug lead or replace ignition coil and/or high tension spark plug lead assembly.

130

Engine Monitor Screen, Engine RPM display

005141

Check CPS resistance (560 Ω ± 10%). Make certain ohmmeter is calibrated properly. Refer to Crankshaft Position Sensor (CPS) Test on p. 139.

SYSTEM ANALYSIS FUEL DELIVERY

FUEL DELIVERY 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. 189. Use the Evinrude Diagnostics Software program to review service codes prior to troubleshooting. Correct all conditions related to service codes FIRST. Inspect all fuel hoses, filters, and connections. Check quality of fuel supply.

Manifold Pressure Test If the outboard runs, check pressure with the outboard running. Perform pressure tests outlined in FUEL COMPONENT TESTS on p. 184. If the outboard does not run, use the primer bulb to fill the vapor separator. Make sure circulation pump activates with key switch in ON position. The Fuel Pump test of the diagnostic program can be used to activate electric fuel pump.

Static Tests Screen

Results: Pressure test indicates 20 to 30 psi (138 to 207 kPa): • Circulation pump output is good. Make sure fuel system pressure does not fall below 15 psi (103 kPa) after outboard (pump) is OFF for five minutes. Leakdown indicates a fuel system leak or leaking injector. Low or no pressure, pump runs:

• Suspect damaged fuel pressure regulator in vapor separator or faulty circulation pump. Perform Pressure Regulator Test on p. 186. Pump does not run:

• Check voltage at pin 1 of fuel pump connector. Voltage should be 12 V at initial key ON, 12 V fuel pump test activated, or outboard cranking or running. • Check voltage at pin 2 of fuel pump connector. The EMM controls power to the fuel pump (purple/black wire). Outboard must be cranking or running. Use the fuel pump test of the diagnostic program to activate the control function of the EMM. Connect voltmeter positive lead to pin 2 and negative meter lead to ground. Activate Fuel Pump test or run outboard. Voltage reading should be 12 volts. Excessive pressure: • Check for restricted pressure regulator in vapor separator or restricted fuel return manifold.

005155

131

5

SYSTEM ANALYSIS FUEL INJECTOR OPERATION

Vapor Separator Checks Fuel Supply The vapor separator must provide “solid” fuel to the fuel circulation pump. Make sure the vapor separator receives the proper fuel supply from the fuel lift pump. Perform Lift Pump Pressure Test on p. 187. • Use primer to check fuel movement through fuel lift pump. • Outboard runs: Check pressure with outboard running. • Outboard does not run: Check pressure with outboard cranking.

Venting Monitor the vapor separator vent hose. No fuel or a trace of fuel is acceptable. Excessive fuel discharge indicates a vapor separator vent malfunction. Monitor vent for presence of fuel during testing. Temporarily install clear tubing for monitoring. Replace vapor separator if the venting of fuel is continuous.

Fuel Delivery to Lift Pump Perform the Lift Pump Vacuum Test on p. 187. Make sure no restrictions or air leaks exist in the fuel supply hose or boat fuel system.

FUEL INJECTOR OPERATION Static Tests Perform the Fuel Injector Static Test using the diagnostic program. Static tests are performed with the outboard “static” or not running. Listen for an audible “click” from each injector when it is actuated.

IMPORTANT: This test is operating injector on 12 V battery power / system voltage (55 V). Battery must be fully charged and connections must be clean and tight. The start assist circuit (SAC) of the EMM should convert battery voltage (12 V) to 30 V of system voltage. Injector activation should be carefully confirmed. Results: No injectors actuate: • Use the diagnostic software to monitor system voltage (55 V). Check individual injector circuits from EMM to injectors. See Stator Voltage Output Test on p. 142 if system voltage is low. Some injectors actuate; some do not:

• Make sure individual injector circuits and injectors are functional. See Fuel Injectors on p. 184. All injectors actuate:

• Confirm fuel system pressure and fuel supply to injectors.

132

SYSTEM ANALYSIS FUEL INJECTOR OPERATION

Dynamic Tests Use the engine Monitor screen of the diagnostic software program to monitor outboard system voltage. Perform these tests while monitoring voltage. If voltage drops as RPM increases, check stator and system voltage operation. Run or crank outboard. Monitor the injector control wire for each injector with an inductive timing light. Make certain the inductive pickup is attached to only one wire. Flashes on the timing light indicate current in the circuit is being switched by the EMM. The Dynamic Tests screen allows fuel injectors or ignition to be turned off to a particular cylinder.

IMPORTANT: Some timing lights may not flash consistently at cranking speeds. Always check the orientation of the timing light pickup and the operation of the timing light to avoid needless part(s) replacement.

Results: Steady light activation on all injector wires and consistent voltage readings: • EMM injector control function is good. Irregular or no light activation on some injector wires: • Test the resistance of each injector circuit. Measure resistance between the injector connector and injector control wire at the EMM connector. • Check battery cable connections. • Make sure all grounds are clean and tight. • Eliminate all other possibilities to isolate a faulty EMM. No light activation on any injector wires (outboard cranks and starter turns flywheel): • Confirm stator input to EMM, CPS operation, and all grounds and wiring connections. Possible open circuit(s), faulty CPS or EMM.

133

5

SYSTEM ANALYSIS EXHAUST VALVE (V4 MODELS)

EXHAUST VALVE (V4 MODELS) The inner exhaust housing on Evinrude E-TEC V4 models is designed with an adjustable “tuning” length. Two modes of exhaust gas flow are accomplished through the use of an exhaust valve. A control module and actuator motor are used to move the valve. The EMM controls the position of this valve which opens and closes a chamber in the inner exhaust. Switching the position of the exhaust valve provides optimum exhaust tuning for various running conditions. At slower speeds and under acceleration, this system opens a longer path, allowing the engine to develop more midrange horsepower as the boat comes on plane. At higher RPMs, the path is shortened for maximum high speed performance. Refer to Exhaust Valve Diagram below. HIGH SPEED

Exhaust Valve Diagram

SLOW SPEED

005434

Refer to EXHAUST VALVE RELAY TESTS on p. 152. Use the Evinrude Diagnostic Software program for “static” test of actuator motor.

134

ELECTRICAL AND IGNITION

ELECTRICAL AND IGNITION TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 DASH CONNECTIONS, INSTRUMENT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 SENSOR RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 STATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 CHARGING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 SYSTEMCHECK CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 REMOTE CONTROL SWITCH TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 NEUTRAL START CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 NEUTRAL START SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 EMERGENCY STOP SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 TACHOMETER CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 ELECTRIC STARTER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 NO LOAD CURRENT DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 TILT/TRIM RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 EXHAUST VALVE RELAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 EMM SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 FLYWHEEL AND STATOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 STATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 TIMING ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 TIMING POINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 TIMING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 TPS CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 ELECTRIC STARTER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 CONNECTOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

135

6

ELECTRICAL AND IGNITION SERVICE CHART

SERVICE CHART

12-16 In. lbs. (1.5-2 N·m)

60-84 In. lbs. (7-9.5 N·m)

24-26 Ft. lbs. (33-35 N·m) 12-16 In. lbs. (1.5-2 N·m)

48 In. lbs. (5.5 N·m)

E

A

B

F J

24-36 In. lbs. (2.7-4.1 N·m)

F

See Text 60-84 In. lbs. (7-9.5 N·m)

60-84 In. lbs. (7-9.5 N·m)

IMPORTANT See - Spark Plug Indexing Procedure 15-30 Ft. lbs. (20-41 N·m) 10-16 In. lbs. (1-2 N·m)

A

005198

136

60-84 In. lbs. (7-9.5 N·m)

A B C D E F T X

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Liquid Neoprene Index per Service Manual

ELECTRICAL AND IGNITION SERVICE CHART

N

60-84 in. lbs (6.8-9.5 N·m)

6

60-84 In. lbs. (7-10 N·m)

T 60-84 In. lbs. (7-10 N·m)

F 168-192 in. lbs (19.0-21.7 N·m)

A B C D E F N T

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Starter Bendix Lube Liquid Neoprene

004100

137

ELECTRICAL AND IGNITION DASH CONNECTIONS, INSTRUMENT HARNESS

DASH CONNECTIONS, INSTRUMENT HARNESS 3-pin connector – Connect to trim switch located in the handle of the remote control or to trim switch mounted on the boat dash.

6-pin connector – Connect to a pre-wired remote control or to a dash-mounted key switch.

Black, purple, white/tan wires – Connect to the trim gauge.

8-pin connector – Connect to a 2 in. SystemCheck gauge or to a 3 1/2 in. SystemCheck tachometer.

2-pin connector – Must connect to the warning horn in all installations.

Black, purple, gray wires – Connect to a conventional tachometer when a SystemCheck tachometer is not used.

Instrument Harness Diagram (MWS)

138

DRC6165R

ELECTRICAL AND IGNITION SENSOR RESISTANCE TESTS (1.85 mm). The acceptable clearance is 0.036 to 0.110 in. (1 to 2.8 mm).

SENSOR RESISTANCE TESTS All sensor circuits are dependent on wiring and connections, EMM supplied current (5 V), and sensor resistance. The supplied current flows through the wiring circuit and sensor before returning to the appropriate circuit in the EMM.

1

IMPORTANT: Use the Evinrude Diagnostics Software program to monitor sensor circuit voltages or values.

Crankshaft Position Sensor (CPS) Test Disconnect the battery cables at the battery. Use an ohmmeter to measure sensor resistance between the yellow and white wires.

1. CPS gap

005321

Throttle Position Sensor (TPS) Test TPS voltage can be monitored using the diagnostic program. Use the engine Monitor screen to observe voltage while outboard is running. Voltage should change evenly as sensor lever is moved. Use an ohmmeter to measure sensor resistance. Disconnect the battery cables at the battery. Remove the electrical connector from the TPS.

1 STEP 1 Connect red meter lead to terminal “A” and black meter lead to terminal “B.” 1. CPS Connector

Sensor Resistance (between “A” and “B”) > 3000 Ω @ 77°F (25°C)

005431

Sensor Resistance 560 Ω ± 10% @ 77°F (25°C)

Sensor Resistance (between “A” and “C”) > 4000 Ω @ 77°F (25°C)

The CPS is mounted to throttle body housing and requires no adjustment. Air gap or clearance to flywheel is fixed at approximately 0.073 in.

1

1. TPS

005430

139

6

ELECTRICAL AND IGNITION CAPACITOR TEST STEP 2 Connect red meter lead to terminal “A” and black meter lead to terminal “C.” Rotate the sensor lever through its range of travel. Resistance reading must change evenly as the sensor lever is moved. STEP 3 Connect red meter lead on terminal “B” and black meter lead to terminal “C.” Rotate the sensor lever. Resistance reading must change evenly as the sensor lever is moved.

Air Temperature Sensor (AT) Test Use an ohmmeter to measure resistance. AT Sensor Resistance 9000 to 11000 Ω @ 77°F (25°C)

1

Engine Temperature Sensor Test Use an ohmmeter to measure resistance. Engine Temperature Sensor Resistance 9000 to 11000 Ω @ 77°F (25°C) 1. AT sensor

1

1. Engine temperature sensor (2)

140

004196

004216

CAPACITOR TEST The capacitor should charge when you use an ohmmeter on the high ohms scale with the proper polarity. The resistance will increase until it goes to (nearly) infinity. If the capacitor is shorted, then it will never charge. If it is open, the resistance will be infinite immediately and won't change. If the polarity of the probes is reversed, it will not charge properly either. Determine the polarity of your meter and mark it. Black is usually negative with VOMs, for example. Confirm with a marked diode. A low reading across a good diode indicates that the positive lead is on the anode (triangle) and negative lead is on the cathode (bar).

ELECTRICAL AND IGNITION IGNITION COIL TESTS

IGNITION COIL TESTS

STATOR TESTS

Primary Winding Resistance Test

The stator consists of 3 windings (6 poles each) on a 7 inch diameter core and generates an output voltage of 55 VAC (1700 watts maximum). This voltage is converted by the EMM and used to provide 12 VDC for battery charging (10 A at 500 RPM and 50 A from 2000 RPM to WOT) and 55 VDC for fuel injector, fuel and oil pump operation. The ignition module of EMM is also powered by the 55 VDC output.

Connect ohmmeter between coil primary terminal and clean engine ground. Ignition Coil Primary Resistance 0.090 ± .005 Ω @ 77°F (25°C)

IMPORTANT: A reading of less than 2 ohms is acceptable. Make sure meter is calibrated to read 1 ohm or less.

Stator Resistance Tests Disconnect the battery cables at the battery. Use an ohmmeter to check resistance of stator windings. STEP 1 Disconnect EMM J2 connector from EMM.

1

000741

Secondary Winding Resistance Test Connect ohmmeter between coil secondary terminal and coil primary terminal.

1. EMM J2 Connector

005434

Calibrate ohmmeter to appropriate scale and connect meter leads to the following pins: • Yellow/white and yellow (pins 17 and 7) • Brown/white and brown (pins 28 and 8) • Orange/white and orange (pins 18 and 10)

Ignition Coil Secondary Resistance 301 ± 14 Ω @ 77°F (25°C)

IMPORTANT: A reading of less than 2 ohms is acceptable. Make sure meter is calibrated to read 1 ohm or less.

000742

Stator Winding Resistance Specification Yellow & Yellow / white .512 ± .020 Ω @ 73°F (23°C) Brown & Brown / white .512 ± .020 Ω @ 73°F (23°C) Orange & Orange / white .512 ± .020 Ω @ 73°F (23°C)

141

6

ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS STEP 2 To check for a grounded condition, connect one meter lead to ground wire and alternately connect the other meter lead to each stator wire. Meter should read no continuity. If meter reads continuity, replace stator due to grounded winding.

Stator Voltage Output Test Use a voltmeter to check the stator output voltage. Set meter to read 110 VAC output.

WARNING To prevent accidental starting of outboard, disconnect crankshaft position sensor (CPS). Disconnect CPS.

CHARGING SYSTEM TESTS 12 V Charging Circuit To test the operation of the regulator in the EMM, you must be able to run the outboard continuously at approximately 5000 RPM, such as in a test tank or on a marine dynamometer. The test consists of monitoring the system’s response to a partially discharged battery. Use a variable load tester to discharge the battery.

IMPORTANT: The regulator requires battery voltage on the red wire to operate. Before proceeding, make sure battery voltage is at the connector red wire when key is ON.

Disconnect stator (6-pin) connector from the engine harness (6-pin) connector.

Test Procedure

Connect Stator Test Adaptor tool, P/N 5006211, to stator connector.

Use an inductive amp meter or connect a 0 to 50 A ammeter in series between the red wire(s) of engine wire harness (alternator output from EMM) and the positive (B+) battery cable terminal of starter solenoid.

Connect meter leads to terminals of adaptor tool.

Disconnect the battery cables at the battery.

IMPORTANT: This outboard has dual output charging. Each output is isolated and regulated. Each output is 25 A. Combined output is approximately 50 A. Refer to engine wiring diagram.

1

Fluke † model 334 or 336, Snap-On † model MT110 or EETA501, and various other amp meters should be available through local tool suppliers. Reconnect the outboard’s battery cables. 1. Stator Test Adaptor

005436

With a fully charged battery, crank outboard (100 RPM minimum) and observe meter reading. Stator Voltage Output (Measured between terminals 1 and 6 of tool)

20 VAC at 100 RPM 30 VAC at 150 RPM 42 VAC at 200 RPM 52 VAC at 250 RPM 62 VAC at 300 RPM

142

ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Following the manufacturer’s directions, connect the variable load tester (carbon pile) across the battery terminals. Stevens model LB-85 and Snap-On model MT540D are examples of testers available.

WARNING Excessive battery discharge rates might overheat battery causing electrolyte gassing. This might create an explosive atmosphere. Always work in a well ventilated area.

Decrease the battery load toward 0 A.

• Ammeter should show a reduced output. As the current draw decreases, the battery voltage should stabilize at approximately 14.5 V. • If results vary, check stator BEFORE replacing the EMM. See STATOR TESTS on p. 141.

4 2 1

5 3

Variable Load Test Diagram 1. Red wire (alternator output from EMM) 2. Starter solenoid 3. Battery cable terminal (B+) 4. Variable load tester 5. Ammeter

Start the outboard and run it at approximately 5000 RPM. Use the variable load tester to draw the battery down at a rate equivalent to the stator’s full output. • The ammeter should indicate nearly full output, Approximately 50 A (or 25 A for each output) @ 5000 RPM.

55 V Alternator Circuit STEP 1 Check battery ground cable for continuity. STEP 2 With the key switch ON, check battery voltage at battery (12 V), then check voltage on white/red wires at J2 connector of EMM. Use Electrical Test Probe Kit, P/N 342677 and a multimeter set to read 55 VDC. Voltage at EMM connector should be approximately 30 V.

002077

1

1. J2 connector

Battery Charging Graph

005235

005193

143

6

ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS STEP 3 With outboard running at 1000 RPM, voltage on white/red wires should increase to 55 V. Voltage readings at a specific speed (RPM) should be steady. If there is any other reading, perform Stator Resistance Tests on p. 141 and Stator Voltage Output Test on p. 142. Inspect the stator wiring and connections. Inspect the capacitor wiring, connections, and capacitor. Repair the wiring or replace a faulty capacitor, stator, or EMM.

STEP 2 With the key switch OFF, check battery voltage at auxiliary battery, then check voltage at auxiliary battery connection. If the readings are not the same, replace wire to auxiliary battery. The auxiliary battery wire must be at least 10-gauge and it must be protected by a 50 A fuse or circuit breaker at the battery.

1

Auxiliary Battery – Charge Wire The auxiliary battery charge feature requires auxiliary battery charge kit, P/N 5006253 (or equivalent).

IMPORTANT: Disconnect all accessories from the auxiliary battery. Auxiliary battery must read a minimum of 8.5 V at the beginning of these tests and remain connected to the outboard during the tests. STEP 1 Check battery ground cable for continuity.

1. Accessory battery charge connector

004944

STEP 3 With outboard running at 1000 RPM, voltage must read higher than in STEP 2 and increase steadily to approximately 14.5 V as the outboard RPM increases. If there is no increase, turn the key switch to OFF and test red/black wire between the EMM and auxiliary battery connection. • Continuity indicates faulty output from EMM. Check 12 V alternator output before replacing EMM for faulty auxiliary battery, charge isolator circuit. • No continuity indicates faulty wiring.

144

ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS instrument harness terminal 1 (purple wire) and terminal 2 (black wire).

SystemCheck CIRCUIT TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “WATER TEMP” or “HOT,” “CHECK ENGINE,” or “LOW OIL” condition. Check the condition of the warning system and associated wiring and connections. Test the engine monitor regularly and anytime you suspect an alert situation has been missed. The instrument harness must be connected to the outboard before performing the following tests. Refer to the Engine Wiring diagram and the MWS Instrument Wiring diagram in the back of this manual.

IMPORTANT: Use jumper wires made with the appropriate terminals to test the warning circuits.

42811

Gauge Self-Test Check Turn the key switch to ON with the outboard NOT running. The gauge warning lights for NO OIL, WATER TEMP, CHECK ENGINE, and LOW OIL must all light at once, then turn off in sequence, and the warning horn must sound for one-half second.

2

1 1. Test adapter(s) 2. Connector, SystemCheck gauge

42761

• If battery voltage is present, replace the gauge. • If there is no battery voltage, check that 12 V is present at terminal “B” of the key switch. Check condition of the instrument harness, key switch, and connections. If the lights worked, but the warning horn did not sound for one-half second, turn the key switch OFF. Disconnect the warning horn 2-pin connector. Substitute a known good warning horn. Turn the key switch ON. • If the substitute horn beeps, the original horn is defective and must be replaced. • If the substitute horn does not beep, check for battery voltage between instrument harness 2pin connector, terminal 2 (purple wire) and ground with the key switch ON. Also, check the tan/blue wire for continuity between pin 8 of the 8-pin connector and pin 1 of the 2-pin connector. • If battery voltage is present at the purple wire and the tan/blue wire has continuity between

If the gauge lights do not turn on, turn the key switch OFF. Disconnect the gauge 8-pin connector from the back of the gauge and turn the key switch ON. Test for battery voltage between

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6

ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS the two connectors, replace SystemCheck gauge.

WATER TEMP/ HOT Circuit Test The tan wire of engine harness and the MWS harness receives a signal from the EMM. The EMM receives information from the temperature sensor on the cylinder head. Using a jumper wire, connect tan wire (pin 6) of the engine harness connector to a clean engine ground.

2

1

1. Purple wire 2. Tan/blue wire

DRC6280

Turn the key switch OFF and reconnect all disconnected circuits.

CHECK ENGINE Circuit Test Separate the 6-pin SystemCheck connector of MWS instrument harness from engine harness. Black wire (pin 3) must be grounded. Using a jumper wire, connect tan/orange wire (pin 2) to a clean engine ground. Turn the key switch ON. After the normal self-test sequence, the CHECK ENGINE light should stay on. • If the CHECK ENGINE light is not on, test circuit for continuity. Check continuity of the MWS instrument harness (tan/orange wire). • Check continuity of the engine wire harness between terminal 2 (tan/orange wire) of the SystemCheck connector and pin 17 of the EMM J1A connector. Turn the key switch OFF and reconnect all disconnected circuits.

146

002079

Turn the key switch ON. After the normal self-test sequence, the gauge WATER TEMP / HOT indicator should stay on. • If LED is not on, test circuit for continuity. Test for continuity of both the engine harness (tan wire) and the MWS instrument harness (tan wire). Turn the key switch OFF and reconnect all disconnected circuits.

IMPORTANT: To test the temperature sensor itself, refer to Engine Temperature Sensor Test on p. 140.

ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS

LOW OIL Circuit Test Turn the key switch ON. Using a jumper wire, connect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW OIL light should turn on after 40 seconds.

REMOTE CONTROL SWITCH TESTS Key Switch Test Refer to Wiring Diagrams at back of manual. Use an ohmmeter or a continuity light to test key switch operation. Replace switch if results are incorrect with any of the following tests.

IMPORTANT: Disconnect

battery and key switch wiring before proceeding with the following tests.

002079

If the LOW OIL light does not turn on after connecting the terminal to ground, test circuit for continuity. Turn the key switch OFF and reconnect all disconnected circuits.

NO OIL Circuit Separate the 6-pin SystemCheck connector of MWS instrument harness from engine harness. Black wire (pin 3) must be grounded.

STEP 1 Stop/Ground Terminals (M) – Connect meter between the two “M” terminals. Meter must indicate NO continuity at START or ON. Turn key switch OFF. Meter must indicate continuity. STEP 2 Accessory Terminal (A) – Make sure the key switch is OFF. Connect the ohmmeter or continuity light between terminals “B” (battery) and “A” (accessory) of key switch. Meter must indicate NO continuity. Turn switch ON. Meter must indicate continuity.

Using a jumper wire, connect tan/yellow wire (pin 5) to a clean engine ground.

Turn key switch to START. Meter must continue to indicate continuity.

Turn the key switch ON. After the normal self-test sequence, the NO OIL light should stay on. • If the NO OIL light is not on, test circuit for continuity. Test for continuity of the MWS instrument harness (tan/yellow wire). • Test for continuity of the engine wire harness between terminal 5 (tan/yellow wire) of the SystemCheck connector and pin 24 of the EMM J1A connector.

STEP 3 Starter Terminal (S) – Hold key switch at START. Connect meter between terminal “B” and terminal “S.” Meter should indicate continuity.

IMPORTANT: The choke function or terminal “C” of the key switch is NOT used. 1

2

3

Turn the key switch OFF and reconnect all disconnected circuits.

1. OFF 2. ON 3. START

000443

147

6

ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS

Neutral Start Circuit Test

Neutral Start Switch Test

Use an ohmmeter or continuity light to test the continuity of the circuit while positioning the remote control in NEUTRAL, FORWARD, and REVERSE.

Use an ohmmeter or a continuity light to test neutral start switch operation.

IMPORTANT: Turn propeller shaft or disconnect shift cable to allow proper remote control shift action while outboard is not running. Disconnect the MWS instrument harness connector from the key switch harness connector. Make sure the remote control handle is in NEUTRAL. Connect meter between terminal 5 (red/purple wire) and terminal 2 (yellow/red wire). Turn the key switch to START. Meter must indicate continuity. Move the remote control handle to FORWARD and turn the key switch to START. Meter must NOT indicate continuity. Move the remote control handle to REVERSE and turn the key switch to START. Meter must NOT indicate continuity.

IMPORTANT: All wiring must be disconnected from the switch before proceeding with this test. Disassemble the remote control and remove the neutral start switch. Connect one meter lead to each terminal of the switch. • Meter must indicate continuity when the plunger is depressed • Meter must indicate no continuity when the plunger is released.

1

2

TYPICAL 1. Plunger 2. Neutral start switch

Replace switch if results are incorrect.

1 1. Key switch harness connector 2. Neutral start switch 3. Key switch

3

2 000443

IMPORTANT: Reconnect shift cable and MWS instrument harness connector to key switch harness connector.

148

3224

ELECTRICAL AND IGNITION TACHOMETER CIRCUIT TESTS

Emergency Stop Switch Test This switch can be incorporated into the key switch or installed as a separate switch. Either style effectively connects the “M” terminals of the key switch.

TACHOMETER CIRCUIT TESTS Check voltage at the battery. Use this reading as a reference for battery voltage.

The emergency stop switch function grounds the stop circuit wire (black/yellow) when the lanyard clip is removed. One “M” terminal is the ground wire (black) and one “M” terminal is the stop circuit wire (black/yellow). 4

1

1

2

2

6 3 1. Purple lead 2. Black lead 3. Gray lead

3 1. 2. 3. 4.

Lanyard and clip assembly Emergency stop switch, separate from key switch Stop circuit wire (black/yellow) Ground wire (black)

004287

000444

Install the clip on the emergency stop switch or key switch. Start the outboard. Pull the clip from the switch. The outboard must stop running.

STEP 1 Connect the red meter lead to the tachometer purple wire and the black meter lead to the tachometer black wire (key ON, outboard NOT running). • If meter shows battery voltage, go to STEP 2. • If meter shows less than battery voltage, check the purple, red/purple, and black wiring circuits, fuse, key switch, and battery connections. STEP 2 Disconnect gray and black wires at tachometer. Set Fluke 29 Series II meter, or equivalent, to Hz scale. Connect meter between gray wire and black wire. With outboard running at 1000 RPM, meter should indicate 90 to 105 Hz. • If meter reads 90 to 105 Hz, replace tachometer. • If meter reads low or no signal, confirm output on gray wire at pin 16 of EMM J1-A connector. – Reading OK – Check condition of tachometer circuit (gray wire). Repair as needed. – Reading not OK – Check connection at EMM; replace faulty EMM.

149

ELECTRICAL AND IGNITION ELECTRIC STARTER TESTS

ELECTRIC STARTER TESTS Starter Solenoid Test Disconnect the B+ (POS) battery cable at the battery.

IMPORTANT: Disconnect all wiring from solenoid terminals before proceeding with this test. Use an ohmmeter to measure resistance. STEP 1 Put one ohmmeter lead on the starter positive (+) cable terminal and the other ohmmeter lead on the battery positive (+) cable terminal: • Ohmmeter must not show continuity (high reading). • If ohmmeter shows continuity (low reading), replace the solenoid.

1

STEP 2 Apply B+ to terminal “A” of solenoid and ground (NEG) to terminal “B” of solenoid. Measure resistance between the starter positive (+) cable terminal and the positive battery (+) cable terminal. • The solenoid must close with an audible click. • Ohmmeter must show continuity (low reading). • If ohmmeter shows no continuity (high reading), replace the solenoid. After re-installing the solenoid, coat all wires and terminals with Black Neoprene Dip.

2

3

1

4 1. Starter solenoid 2. Starter cable 3. POS battery cable

005320

No Load Current Draw Test Securely fasten starter in a vise or suitable fixture before proceeding with this check. Use a battery rated at 500 CCA (60 amp-hr) or higher that is in good condition and fully charged.

IMPORTANT: The driven gear and assembly must be removed for this test. 2 1. 2. 3. 4.

“A” terminal, B+ (purple) “B” terminal, NEG (brown/white) Starter positive (+) cable terminal Battery positive cable (B+) terminal

150

3 004121

pinion

ELECTRICAL AND IGNITION TILT/TRIM RELAY TEST Use an inductive ammeter or connect a 0 to 100 amp ammeter in series with a heavy jumper between the battery positive (+) terminal and the starter positive (+) terminal. Fluke model 334 or 336, Snap-On model MT110 or EETA501, and various other ammeters should be available through local tool suppliers.

TILT/TRIM RELAY TEST The tilt and trim (TNT) module contains the circuitry and relays required for power trim and tilt operation.

Attach or hold a vibration tachometer, such as a Frahm † Reed tachometer, to the starter.

1

1. Tilt and trim module

005372

The tilt and trim switch provides B+ input to green/white or blue/white wire of the TNT module. TYPICAL

24083

Complete the circuit with a heavy jumper between the battery negative (–) terminal and the starter frame. Monitor the starter RPM and current draw. • At 10,500 RPM the ammeter should show a maximum of 30 A.

Operation The relay activates when B+ input from the switch is supplied to terminal 86 of the internal relays. Terminal 87a connects to ground (B–). Terminal 87 connects to B+. Terminal 30 connects TNT motor. Terminals 87a and 30 are connected when relay is not activated. This supplies ground (B–) connection to TNT motor. Terminals 87 and 30 are considered “normally open.” B+ is applied to terminal 30 when relay is activated. This supplies ground B+ connection to TNT motor. Refer to Tilt and Trim Module Diagram.

151

6

ELECTRICAL AND IGNITION EXHAUST VALVE RELAY TESTS

Test Procedure Make sure red and black wires are connected to 12 V battery power supply. Set voltmeter to 12 VDC scale. Connect test leads to terminals “A” and “B” of TNT motor connector. Use a wire jumper to alternately connect B+ to terminals “1” and “2” of tilt and trim switch connector. The meter must indicate battery voltage (12 V) with B+ connected to either terminal.

3

EXHAUST VALVE RELAY TESTS The exhaust valve control module contains the circuitry and relays required to operate the exhaust valve actuator.

1

4

1

1. Exhaust valve relay module

005374

2

6 5 Tilt and Trim Module Diagram 1. Green/white wire 2. Blue/white wire 3. B+, red wire 4. B–, black wire 5. TNT motor connector 6. TNT switch connector

152

1 002063

1. Exhaust valve actuator

005247

ELECTRICAL AND IGNITION EMM SERVICING

EMM SERVICING Removal 3 1 2

Disconnect exhaust pressure hose and cooling hoses from EMM. Disconnect J1-A and J1-B connectors. Remove two EMM retaining screws. Lift EMM up and to the port side.

6 4 5 1 Exhaust Valve Relay Module Diagram 1. Purple/Black wire 2. Red/Purple wire 3. Blue/Black wire 4. Black wire 5. Orange/Red wire 6. Red wire

005429

Operation

6 1. EMM mounting screws

005375

Disconnect J2 connector.

When the outboard is running, the fuel pump circuit (purple/black wire) provides 12V to activate relay 3. Relay 3 provides fused 12V (red/purple wire) to relay 1 and relay 2.

1

The EMM controls the exhaust valve by grounding the blue/black wire. When the blue/black wire is NOT grounded, fused 12V is supplied to the exhaust valve actuator through the orange/red wire and the actuator is grounded through the black wire on relay 1.

1. J2 Connector

005376

When the blue/black wire IS grounded, relay 1 and relay 2 are activated. Relay 2 supplies fused 12V to the exhaust valve actuator through the red wire and the actuator is grounded through the orange/red wire. Use the Evinrude Diagnostic Software program for “static” test of actuator motor.

153

ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING

Installation IMPORTANT: If a new EMM is being installed, refer to EMM Transfer on p. 111.

IMPORTANT: Weak

Install J2 connector Align slots in starboard side of EMM case with isolator mounts on electrical harness base. Slide EMM into position.

1

FLYWHEEL AND STATOR SERVICING

2

flywheel magnets can cause low ignition voltage and affect outboard performance. Weak flywheel magnets can also cause low readings on ignition test equipment such as the peak-reading voltmeter, which might cause unnecessary replacement of ignition components. An accurate test of alternator output can help determine the flywheel’s condition. Refer to CHARGING SYSTEM TESTS on p. 142.

Flywheel Removal WARNING

1. EMM mounting slots 2. Isolator mounts

005377

Install two EMM retaining screws. Tighten screws 12 to 16 in. lbs. (1.5 to 2 N·m).

To prevent accidental starting while servicing, disconnect battery cables at the battery. Remove the EMM. Refer to EMM SERVICING on p. 153. Disconnect the vapor separator vent hose, crankshaft position sensor, throttle position sensor, air temperature sensor, and oil pump electrical connectors. Disconnect the stator connector, two port side trim system connectors, port engine temperature sensor, and the port ground terminal.

1

Remove the four screws holding the electrical harness base. 1. EMM mounting screws

005375

Install J1-A and J1-B connectors. Install exhaust pressure hose and cooling hoses. Secure with tie straps.

1

1

1. Harness base screws

154

005378

ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING Lift the electrical harness base out of the way.

Use two 3/8-24x2 in. screws from the adaptor kit to attach the tool to the flywheel. Two holes are tapped in the flywheel for the tool.

1 3 2

005379

Use Flywheel Holder, P/N 771311, or equivalent, to remove the five flywheel retaining nuts and washers. Discard the nuts.

1. Puller 2. Bushing 3. Screws - 3/8 - 24 x 2 in. (2)

005369

Turn the center screw of the puller in to lift the flywheel off of the crankshaft.

1

1. Flywheel retaining nuts

005380

CAUTION

005381

To avoid damage to flywheel magnets, or injury to fingers, Flywheel service kits, P/N 434649 and P/N 5007181, must be used to remove or install the flywheel. Install bushing from Flywheel Puller Adaptor Kit, P/N 5007181, on top of crankshaft. Place puller from Flywheel Service Kit, P/N 434649, over bushing.

155

6

ELECTRICAL AND IGNITION FLYWHEEL AND STATOR SERVICING

Stator Service Remove six allen head screws to remove stator.

wheel onto crankshaft. Remove tools from the flywheel and crankshaft.

1

1. Stator screws

005383

005382

To install stator, position stator on cylinder block. Apply Nut Lock to screw threads. Install screws and tighten in crossing pattern. Torque screws to 24 to 36 in. lbs. (3 to 4 N·m).

Flywheel Installation If studs must be replaced in crankshaft, apply Ultra Lock to threads and tighten by hand, no more than 48 in. lbs. (5.5 N·m). Remove any debris from the flywheel magnets and the flywheel and crankshaft mating surfaces.

CAUTION To avoid damage to flywheel magnets, or injury to fingers, Flywheel service kits, P/N 434649 and P/N 5007181, must be used to remove or install the flywheel. Apply Triple-Guard grease to studs and install five new flywheel retaining nuts and washers. Follow torque sequence below. Torque nuts to 24 to 26 ft. lbs. (32.5 to 35 N·m).

Apply Nut Lock to the raised mounting bosses on the bottom of the flywheel.

2

5

4 1

1 Flywheel Torque Sequence

1. Flywheel mounting bosses

005370

Use Flywheel Puller Adaptor Kit, P/N 5007181, and Flywheel Service Kit, P/N 434649, to position flywheel on top of crankshaft. Align the alignment hole in flywheel with alignment pin of crankshaft. Turm center screw counterclockwise to lower fly-

156

3

DRC3737

ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Install the electrical harness base and secure with four screws. Torque screws to 60 to 84 in. lbs (7 to 9.5 N·m).

1

1

TIMING ADJUSTMENTS Timing Pointer The timing pointer must be adjusted to indicate “top dead center” (TDC) of the number 1 piston. This reference to the position of the number 1 piston is used to synchronize the electronic timing controlled by the EMM with the mechanical position of the number 1 piston. Use the Evinrude Diagnostics Software program to verify and adjust timing. Refer to the software’s “Help Info” for outboard timing verification procedures.

WARNING 1. Harness base screws

005378

Reconnect the stator connector, two port side trim system connectors, port engine temperature sensor, and the port ground terminal. Reconnect the crankshaft position sensor, throttle position sensor, air temperature sensor, and oil pump electrical connectors. Install the EMM. Refer to EMM SERVICING on p. 153.

To prevent accidental starting while servicing, remove emergency stop lanyard and disconnect the battery cables at the battery.

IMPORTANT: The pointer on these models has two indicator points. The point labeled “V4” is used for 60° V4 models. The unlabeled point is used for 60° V6 models.

IMPORTANT: Perform the timing verification procedure after flywheel removal or replacement. Refer to TIMING ADJUSTMENTS on p. 157.

1

1. V4 pointer 2. V6 pointer

2

005385

Turn the key switch OFF and disconnect the battery cables at the battery. Remove spark plugs.

157

6

ELECTRICAL AND IGNITION TIMING ADJUSTMENTS Rotate the flywheel clockwise to 30° ATDC.

Rotate the flywheel in a clockwise direction until the piston contacts the tool. Mark the flywheel directly across from the pointer. Label this mark “B.” Rotate flywheel counterclockwise slightly to release tool and remove it from spark plug hole. Use the cast in markers on the flywheel to calculate the exact center between marks “A” and “B.” Mark and label the center point “C.” If mark “C” and the cast-in TDC boss on flywheel are in alignment, the timing pointer is in the correct location.

005384

Install Piston Stop Tool, P/N 342679, into the spark plug hole of the number 1 cylinder.

If the pointer alignment is NOT correct, rotate the flywheel clockwise to align the mark “C” with the pointer. Hold the flywheel in this position. Loosen the pointer retaining screw and adjust the pointer location to align with the cast-in TDC boss on the flywheel. Tighten retaining screw.

1 1 3 2

1. Piston stop tool

005386

Rotate flywheel in a counterclockwise direction until the number 1 piston contacts the tool. Keep pressure on the flywheel to position the piston firmly against the tool. Mark the flywheel directly across from the pointer. Label this mark “A.”

1. Cast in TDC mark 2. Mark B 3. Mark C

005388

Repeat the entire adjustment process to make sure pointer is aligned correctly. Install spark plugs. Refer to Spark Plug Indexing on p. 160.

1

1. Mark A

158

005387

ELECTRICAL AND IGNITION TPS CALIBRATION

Timing Verification Use the Evinrude Diagnostics Software program to synchronize the mechanical timing of the outboard with the electronic timing control function of the EMM.

TPS CALIBRATION Use the Evinrude Diagnostics Software program to tell the EMM what the throttle position sensor voltage level is when the throttle plates begin to open. Remove the air silencer. On the Settings screen of the diagnostic software, click the “Set TPS Calibration” button.

1 Timing Adjustment Screen

6

005148

Perform timing verification after any of the following procedures: • Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement • CPS replacement • EMM replacement • EMM software replacement (reprogramming)

IMPORTANT: Make sure the timing pointer is set and the outboard reaches operating temperature before timing verification is performed.

1. TPS Calibration button

006311

While holding the throttle plates closed, advance the throttle linkage until it stops. The “Measured TPS Calibration” field on the screen will increase. Click the “Working” button in the software to calibrate the TPS. Install the air silencer. Perform TPS Calibration after replacing or adjusting any throttle body or throttle linkage parts.

159

ELECTRICAL AND IGNITION SPARK PLUGS Apply Triple-Guard grease to the gasket surface of the spark plugs. Install all spark plugs and tighten them to a torque of 15 ft. lbs. (20 N·m).

SPARK PLUGS Inspection Spark plugs should be removed and examined periodically. Replace worn, fouled or damaged spark plugs. Use only recommended spark plugs with the correct gap setting.

If the mark is in unshaded area do not tighten anymore.

1

2

Spark Plug, Champion QC10PEPB @ 0.028 ± 0.003 in. (0.71 mm)

• Remove spark plugs and inspect condition. • Set spark plug gap on new, replacement spark plugs.

• Mark spark plugs for ground electrode orientation. • Apply Electrical Grease to the ribbed portion of the spark plug ceramic and to the opening of the spark plug cover to prevent corrosion. • Install spark plugs using “indexing” procedure.

Indexing Spark plug indexing positions the ground electrode of the spark plug opposite the fuel injector nozzle. Put an ink mark on the ceramic of the spark plug that is in line with the OPEN side of the ground electrode. This mark will be used to orient the spark plug with the OPEN side of the ground electrode facing the fuel injector.

2 1. Ink mark 2. Open side

160

1 000758

Spark Plug Indexing Diagram 1. Unshaded area 2. Shaded area

004294

If the mark is in the shaded area, reset torque wrench to 30 ft. lbs. (41 N·m) and continue to turn until the mark is in the unshaded area. If the mark does not reach the unshaded area before the torque of 30 ft. lbs. (41 N·m) is reached, the spark plug cannot be indexed for that cylinder. Try another spark plug and repeat the steps above.

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the screws, lock washers, and pinion housing.

ELECTRIC STARTER SERVICING Removal IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator. Disconnect the battery cables at the battery. Remove the starter positive (+) cable. Remove the four frame and bracket mounting screws. Remove the starter.

30373

Disassembly Lift and remove the wave washer and bushing.

6 1

2

005373

Loosen the two nuts used to fasten the starter bracket. Remove the nuts and bracket. 30372

Place an appropriate-sized deep socket on the spacer.

30374

161

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Hit the socket with a mallet to lower the spacer and expose the retaining ring under the spacer.

Remove pinion and plastic weather cover from pinion shaft.

30368

Remove the driven gear and thrust washer. 30371

30367 30360

Remove the retaining ring, spacer, and spring from pinion shaft.

Using No. 2 external retaining ring pliers, remove the retaining ring and drive gear from the armature shaft.

30366 30369

162

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Remove the two thru-bolts. Mark the end cap orientation, and remove the cap.

Note the alignment marks by the positive terminal stud. Hold the armature in place, and slide the frame away from the gear housing.

30365

Gently tap the starter frame with a rubber mallet to loosen it. Find the insulator cap (end of the shaft or inside the end cap). Inspect and replace, if necessary.

30352

Slowly remove the armature and thrust washer. Do not lose the brush springs.

30354B

30351

163

6

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING

Cleaning and Inspection Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs.

matter which could contribute to failure of windings.

TYPICAL

30349

Inspect and replace locating ring on armature shaft, if necessary.

24058

Check permanent magnets. Make sure they strongly attract any steel or iron object held inside frame. Weak magnetism could cause excessive RPM on No Load Current Draw Test on p. 150.

TYPICAL

24057

30345

Clean the commutator with 300-grade emery cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove any trace of oil or metal dust from the commutator. Check the armature on a growler for shorted turns using a test light or meter. Inspect armature insulation for indications of overheating or damaged windings. Clean off any carbon deposits or foreign

After disassembling the drive, clean each part with Cleaning Solvent and inspect for wear and distortion. If the pinion does not properly engage the flywheel, the pinion and screw shaft assembly could be worn, distorted, or dirty. Locate the cause of binding and correct it before completing the assembly. Inspect and replace end cap thrust washer if distorted or worn excessively. Inspect and replace armature shaft snap ring if worn or distorted.

164

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING

Assembly IMPORTANT: If removed, apply Locquic Primer and Screw Lock to the brush card screws before installing. Route the brush leads and install the springs and brushes. Compress the spring with a modified putty knife.

Align the starter frame and make sure the long alignment mark matches the mark next to the positive terminal stud on the gear housing. Push the armature down firmly and slide the frame into place. Align the notches in the gear housing and frame.

6

30364

IMPORTANT: Incorrect

orientation of the brushes could damage the starter or cause reverse rotation.

30352

Install insulator cap on end of shaft.

Apply Moly Lube to the armature bushing. Install the thrust washer and armature.

30354B

Apply a light coat of Moly Lube to the end cap bearing, and install the end cap.

30351

165

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Install the two thru-bolts. Tighten to a torque of 50 to 65 in. lbs. (5.6 to 7.3 N·m).

Guard grease. Install the thrust washer and driven gear.

30362 30363

Install the weather cover.

Lightly coat the drive gear with Triple-Guard grease, and install it on the armature shaft. Install the retaining ring (flat side up) with No. 2 external retaining ring pliers.

30361

If removed, install the spring and spacer (large diameter up) on the pinion shaft. Secure with retaining ring. Install bushing and wave washer (convex side down). 30366

Lightly coat the gear housing bearing with Moly Lube. Lightly coat the driven gear with Triple-

30369

166

ELECTRICAL AND IGNITION ELECTRIC STARTER SERVICING Lightly coat the pinion shaft splines (helix) with Starter Bendix Lube. Lower the pinion into place without displacing the driven gear or thrust washer.

To test the assembly and operation of the starter, refer to No Load Current Draw Test on p. 150.

Installation Apply Locquic Primer and Nut Lock to the threads of the four starter mounting screws. Position the starter and install the screws and lock washers. First, tighten the top two screws, then the bottom two screws, to a torque of 168 to 192 in. lbs. (19.0 to 21.7 N·m).

30359

Lightly coat the pinion housing bearing with Starter Bendix Lube, and install the pinion housing screws and lock washers. Torque the screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

1

1

6 1. Screws

005373

Attach starter positive (+) cable to post with lock washer and nut; tighten securely. Coat connections with Black Neoprene Dip.

30358

Install the bracket. Apply Nut Lock to the thrubolts. Install the nuts and torque to 50 to 65 in. lbs. (5.6 to 7.3 N·m).

30357

167

ELECTRICAL AND IGNITION CONNECTOR SERVICING Release terminal latch and gently pull on wire.

CONNECTOR SERVICING

1

DEUTSCH Connectors

2

Grease is recommended. Incorrect grease application can cause electrical or warning system problems.

IMPORTANT: Electrical

To disconnect the connector, press the latch and pull the connectors apart. To connect the connector, confirm that the seal is in place. Clean off any old grease and dirt from connectors. Apply a light coat of Electrical Grease to seal. Push connectors together until latched.

1. Terminal latch (receptacle) 2. Terminal latch (plug)

42329

Terminal Installation Push terminal through seal until it locks into place. Fill connector with Electrical Grease to 1/32 in. (0.8 mm) below ledge or end of plug.

2 1 2 1 1. Latch 2. Seal

42079A

Terminal Removal Use hook-end of Connector Service Tool, P/N 342667, to pull out wedge from receptacle, or use other end of tool to pry out wedge from plug. Use needle-nose pliers to remove wedge from 3-pin receptacle.

1

1. Wedge

1. Ledge of plug 2. End of plug

Push wedge in until latched. Wedge in 2-pin receptacle is not symmetrical; position latch shoulders next to terminals.

Crimping Terminals Strip insulation back 3/16 in. (5 mm). Place terminal in 18-gauge notch of Crimping Pliers, P/N 322696. Position end of wire strands in terminal past wire crimp area, and position end of insulation past insulation crimp area. Capture all wire strands in crimp; leave no loose strands. Crimp wire securely. Do not solder. Crimp insulation in 14/16-gauge notch of crimping pliers.

2

1

3

4

42327

1. 2. 3. 4.

168

42330

End of wire strands Insulation crimp area End of insulation Wire crimp area

DRC6205

ELECTRICAL AND IGNITION CONNECTOR SERVICING

AMP Connectors IMPORTANT: Always use the appropriate meter test probes and adapters when testing components fitted with these terminals. Electrical grease is NOT used on AMP connectors.

1

2

SUPERSEAL† 1.5 Disconnect Lift latch. Pull connectors apart.

1. Locking tab, plug 2. Locking tab, receptacle

Connect Confirm the seal is in place. Push connectors together until latched.

1

002447

Terminal Installation Align terminal with connector housing. Push connector and seal into housing until seated.

1

6 2 1. Latch 2. Seal

002448 002451

Terminal Removal

1. Terminal and seal

Use Secondary Lock Tool, P/N 777078, to release anti-backout device of connector housing. Next, use Primary Lock Tool, P/N 777077, to release locking tab of connector housing. Release locking tab and pull on wire to remove from connector housing.

Align anti-backout device with connector housing and terminals. Use Secondary Lock Installer, P/N 777079, to seat device in connector.

2

Crimping Terminals Crimping Superseal 1.5 terminals requires the PRO-CRIMPER II † with a specific crimping die set. The PRO-CRIMPER II hand tool assembly, P/N 58583-1, comes with die assembly P/N 58583-2.

1 1 1. Anti backout device, plug 2. Anti backout device, receptacle

002449 002450

2 1. Terminal 2. Seal

002452

169

ELECTRICAL AND IGNITION CONNECTOR SERVICING SUPER SEAL†

POWER TIMER † SERIES

The J1-A and J1-B connectors of the EMM are AMP Super Seal connectors.

The J2 connector of the EMM is a AMP Power Timer Series connector.

Disconnect

Disconnect

Depress BOTH latches and pull connector from plug.

Use a screw driver to open latch. Pull connector from plug.

Connect

Connect

Push connector into plug until latches engage.

Push connector until seated in plug. Close latch completely.

1 1 1

2 1. Latch

002118

Terminal Removal

1. J2 connector 2. Latch (closed)

Open lock mechanism and remove terminal from connector housing.

Terminal Removal

2

2

002120

Use Terminal Release Tool, P/N 351413, to release BOTH locking mechanisms of connector. Pull terminal from housing.

1

1 1. Latch 2. Lock mechanism

1 002453

1

Terminal Installation Push terminal through seal until it is seated in connector housing. Close lock mechanism.

1. Locking mechanism(s)

002455

1. Terminal release tool

002313

1

1. Terminal

170

002454

ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation

Terminal Removal

Align terminal with connector housing and push terminal with seal into connector housing until seated.

A tab on the back side of the terminal engages a shoulder in the connector housing to hold the terminal in place. The terminal is removed by pushing wire and terminal through connector housing.

1

Insert a thin wire, such as a paper clip, into the connector above the terminal to release tab.

2

1. Latch 2. Terminal with seal

002456

Packard † Connectors TYPICAL

DRC5940

Terminal Tool

DRC5941

IMPORTANT: Always use the appropriate meter test probes and adapters when testing components fitted with these terminals. Disconnect Lift latch(s). Remove connector.

Connect Confirm the seal is in place. Push connector onto housing until latched.

DSC02124

171

6

ELECTRICAL AND IGNITION CONNECTOR SERVICING Terminal Installation Install wire gasket on wires and feed wires through the correct terminal position of the connector housing. Terminal is crimped onto wire and then pulled back into connector housing until locking tab engages and terminal is seated.

002304

Crimping Terminals Strip insulation back 3/16 in. (5 mm). Position end of wire strands in terminal past the wire crimp area and the end of insulation in the insulation crimp area of the terminal. Capture all wire strands in crimp; leave no loose strands. Crimp wire and insulation securely using crimping pliers.

172

FUEL SYSTEM

FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 DIRECT INJECTION ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 INJECTOR / CIRCULATION PUMP CIRCUITS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 FUEL COMPONENT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 IN-LINE FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 OPTIONAL FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

173

7

FUEL SYSTEM SERVICE CHART

SERVICE CHART FUEL PUMP, FUEL FILTER, VAPOR SEPARATOR

L

60-80 in. lbs. (7-9 N·m)

L

60-84 In. lbs. (7-10 N·m)

60-84 In. lbs. (7-10 N·m)

F

A B C E F H L P

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant Pipe Thread Sealing Compound Permatex #2

174

004940

FUEL SYSTEM SERVICE CHART REED PLATE ASSEMBLY AND THROTTLE BODY

C

Bond seals to air silencer

IMPORTANT: DO NOT lubricate TPS to throttle shaft surface

B

10-18 in. lbs. (1-2 N·m)

96-120 in. lbs. (11-13.5 N·m) Start at center and use a spiral torque pattern

7 60-80 in. lbs. (7-9 N·m)

K 30-42 in. lbs. (3-5 N·m)

B

F 96-120 in. lbs. (11-13.5 N·m)

A B C D E F G K

Triple-Guard Grease Gasket Sealing Compound Adhesive 847

60-80 in. lbs. (7-9 N·m)

F 72-96 in. lbs. (8-11 N·m)

Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Purple, Screw Lock

004941

175

FUEL SYSTEM SERVICE CHART FUEL MANIFOLDS AND INJECTOR

S

Torque in 3 stages A

H

24-36 in. lbs (2.7-4 N·m)

R

A

1

60-84 in. lbs. (6.8-9.5 N·m)

2

120 in. lbs. (14 N·m)

3

24-26 Ft. lbs. (33-35 N·m)

R

S R S = Supply R = Return S

S

R S

S

R

R

R

R

S S

A B C D E F G H S

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease Outboard Engine Lubricant STP Oil Treatment

176

004942

FUEL SYSTEM COMPONENTS

COMPONENTS

Fuel Filter

The Evinrude E-TEC direct injection system consists of the following components: • Fuel Lift Pump • Fuel Filter • Vapor Separator • Fuel Circulation Pump • Fuel Supply Manifolds • Fuel Injectors • Fuel Return Manifolds

The fuel filter protects the vapor separator and the high-pressure components of the fuel system from water and contaminants. Refer to INSPECTION AND MAINTENANCE SCHEDULE on p. 80 for service frequency.

Fuel Lift Pump

1

The fuel lift pump is a mechanical, pressure-pulse pump. The diaphragm of the pump is driven by two pulse hoses that connect to the front of the cylinder/crankcase assembly. Fuel lift pump pulse hose locations: • V4 models: cylinders 2 and 4 • V6 models: cylinders 4 and 6

1. In-line fuel filter

005234

Accessory kit, P/N 5007045, is available to add a water-separating cannister fuel filter to Evinrude E-TEC 60° V outboards.

1 2 1

1. Fuel lift pump 2. Pulse hose fittings

005261

Vacuum from the fuel lift pump pulls fuel from the fuel tank. Once fuel reaches the pump, internal pump pressure forces the fuel from the pump through the fuel filter and into the vapor separator.

1. Water-separating fuel filter

005237

177

7

FUEL SYSTEM COMPONENTS

Vapor Separator

Venting

The vapor separator: • Serves as a water-cooled fuel reservoir to accumulate incoming fuel from the fuel lift pump and from the fuel return manifold; • Contains a float controlling the venting of fuel vapors; and • Contains a fuel pressure regulator for the high pressure fuel system.

The fuel vapor vent regulates fuel vapor pressure in the fuel system.

1

The vapor separator is serviced as an assembly and includes the fuel circulation pump.

1. Vent

005323

1 1

Vapor Separator Assembly 1. Circulation pump

005322

Fuel Reservoir The vapor separator accumulates fuel in an internal fuel reservoir and supplies fuel to the electric circulation pump. It is water-cooled to enhance vapor separating capabilities.

Cooling Water is used to cool the fuel as it flows through the vapor separator. The cooling passage of the separator self-drains when the outboard is stored vertically. Refer to HOSE ROUTING AND WATER FLOW DIAGRAMS on p. 226.

178

1. Vent hose connection to intake

005326

The vapor separator vent is opened and closed by a float valve. The float valve moves relative to the fuel level in the fuel chamber. Hot fuel causes an increase in vapor pressure. This results in a lower fuel level in the vapor separator. The float valve drops and the vent opens. This allows fuel vapor to flow to the intake manifold through the vent hose. As the vapor pressure in the vapor separator decreases, the fuel level begins to increase. An increase in the fuel level raises the float valve and the vent closes.

FUEL SYSTEM COMPONENTS Pressure Regulator

Fuel Manifolds

The fuel pressure regulator helps maintain consistent fuel pressure in the fuel system.

The fuel supply and return manifolds route fuel through the high pressure side of the fuel system.

Fuel returning from the injectors enters the fuel chamber of the vapor separator through a pressure regulator. The pressure regulator maintains approximately 20 to 30 psi (138 to 207 kPa) of fuel pressure in the high pressure side of the fuel system.

Fuel Circulation Pump The fuel circulation pump is an electric high pressure fuel pump. The pump is controlled by the EMM.

Fuel Supply Manifold The fuel supply manifold supplies pressurized fuel to the inlet port of each fuel injector.

Fuel Return Manifold The fuel return manifold provides a route for fuel passing through the fuel injectors to flow back to the fuel chamber of the vapor separator.

2

Fuel Supply The pump is mounted to the vapor separator and draws fuel from the fuel chamber. The fuel injectors receive pressurized fuel from a fuel supply manifold connected directly to the circulation pump.

1

Electrical Circuit Activation of the circulation pump is controlled by the EMM and operates on the 12 V circuit. The circulation pump is activated momentarily when the EMM powers up.

1. Fuel supply manifold 2. Fuel return manifold

1

1

2

1. Inlet ports 2. Return ports 1. Fuel pump electrical connector

005328

005332

005327

179

7

FUEL SYSTEM COMPONENTS

Fuel Injectors

Injector Fuel Supply

Fuel injectors are fuel metering (55 V), electric solenoids bolted directly to the cylinder head. The EMM supplies 55 V and controls the activation of each injector.

Fuel is supplied to the injectors by the fuel circulation pump and the fuel supply manifold.

Fuel Flow Compensation Flow tests included in the injector manufacturing process measure the flow rates of each injector. Each injector's fuel flow rate is recorded and converted to specific coefficients. These coefficients are assigned to the injector by serial number.

Each injector has internal fuel passages. These passages are designed to: • Provide fuel to the injector's injection chamber • Route fuel through the injector housing to cool the injector coil and armature

Each individual service injector includes these coefficients on a 3.5 in. floppy disk. This software information enables the EMM to control each injector based on unique fuel flow characteristics.

IMPORTANT: The cylinder location of each injector must always be maintained. EMM programming is associated with the cylinder location of each injector.

180

005333

FUEL SYSTEM FUEL SYSTEM HOSE ROUTING

FUEL SYSTEM HOSE ROUTING V4 MODELS 5

11

Fuel Supply Fuel Return

10

4

3

7

9

10

14

3

6

10

8

1

10

2

9 9 13

12 005194

V6 MODELS

5

7

11 4

3

10

7 10

3 10

9

1 2

10

14 6

Fuel Supply

10

8

Fuel Return

10

9 9 13

12 004943

1. 2. 3. 4. 5. 6. 7.

Fuel supply from boat fuel system Fuel lift pump (2 to 8 psi) Pulse hose(s) from cylinder/crankcase Fuel filter Fuel supply to vapor separator Vapor separator Vent hose to throttle body

8. 9. 10. 11. 12. 13. 14.

Electric fuel circulation pump (20 to 35 psi) Fuel supply manifold Fuel injector(s) Fuel return manifold Pressure regulator (high pressure) Test fitting (low pressure) Test fitting (high pressure)

181

FUEL SYSTEM DIRECT INJECTION ELECTRICAL CIRCUITS

DIRECT INJECTION ELECTRICAL CIRCUITS The outboard’s 55 V alternator circuit supplies the injectors with the necessary current. Unique circuits from the EMM distribute this current to the specific injector. The EMM controls injector operation by rapidly connecting and disconnecting one side of each component’s internal coil to ground. Current must flow from the EMM to the injectors, through the winding of the component, back to the EMM, and through the EMM to ground. The injector’s internal coil provides approximately 3 ohms of resistance in the injector circuit.

182

Requirements for injector activation: • 55 V system voltage from the EMM and through the individual circuits; and • Switched ground connection provided by the EMM.

IMPORTANT: System voltage (55 V) output is produced by stator input to EMM and rectifier circuits of EMM. Refer to FUEL DELIVERY on p. 131 for additional test procedures.

10

12

2 1

12 3

123

12 3

66

J2

J1-A

12 3

44

22

7

8 9 10 11 12 13 10 11 12 13 14 15 16 17

14 15 16 17 18 19 18 19 20 21 22 23 24 25

1 2 3 4 5 6 7

1 2 3 4 5 6 7 8 9 5 6 7 8 9 10 1 2 3 4

18 19 16 17 14 15 11 12 13

24 25 26 27 28 29 20 21 22 23

20 21 22 23 24 25 26

11

26 27 28 29 30 31 32 33 34

J1-B

55

33

1

8

10

10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Injector No. 1 Injector No. 2 Injector No. 3 Injector No. 4 Injector No. 5 Injector No. 6 EMM 55 Volt circuit, WHITE/RED Capacitor Grounds (NEG) Fuel injector grounds Fuel pump, high pressure (12 V)

9

FUEL SYSTEM DIRECT INJECTION ELECTRICAL CIRCUITS

Injector / Circulation Pump Circuits Diagram

12 3

12 3

183

7

FUEL SYSTEM FUEL COMPONENT TESTS

FUEL COMPONENT TESTS 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. Remove propeller before servicing and when running the outboard on a flushing device. DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

Fuel Injectors Pressure Test This test requires Injector Test Fitting kit, P/N 5005844. Disconnect the battery cables at the battery. Relieve fuel system pressure. See Relieving Fuel System Pressure on p. 189.

IMPORTANT: Perform test with injector mounted to cylinder head and fittings installed with manifold retainer. Use cap and tie strap to seal off outlet fitting and connect a 0 to 30 psi (0 to 207 kPa) pressure tester to the inlet fitting. Pressurize the injector to 30 psi (207 kPa). Pressure must hold for at least five minutes.

1 2

WARNING Use caution when working on any pressurized fuel system. Wear safety glasses and work in a well ventilated area. Extinguish all smoking materials and make certain no open flames or ignition sources exist. Before starting any fuel system service, carefully relieve fuel system pressure. Failure to properly relieve fuel system pressure can result in spraying fuel and/or excessive fuel spillage during servicing. Fuel is flammable and can be explosive under certain conditions.

1. Outlet fitting 2. Inlet fitting

002379

Static Test Use the Evinrude Diagnostics Software program to test circulation pump and fuel injectors. Refer to FUEL DELIVERY on p. 131 for additional test procedures.

IMPORTANT: Static tests are performed when outboard is not running. Listen carefully for fuel pump and injector activation. These tests are operating components on battery voltage. The

184

FUEL SYSTEM FUEL COMPONENT TESTS fuel pump uses 12 V circuit and the injectors use 55 V circuit.

Fuel Supply Fuel System Pressure Test Relieve fuel system pressure. See Relieving Fuel System Pressure on p. 189. After relieving fuel system pressure, install a 0 to 60 psi (0 to 415 kPa) Fuel Pressure Gauge, P/N 5007100 or equivalent, to the upper fuel pressure test fitting.

1

2 Static Tests Screen

005146

Resistance Test Disconnect the battery cables at the battery. Use a digital multimeter to measure the injector circuit and coil resistance.

1. Fuel pressure gauge 2. Test fitting

005432

START outboard and check pressure. System pressure should be 20 to 35 psi (138 to 241 kPa).

Fuel Injector Coil Resistance 2 to 3 Ω @ 72°F (22°C) Use electrical test probe kit, P/N 342677, and a multimeter to check resistance. Wire harness adaptor leads, P/N 342228 can be used to make connection at EMM J1-B connector. Measure resistance between pin 1 of injector connector and the appropriate pin location of EMM J1-B connector. Refer to engine wiring diagram for specific EMM J1-B connector pin location for the injector circuit being tested.

Shut OFF outboard. Monitor pressure gauge. Pressure should not drop below 15 psi (103 kPa).

IMPORTANT: If outboard does not run, prime fuel system and crank outboard; check circulation pump operation; check fuel system pressure. Results: Normal pressure • Observe pressure reading after outboard is shut OFF. • Proceed to Lift Pump Pressure Test on p. 187. Pressure drops after outboard shut OFF

• Leaking fuel injector • Leaking pressure regulator • External fuel system leak

005437

185

7

FUEL SYSTEM FUEL COMPONENT TESTS High pressure • Suspect restricted filter or fuel return fitting of vapor sperator, damaged pressure regulator in vapor separator, or restricted fuel return manifold.

Apply pressure to check regulator operation. The pressure should open check valve at approximately 15 psi (103 kPa).

Low pressure

• Check fuel supply to fuel lift pump. Refer to Lift Pump Vacuum Test on p. 187. Higher vacuum readings indicate restrictions in the fuel supply. Repair or replace as needed. • Restricted fuel filter/water seperator assembly. • Lift pump not supplying adequate fuel to vapor separator. Refer to Lift Pump Pressure Test on p. 187. • If the above requirements are met and vapor separator remains full of fuel, suspect damaged circulation pump. Replace vapor separator assembly. No pressure

• Check electrical circuit and ground connections

2

for circulation pump.

• Voltage present and pump does not run. Repair connection or replace vapor separator assembly.

• Pressure Regulator Test Refer to Vapor Separator on p. 191 to remove vapor separator. Make sure filter is not clogged. Clean or replace as needed. Apply oil to valve and connect pressure pump and hose to the fuel return fitting of vapor separator.

186

3 1. Filter 2. Fuel return fitting 3. Pressure regulator

1 000249r

FUEL SYSTEM FUEL COMPONENT TESTS Circulation Pump Resistance Test Disconnect the battery cables at the battery. Use a digital multimeter to measure the fuel pump circuit and coil resistance. Fuel Pump Resistance 3 Ω @ 77°F (25°C)

Results: Normal pressure • Perform the Lift Pump Vacuum Test on p. 187. Make certain no air leaks or restrictions exist in the fuel supply hose or boat fuel system. Low pressure • Check pulse hoses and fittings for restrictions. • Perform the Lift Pump Vacuum Test on p. 187. Make sure no air leaks or restrictions exist in the fuel supply hose or boat fuel system. • Check fuel flow through fuel lift pump. Use fuel primer bulb to force fuel through pump. No pressure

• Check pulse hoses and fittings restrictions. • Check fuel flow through fuel lift pump. Use fuel

005438

Lift Pump Pressure Test Install a 0 to 15 psi (0 to 103 kPa) Fuel Pressure Gauge, P/N 5006397 or equivalent, to the lower fuel pressure test fitting.

1

7

Lift Pump Vacuum Test Confirm fuel supply to the fuel lift pump. Temporarily install a vacuum gauge, T-fitting, and 8 in. (20.3 cm) of clear vinyl hose between the fuel supply hose and fuel lift pump (inlet). Secure connections with tie straps to prevent fuel or air leaks.

IMPORTANT: Do not use fuel primer bulb, man-

2

1. Fuel pressure gauge 2. Test fitting

primer or primer bulb to force fuel through pump. • Momentarily prime or squeeze primer bulb to check gauge operation. • Check pulse hose and fittings for restrictions.

ual fuel primer, or electric fuel pump primer to restart outboard. A positive pressure in the fuel supply could damage some vacuum gauges.

005439

Prime the fuel system and check for leaks. START outboard and run at idle speed. Hold gauge level with inlet fitting and monitor gauge for pressure reading. Pressure should stabilize and gauge must not indicate less than 3 psi (21 kPa).

000243

187

FUEL SYSTEM FUEL COMPONENT TESTS START outboard and run at FULL THROTTLE for at least two minutes. Monitor clear vinyl hose for the presence of air. Air bubbles indicate a faulty hose, connection, or fuel tank pick-up. Repair, if necessary, before proceeding. There should be no air or vapor bubbles visible in the clear hose. The maximum inlet fuel vacuum should not exceed 4 in. Hg. (13.5 kPa) at the inlet to the fuel lift pump under any operating conditions (IDLE to WOT). A higher vacuum indicates an excessive restriction in the fuel supply. Repair as needed. Refer to Fuel System Requirements on p. 41 for fuel supply component requirements.

Anti-Siphon Valve Test Remove anti-siphon valve from fuel tank. Install adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve.

3

20 in. (500 mm)

2

1

Lift Pump Diaphragm Test Perform this test only if a damaged pump is suspected. This test does not check the performance of internal fuel pump check valves. Pump diaphragms can be pressure tested by removing both pulse hoses from the crankcase fittings. Apply 15 psi (103 kPa) to each of the pulse hoses of the pump. Both sides of pump should hold pressure. Replace lift pump if either side fails to hold pressure.

1

1. Pulse fitting

188

000670

1. Anti-siphon valve 2. Adapter fitting 3. Clear hose

DR2277

Fill clear hose with water to a height of 20 in. (500 mm). Water must NOT flow through valve. An occasional drip is acceptable. Replace valve if water drips continuously. Increase height of water to 25 in. (630 mm). Water should flow through valve as water level reaches 25 in. (630 mm). Replace the anti-siphon valve if test results are different.

FUEL SYSTEM FUEL COMPONENT SERVICING

FUEL COMPONENT SERVICING

of high pressure fuel pump/vapor separator assembly.

WARNING

1

Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure. Always disconnect the battery cables at the battery before servicing the fuel system unless instructed to do otherwise. Always work in a well ventilated area and wipe off any fuel spillage.

1. High pressure test fitting

005334

Insert venting hose of gauge into a suitable container. Slowly open gauge’s venting valve. Clean up any spilled fuel with shop towels.

DO NOT smoke and make certain no open flames or ignition sources exist. After servicing the fuel system check for leaks. Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.

7 1 3

Relieving Fuel System Pressure 2

IMPORTANT: Minimize fuel system pressure prior to disassembly. Temporarily restrict the fuel supply hose from fuel tank with hose pincer. Remove propeller and disconnect circulation fuel pump electrical connector. If outboard runs, start and run at IDLE for 5 seconds and STOP outboard. If outboard does NOT run, crank for 10 seconds.

1. Test fitting 2. Venting hose 3. Venting valve

005335

Disconnect the battery cables at the battery. Wrap a shop towel completely around the pressure test valve while connecting fitting from Fuel Pressure Gauge, P/N 5007100, to top test fitting

189

FUEL SYSTEM FUEL COMPONENT SERVICING

In-Line Fuel Filter

Optional Fuel Filter

Removal

Accessory kit, P/N 5007045, is available to add a water-separating cannister fuel filter to Evinrude E-TEC 60° V outboards.

Disconnect the battery cables at the battery. Remove filter carefully to prevent spilling contents.

Removal

Inspect contents for any presence of water. If water is present, identify the source and correct the problem. Take additional fuel samples and drain fuel tank(s) if necessary.

Use an appropriate filter wrench to turn the filter in a counterclockwise direction. Remove the filter carefully to prevent spilling the filter’s contents.

Disconnect the battery cables at the battery.

Inspect contents for any presence of water. If water is present, identify the source and correct the problem. Take additional fuel samples and drain fuel tank(s), if necessary.

1

1 1. In-line fuel filter

005234

Installation Position filter in fuel supply hoses. Note arrow indicating direction of fuel flow on filter. Secure fiter with appropriate clamps. Refer to Oetiker Clamp Servicing on p. 48. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks. Connect battery cables. Run outboard and check for fuel leaks.

1. Water-separating fuel filter

005237

Installation Lubricate filter seal with outboard lubricant and position filter on threaded mounting tube of filter bracket. Take care not to damage water in fuel sensor probe. Turn filter clockwise onto the tube until seated against the bracket. Tighten filter approximately 3/4 turn after the gasket contacts the bracket. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks. Connect battery cables. Run outboard and check for fuel leaks.

190

FUEL SYSTEM FUEL COMPONENT SERVICING

Fuel Lift Pump

Vapor Separator

The fuel lift pump is serviceable as a complete assembly. Refer to parts catalog for service parts.

Removal

Removal Disconnect the battery cables at the battery.

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189.

Remove air silencer.

Disconnect circulation pump electrical connector.

Disconnect the fuel supply hose from the in-line fitting.

Remove clamp and fuel supply manifold from top of circulation pump. Remove clamp and vapor vent hose from separator cover.

Disconnect the fuel outlet hose from the fuel filter housing. Disconnect the fuel lift pump pulse hoses at the crankcase fittings. Remove the fuel lift pump and hoses as an assembly.

Disconnect the battery cables at the battery.

Remove clamps and vapor separator cooling water hoses. Remove clamps and fuel return manifold and fuel supply manifold from bottom of vapor separator. Remove the vapor separator housing retainer clip.

1 2

1. Pulse hose crankcase fitting 2. Fuel supply fitting

1

005336

Installation Connect the fuel lift pump pulse hoses to the crankcase. Secure with tie straps. Connect the fuel outlet hose to the fuel filter. Secure with 18.5 mm Oetiker clamp. Connect the fuel supply hose to the in-line fitting. Secure with 18.5 mm Oetiker clamp. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks. Install air silencer and connect battery cables. Run outboard and check for fuel leaks.

1. Retainer clip

004189

Remove vapor separator/fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts.

Installation Installation is essentially the reverse of removal. Pay close attention when performing the following additional tasks. Reinstall all hoses and manifolds to original locations and secure in place with appropriate clamps. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and observe for fuel leaks. Install air silencer and connect battery cables. Run outboard and check for fuel leaks.

191

7

FUEL SYSTEM FUEL COMPONENT SERVICING Disconnect fuel manifold fittings from fuel injector ports, then remove the manifold assembly(s).

Fuel Manifolds Removal

Installation

Disconnect the battery cables at the battery. Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189.

IMPORTANT: Note the locations and positioning of all spark plug leads and retainer clips prior to disassembly. Remove clamps and disconnect the fuel manifolds as follows: • Fuel supply manifold to circulation pump • Fuel return manifold to vapor separator

Check condition of sealing O-rings on fuel manifold fittings. Lubricate O-rings with outboard lubricant and insert fuel manifold fittings into injector. Both fittings must be fully seated into the injector fuel ports. Install retainer and screw. Retainer must engage the outer groove of the manifold fittings.

1

1

2

2 1. Fuel supply manifold 2. Fuel return manifold

005341

Remove fuel manifold retainer screw and remove retainer from fuel injector.

1. Retainer 2. Manifold fitting groove

005342

1

2

3

1

2

3 1. Retainer screw 2. Fuel supply manifold fitting 3. Fuel return manifold fitting

1. Retainer screw 2. Fuel supply manifold fitting 3. Fuel return manifold fitting

005337

Reconnect spark plug leads and battery cables. Start outboard briefly to pressurize fuel system. Turn outboard OFF and inspect all fuel system components for leaks. Install lower engine covers and air silencer.

192

005337

FUEL SYSTEM FUEL COMPONENT SERVICING

Fuel Injectors

Removal

Mark fuel injector(s) to indicate cylinder location(s).

Disconnect the battery cables at the battery.

IMPORTANT: Fuel injector(s) must be installed in the correct cylinder location(s). Use the Evinrude Diagnostics Software program to confirm that the EMM programming matches injector positioning by cylinder location. The injector information screen of the diagnostic program displays injector serial numbers.

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189. Remove fuel manifolds. Refer to Fuel Manifolds on p. 192. Disconnect the fuel injector/coil electrical connector.

IMPORTANT: To remove ignition coil lead from injector connector, refer to CONNECTOR SERVICING on p. 168. Remove injector screws.

1

7 Injector Coefficients Screen

005142

Use caution when handling fuel injectors. Prevent dirt and debris from entering fuel inlet and outlet ports of injectors or fuel tubes. Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber.

1. Injector screws

005338

Remove fuel injector and insulator.

193

FUEL SYSTEM FUEL COMPONENT SERVICING Crush Ring Replacement IMPORTANT: Injector crush rings must be replaced if injector is installed in a different head or cylinder location.

2

Use Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, components to remove injector from mounting cup. Thread adaptor and stud into face of injector. Hold mounting cup securely. Work slide hammer to separate injector from mount housing.

1

1. Crush ring 2. O-rings

002317

Reinstall injector into mount housing. Press on injector face until injector seats in mount housing.

002345

Remove adaptor from injector. Remove crush ring and O-rings from injector. Inspect and clean injector filter. Install new crush ring and O-rings. Lubricate O-rings with STP † Oil Treatment.

002318

Installation IMPORTANT: All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in outboard failure. 1

1. Adaptor

194

002196

Installation of replacement injectors requires the use of diagnostic software and coefficient data

FUEL SYSTEM FUEL COMPONENT SERVICING supplied with all replacement injectors on 3.5 in. floppy disk.

through mounting flange of injector and thread into cylinder head.

002316

004160

The following items and their mating surfaces must be cleaned prior to reassembly: • Injector • Cylinder head • Adapter • Screws • Threaded areas

Tighten screws in stages, starting with the lower screw. • First torque is 5 ft. lbs. (7 N·m) • Second torque is 10 ft. lbs. (14 N·m) • Final torque is 24 to 26 ft. lbs. (33 to 35 N·m).

1

CAUTION All injector components must be clean to ensure correct torque tightening specifications. To prevent fuel leakage, carefully follow these installation instructions. Tighten Screws in Stages 1. Screws

005338

Position injector and insulator in the proper cylinder location.

Reconnect fuel injector/coil electrical connectors.

IMPORTANT: Be careful not to pinch any wiring or hoses during assembly.

If ignition coil lead was removed from connector, refer to CONNECTOR SERVICING on p. 168.

Lubricate mounting screw threads and under the head of the screw with a light coat of Triple-Guard grease. Install washers (one per screw) on injector retaining screws. Install screws and washers

Install fuel manifolds. Refer to Fuel Manifolds on p. 192.

IMPORTANT: Install injector service software (3.5 in. floppy disk) by using the Injector Replacement Utility of the Evinrude Diagnostics Software program. Use the diagnostic program to confirm that all injectors are positioned properly.

195

7

FUEL SYSTEM INTAKE MANIFOLD

Removal

Remove oil distribution hoses from oil pump/manifold and reed plate bracket. Refer to OIL COMPONENT SERVICING on p. 222.

Disconnect vapor separator vent hose, throttle position sensor connector, and throttle link arm.

Remove oil recirculation hose from starboard side of reed plate assembly.

Remove crankshaft position sensor from reed plate assembly.

Remove screws and reed plate assembly from the crankcase.

INTAKE MANIFOLD

Remove oil filter from retainer. Remove oil pump bracket screws. Remove throttle body screws and throttle body assembly.

1

1

1 1. Reed plate screws (3 on V4, 5 on V6)

005367

Disassembly

1. Throttle body screws (14 on V4, 18 on V6)

005368

Remove gasket from throttle body. Remove tie straps holding connectors to side of reed plate assembly.

All reed plate assembly and reed valve assemblies must be cleaned prior to reassembly. DO NOT use strong carburetor cleaner or the hot soaking tank method for cleaning. Remove the reed valve retainer screws and remove the assembly.

Remove two screws holding electrical harness base to reed plate assembly.

1

1

005366

1. Harness base screws

196

005345

FUEL SYSTEM INTAKE MANIFOLD Use caution to prevent damaging reed valve assemblies.

Assembly Remove old adhesive from reed valve retaining screws. Prime the threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate and install screws. Final torque is 30 to 42 in. lbs. (3 to 5 N·m).

005364

Inspection Inspect the leaf plate assemblies for damage or contamination: • Leaf plates must not be distorted. • Leaf valve must not be cracked or chipped. • Leaf plate stops must not be distorted or loose. • Leaf plate assemblies must be clean.

IMPORTANT: DO NOT disassemble reed valve assemblies. Damaged reed plates are not serviceable and are replaced as an assembly. Inspect the intake manifold. All gasket surfaces must be cleaned, smooth, and free of nicks. Use a machinist’s straight-edge to check flatness in all directions. Surface must be flat, ±0.004 in. (0.10 mm).

005365

Installation Position reed plate assembly on cylinder/crankcase. Apply Nut Lock to screws. Install all screws. Tighten the center screws first and expand outward. Tighten in stages. Final torque is 96 to 120 in. lbs. (11 to 13.5 N·m).

1

005363

1. Straight-edge

004193

Install electrical harness base screws.

197

7

FUEL SYSTEM INTAKE MANIFOLD Position gasket on throttle body. Install throttle body, with oil pump bracket on reed plate and install screws.

Install oil filter and oil and fuel supply hoses.

Tighten the center screws first and expand outward. Final torque is 96 to 120 in. lbs. (11 to 13.5 N·m). Tighten small oil pump bracket screw 24 to 36 in. lbs. (3 to 4 N·m).

1

1. Tie strap

005343

Install crankshaft position sensor. Install vapor separator vent hose and oil recirculation hose. Secure with tie straps. 005362

Install oil pump in bracket and secure with 60.5 mm Oetiker clamp. Route oil distribution hoses through reed plate bracket and install in oil pump manifold. Refer to Oil Supply and Distribution Diagrams – V4 on p. 208 or Oil Supply and Distribution Diagrams – V6 on p. 206.

Connect throttle linkage and throttle position sensor connector. Secure connector to reed plate bracket with tie strap.

1

3

2 4

1. 2. 3. 4.

Vapor separator vent hose Throttle linkage TPS electrical connector Tie strap

Refer to TPS CALIBRATION on p. 159. 005344

198

005361

OILING SYSTEM

OILING SYSTEM TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 OIL INJECTION PUMP DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 OILING SYSTEM ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 SYSTEMCHECK, I-COMMAND AND EMM OILING SYSTEM WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 OIL SUPPLY AND DISTRIBUTION DIAGRAMS – V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 OIL SUPPLY AND DISTRIBUTION DIAGRAMS – V4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 RECIRCULATION HOSE ROUTINGS AND CHECK VALVE DIAGRAMS – V6 . . . . . . . . . . . . . . . . . . . . . . . . 211 RECIRCULATION HOSE ROUTINGS AND CHECK VALVE DIAGRAMS – V4 . . . . . . . . . . . . . . . . . . . . . . . . 213 PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 OIL HOSE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 OIL DISTRIBUTION MANIFOLD PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 OILING RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 XD100 OUTBOARD OIL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 OIL INJECTION PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 OIL INJECTION PUMP VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 OIL INJECTION PUMP CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 OIL SUPPLY VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

199

8

OILING SYSTEM SERVICE CHART

SERVICE CHART

Engine Oil Programming Labels XD 30 XD 50 (Yellow)

*IMPORTANT*

*IMPORTANT*

This outboard has been programmed ® for use of Evinrude®/Johnson TCW3RL OIL

is outboard has Th been programmed for use of rude®/Johnson® Evi XD100™ oil. n your Dealer if See

See your Dealer if you decide to discontinue using Evinrude/Johnson

TCW3RL OIL Refer to the Operator’s Guide for Oil Requirements. P/N 351520

XD 100 (Blue)

you decide to discontinue using Evinrude/Johnson XD100 oil. Refer to the Operator’s Guide for Oil Requirements. P/N 351520

XD 100 Tank Label (Accessory)

*IMPORTANT* This outboard has been programmed for the use of Evinrude®/Johnson® XD100™ outboard oil ONLY. Failure to use Evinrude/Johnson XD100 outboard oil may harm engine performance and shorten engine life. EVINRUDE.COM

XD 100 Boat Label

P/N 352369

*IMPORTANT*

WWW.EVINRUDE.COM P/N 352927

This outboard has been programmed for the use of Evinrude®/Johnson® XD100™ outboard oil ONLY. Failure to use Evinrude/Johnson XD100 outboard oil may harm engine performance and shorten engine life.

60-80 in. lbs. (7-9 N·m) Arrow faces incoming oil

005360

200

OILING SYSTEM COMPONENTS

COMPONENTS The oiling system consists of the following components: • Oil tank • Oil injection pump and manifold assembly • Oil pressure sensor • Electrical circuit • LOW OIL (SystemCheck) and NO OIL warning signals (EMM LED’s, SystemCheck and I-Command) • Cylinder and crankcase • Rear oil manifold assembly • Oil recirculation system

Oil Pick-up Components • Pickup hose • Sending unit, LOW OIL warning, and oil pickup • Filter • Primer bulb and supply hose 4

1

3

Oil Tank

2

The oil tank must be properly positioned and the oil supply must be properly monitored. Refer to installation instructions provided with oil tank and Oiling System Set-Up on p. 43 for additional information.

1. 2. 3. 4.

Pickup hose Sending unit Filter Primer bulb and oil supply hose

42785

Oil Injection Pump

Oil Tank Components • Tank, 1.8 or 3.0 gallon capacity • Oil pickup assembly (included with tank) • Fill cap (included with tank) • Mounting bracket and hardware • Protective cover (1.8 gallon tank only) • Hose clamp • Hose plug

The oil injection pump is an electric (55 V) actuator style pump. It draws oil from the oil tank through the oil supply hose [25 ft. (7.6 m) maximum] and supplies pressurized oil to the oil manifold. The EMM supplies 55 V and controls activation of the pump.

2

1

1. Oil injection pump 2. Oil manifold 1.8 Gallon Oil Tank Kit

44839B

005371

The oil manifold distributes the oil supplied by the oil injection pump. A pressure-sensor monitors the oil injection pressure. Refer to Oil Injection Pump Diagram on p. 203

201

8

OILING SYSTEM COMPONENTS

Oil Pressure Sensor

Electrical Circuit (55 V)

The oil pressure sensor reacts to changes in oil manifold pressure. The EMM supplies and monitors electrical current to the sensor.

The oil injector is powered by the 55 V electrical circuit. The EMM controls injection pump operation by opening and closing the circuit’s ground. Circuit components: • Oil injection pump winding • Main wire harness and connections • EMM, oil injection pump control function • System voltage (55 V): stator, rectifier/regulator (EMM) • Ground circuits, EMM and oil injection pump

1

Refer to Oiling System Electrical Diagram on p. 204 and OILING SYSTEM TESTS on p. 218. 1. Oil pressure sensor

005371

The sensor provides an output voltage to the EMM based on oil manifold pressures. Oil Pressure Sensor Information: 5 VDC Input on RED wire 0.5 - 4.5 V Output on TAN / WHITE wire Ground on BLACK wire

The EMM monitors the oil injection pump electrical circuit. If circuit voltage is beyond the specified range (open circuit), the EMM: Activates S.A.F.E. Initiates and stores a service code 34 Initiates EMM NO OIL/OVERHEAT FAULT (LED 4) Initiates the SystemCheck or I-Command “NO OIL” warning

The EMM monitors the oil pressure sensor’s electrical circuit. If circuit voltage is beyond the specified range (< 0.12 V, > 4.88 V), the EMM: Stores a service code 71 Initiates EMM SENSOR FAULT (LED 3) If oil pressure is below expected range (< 0.5 V), the EMM: Stores a service code 72 Initiates EMM SENSOR FAULT (LED 3) If oil pressure is above expected range (> 4.5 V), the EMM: Stores a service code 73 Initiates EMM SENSOR FAULT (LED 3) Refer to Oil Pressure Sensor on p. 99.

202

Stored Faults Review Screen

005143

OILING SYSTEM COMPONENTS

Oil Injection Pump Diagram 8 6

5

4

9

3

8 1

1. 2. 3. 4. 5. 6. 7. 8. 9.

Oil supply hose Inlet check valve Oil injection pump Injection pump check valve Oil distribution manifold Filter (screen type) Oil pressure sensor Oil distribution hoses to individual cylinders Oil distribution hose to rear manifold

2

7

004296r

203

OILING SYSTEM COMPONENTS

Oiling System Electrical Diagram 1

14 15 16 17 18 19

20 21 22 23 24 25 26 26 27 28 29 30 31 32 33 34

8 9 10 11 12 13

1 2 3 4 5 6 7

18 19 20 21 22 23 24 25

5 4 3 2 1

5

10 11 12 13 14 15 16 17

J1-A

6

7

8 24 25 26 27 28 29

8

3

4

20 21 22 23

11 12 13

14 15

16 17

18 19

J2 5 6 7 8 9 10

2

1 2 3 4 5 6 7 8 9

J1-B

1 2 3 4

3

4

1. 2. 3. 4. 5. 6. 7. 8.

Oil Injection Pump EMM 55 V Circuit (WHITE/RED) Grounds, NEG (BLACK) EMM to Oil Solenoid (BLUE) Oil Pressure Sensor, +5 V analog (RED) Oil Pressure Sensor Signal (TAN/WHITE) Capacitor

005358

204

OILING SYSTEM COMPONENTS

SystemCheck, I-Command and EMM Oiling System Warnings Evinrude outboards can be monitored by SystemCheck or Evinrude E-TEC 115-250 HP outboards can be equipped with the I-Command Integrated Performance System (CANbus network based on NMEA 2000 † standards.) Both systems warn the operator of a “NO OIL” condition.

Cylinder and Crankcase The primary oil distribution manifold provides crankcase lubrication through oil distribution hoses and pressed-in fittings at the front of the crankcase, port side.

LOW OIL Warning A sending unit in the oil tank pick-up assembly monitors the oil level in the tank. This sending unit is designed to activate the SystemCheck “LOW OIL” light when the oil level falls below one-quarter capacity.

1

1. Pressed-in fittings

005359

The rear oil distribution manifold provides lubrication for each cylinder. Each cylinder of the cylinder/crankcase has a pressed-in fitting which is connected to an oil distribution hose. SystemCheck

I-Command

Warning System Gauges

DR5206 005330

8 1

An optional oil tank sending unit kit is available to interface with the I-Command System. The I-Command System does not provide a “LOW OIL” warning.

NO OIL Warning The EMM monitors the electrical circuit of the oil pressure sensor. If the sensor or circuit fails, or if there is a lack of oil pressure in the oil distribution manifold, the EMM:

1. Rear oil manifold

005347

Activates S.A.F.E. Stores a service code 38 Initiates EMM NO OIL/OVERHEAT FAULT (LED 4) Initiates the SystemCheck or I-Command “NO OIL” warning Refer to External Sensors on p. 98.

205

OILING SYSTEM COMPONENTS

Oil Supply and Distribution Diagrams – V6

Oil Injector / Hose Routing Diagram 150-200HP/60ºV6- Evinrude E-TEC

Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3, #4, #5 and #6 crankcase fittings Primary Oil Manifold

6

4

4 5 3 7 6 2 1

Cylinder 6 Cylinder 5 Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 Auxliary oil manifold

1. 2. 3. 4. 5. 6. 7.

Cylinder 2 Cylinder 4 Cylinder 6 Cylinder 5 Cylinder 3 Cylinder 1 Upper main bearing

8

5 4 5 3 7 6 2 1

7

Rear Oil Manifold

Rear oil manifold delivers oil to: - Upper main bearing - #1, #2, #3, #4, #5 and #6 cylinder sleeves

3

1. 2. 3. 4. 5. 6. 7. 8.

Oil tank assembly Oil pick-up Oil supply hose Oil filter Oil pump assembly Oil distribution hoses Oil pressure switch Auxiliary oil manifold

1. 2. 3. 4. 5. 6. 7. 8.

206

1. 2. 3. 4. 5. 6. 7.

2

1 005357

Oil tank assembly Oil pick-up Oil supply hose In-line oil filter Oil injector assembly Oil distribution hoses Oil pressure sensor Rear oil manifold

OILING SYSTEM COMPONENTS

Port Side View

Starboard Side View

8

005356

207

OILING SYSTEM COMPONENTS

Oil Supply and Distribution Diagrams – V4 Primary oil manifold delivers oil to: - Auxiliary oil manifold - #1, #2, #3 and #4 crankcase fittings Primary Oil Manifold

6

3 4 5 2 1

1. 2. 3. 4. 5.

Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 Auxliary oil manifold

1. 2. 3. 4. 5.

Cylinder 2 Cylinder 4 Cylinder 3 Cylinder 1 Upper main bearing

8

5 4 3 4 5 2 1

7

Rear Oil Manifold

3

Rear oil manifold delivers oil to: - Upper main bearing - #1, #2, #3 and #4 cylinder sleeves 1. 2. 3. 4. 5. 6. 7. 8.

Oil tank assembly Oil pick-up Oil supply hose Oil filter Oil pump assembly Oil distribution hoses Oil pressure switch Auxiliary oil manifold

2

1 005355

1. 2. 3. 4. 5. 6. 7. 8.

208

Oil tank assembly Oil pick-up Oil supply hose In-line oil filter Oil injector assembly Oil distribution hoses Oil pressure sensor Rear oil manifold

OILING SYSTEM COMPONENTS

Port Side View

Starboard Side View

8

005354

209

OILING SYSTEM COMPONENTS

Oil Recirculation System

Crankcase / Main Bearing Recirculation

External hoses and fittings, internal cylinder/crankcase passages, and intake manifold passages are used to “recirculate” any accumulation of oil from various locations in the powerhead. The movement of oil in these “oil circuits” is controlled by check valves.

The movement of oil through the main bearings is controlled by internal passages, external fittings and hoses, and check valves.

Cylinder Recirculation Internal powerhead oil drain passages connect the intake port areas of the cylinders to circulate residual oil in the block. External fittings and in-line check valves on each side of the cylinder block control the movement of oil from the lower cylinder port to the upper cylinder port.

Oil moves from the crankcase areas of the higher cylinders through grooved passages in the crankcase to the center and lower main bearings. Additional oil moves through intake manifold passages to the crankcase and lower main bearing. External Hoses and Check Valves Oil moves from the lower main bearing cavity to an external hose with in-line check valve and to the upper main bearing. Additional oil from the rear oil manifold is supplied to this oil circuit. Oil moves from Intake manifold passages to external check valve fittings and hoses and to the upper main bearing.

005325r 005324r

210

OILING SYSTEM COMPONENTS

Recirculation Hose Routings and Check Valve Diagrams – V6 Port Side View

Oil from auxiliary oil manifold

8

Starboard Side View

Check valves

005353

211

OILING SYSTEM COMPONENTS

Direction of flow*

Check valves Main bearings to cylinders

Direction of flow* Check valves - Intake manifold to lower main bearing

* All check valves are oriented with direction of flow towards cylinders 005352

212

OILING SYSTEM COMPONENTS

Recirculation Hose Routings and Check Valve Diagrams – V4 Port Side View

Oil from auxiliary oil manifold

Starboard Side View

8

Check valve

005351

213

OILING SYSTEM COMPONENTS

Direction of flow*

Check valves Main bearings to cylinders

Direction of flow* Check valves - Intake manifold to lower main bearing

* All check valves are oriented with direction of flow towards cylinders

005350

214

OILING SYSTEM PRIMING

PRIMING

Oil Distribution Manifold Priming WARNING

To prevent injury from contact with rotating propeller, always remove the propeller before running on a flushing device. The oiling system of the outboard must be primed: • After the initial installation of the outboard (predelivery); • Whenever the oil supply to the oil lift pump is disconnected or disrupted; and • Whenever an oiling system component is removed or replaced.

Oil Hose Connections WARNING

Follow these steps for initial outboard set-up: • Position outboard in lowest trim/tilt position. • Squeeze the oil primer bulb to flow oil from the hose connection, through the filter, to the oil pump. • Visually inspect filter to ensure that all air has been purged. • Continue squeezing the primer until oil flows through the distribution manifold into the oil distribution hoses and to the crankcase fittings. All air must be eliminated from oil lines. • Use the Evinrude Diagnostics Software program to confirm that the EMM is programmed for the type of oil being used. • Start the outboard and use the oil priming function in the software for a minimum of 90 seconds to make sure the system is completely primed.

Always use caution while working around machinery with moving parts. The following set-up procedures require running tests that are performed with the outboard’s motor cover removed.

1

8

Insert the end of the oil supply hose (from the oil tank) into a suitable container. Squeeze the oil primer bulb to flow oil from the oil tank. Once oil flow is observed, connect the oil tank hose to the outboard’s oil supply hose and secure with 14.5 mm Oetiker clamp.

Dynamic Tests Screen 1. Prime Oil button

005137

215

OILING SYSTEM PRIMING Observe oil flow through all oil distribution hoses.

Small bubbles are acceptable. Large bubbles must be eliminated through a continued priming process.

1 1

3 1. Crankcase oil distribution hoses (port side)

005348

Make sure that oil flows through the rear oil distribution manifold to the cylinder block fittings.

2

1. Oil distribution hose 2. Small bubbles 3. Large bubbles

004398

IMPORTANT: All clear “blue” oil distribution hoses on the powerhead should fill with oil as the air is purged from the lines. Repair any fuel or oil leaks.

1

1. Rear oil distribution manifold

216

005271

The oiling system can also be primed using the Self-Winterizing feature if diagnostic software is not available. Refer to STORAGE on p. 91.

OILING SYSTEM OILING RATES

OILING RATES

XD100 Outboard Oil Decal

EMM programming controls the rate of oil injection. Use engine diagnostics software to access this EMM feature.

Oil Injection Rate The TC-W3 OIL control setting allows the outboard to be run on TC-W3 outboard lubricant. Changing to the optional XD100 OIL CONTROL setting requires the use of Evinrude XD100 outboard lubricant. Running the outboard in XD100 OIL mode can reduce oil consumption by approximately one third. See Oil Control on p. 109.

Evinrude/Johnson XD100 oil decals are available to label boats equipped with Evinrude E-TEC outboards that have been programmed for the XD100 oil injection ratio. Use the XD100 Outboard Oil Decal, P/N 352369, to accurately inform the boat operator of the XD100 outboard oil requirement.

1

XD100 Outboard Oil Decal

004522

Install decal(s) in one or more of the highly visible recommended locations to alert the outboard operator(s). 1. Oil control setting

005140

Powerhead oil programming labels are provided to identify EMM oil programming. Install the correct label to alert user to specific oil requirements.

IMPORTANT: Make sure the engine label and boat decal match EMM programming. 2 1

Recommended Locations: • Dashboard/deck of boat, adjacent to key switch • Deck of boat, adjacent to the remote oil fill • Deck of boat, adjacent to oil tank assembly • Oil tank cover • Cover of oil tank compartment • Attach to oil tank or oil fill cap

IMPORTANT: Make sure the engine label and boat decal match EMM programming. An optional XD100 Oil Tank Tag, P/N 352927, is available to label oil tanks on outboards programmed to operate on XD100 outboard oil.

Break-in Oiling The Break-in Oil setting doubles the oiling ratio for the first two hours of operation above 2000 RPM. See Oil Control on p. 109. 004964 1. Evinrude /Johnson XD30 outboard lubricant (TC-W3) YELLOW label 2. Evinrude /Johnson XD100 outboard lubricant (Premium) BLUE label (Installed)

217

8

OILING SYSTEM OILING SYSTEM TESTS

OILING SYSTEM TESTS IMPORTANT: Always perform visual inspections to identify oiling system leaks. Make sure the oil tank is filled and oil supply is not contaminated.

Oil Injection Pump Static Test IMPORTANT: Static tests are performed with the outboard not running. Use the Evinrude Diagnostics Software program to activate Oil Injection Pump test. This initiates the EMM control function for the oil injection pump. Oil injection pump should activate with key switch in the ON position.

Oil Injection Pump Voltage Test Acceptable voltage readings: • Key switch ON: approximately 30 V • Outboard running: 55 V STEP 1 Check voltage at pin 1 (white/red wire) of oil injection pump electrical connector with key switch ON. Results:

• Approximately 30 V is acceptable with outboard not running. See Oil Injection Pump Circuit Resistance Test on p. 219. • No voltage reading, proceed to STEP 2. STEP 2 Run outboard. Check system voltage using diagnostic software program. The alternator/system output wires (white/red) are terminals 19 and 29 of the EMM J2 connector. If needed, use Electrical Test Probe Kit, P/N 342677, and a multimeter set to read 55 VDC to check engine harness voltage readings.

1 Results:

• Proper voltage reading, inspect connections

Static Tests Screen 1. Oil injector test button

005146

The EMM provides ground to pin 2 (blue wire) of oil injection pump electrical connector. Refer to Oil Injection Pump Voltage Test on p. 218.

218

and wiring. Replace faulty wire harness or connector. • No or low voltage, check connections from EMM and stator to engine wire harness. Repair faulty connection or refer to STATOR TESTS on p. 141 for testing procedures. STEP 3 Use Electrical Test Probe Kit, P/N 342677, and a multimeter set to read 55 VDC. Check voltage at

OILING SYSTEM OILING SYSTEM TESTS pin 2 (blue wire) of oil injection pump connector. Key switch must be ON.

Oil Injection Pump Circuit Resistance Test The oil injection pump circuit includes the engine wire harness, the injection pump winding and connector, and the oil injection control circuit of the EMM. Disconnect the battery cables at the battery. Use Electrical Test Probe Kit, P/N 342677, to make a connection to pin 23 of the EMM J1-B connector.

1

1. Oil injection pump connector (pin 2)

005442

Results: • Approximately 30 V is acceptable, leave adapter connected, proceed to STEP 4. • No voltage, refer to Oil Injection Pump Circuit Resistance Test on p. 219. STEP 4 Activate oil injector using the Evinrude Diagnostics Software program. Monitor the voltage on oil injector pump circuit at pin 2 of oil injection pump connector.

Calibrate ohmmeter to the LOW OHMS scale and measure the resistance between pin 23 of the EMM J1-B connector and pin 1 of oil injection pump connector. Oil Injection Pump Circuit Resistance 2 to 3 Ω

1

8 2

1 1. EMM J1-B connector (pin 23) 2. Oil injection pump connector (pin 1)

Static Tests Screen 1. Oil injector test button

005146

005443

Results: • An infinite reading (∞) indicates an open circuit. Isolate the faulty wiring, connection, or injection pump winding. Repair faulty wiring or replace faulty component and retest. • For a higher than expected reading, test resistance of the injection pump. If injection pump resistance reading is approximately 2-3 Ω, injection pump winding is good. Isolate faulty component. Repair faulty wiring or replace faulty component and retest.

219

OILING SYSTEM OILING SYSTEM TESTS

Oil Supply Vacuum Test WARNING Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa). Remove the oil pick-up assembly from the oil tank. Carefully remove the pickup filter and flush with a mild solvent to remove any contamination. Reinstall filter.

Attach a vacuum tester to the outboard side of oil supply hose and draw 7 in. Hg (24 kPa) vacuum on the hose for at least five minutes. Repair or replace any leaking components. Reinstall the oil hose. Check height of pickup assembly. Pickup Assembly Height 6.84 to 6.96 in. 1.8 gallon tank (174 to 177 mm) 8.74 to 8.86 in. 3.0 gallon tank (222 to 225 mm)

Carefully remove the oil hose from the oil pickup and remove the oil supply hose from the oil injection pump. Use low pressure air to purge oil from hose.

1 3 2 1. Oil hose 2. Oil pickup 3. Low pressure air

Height of Oil Pickup Assembly

12306

Use Plug/Holder, P/N 329661, and clamp to plug the pickup end of the hose.

COB5657A

Position a new seal on oil tank and reinstall pickup with filter into oil tank. Install and tighten screws.

Oil Injection Pump Function Test This test may be performed in two different ways:

Running Test 2 1

1. Plug/holder 2. Oil hose

220

12307

Remove oil distribution hose from fitting at cylinder block. Start and run the outboard at IDLE speed and observe oil flow. Confirm that a small amount of oil is discharged while injection pump is activated

OILING SYSTEM OILING SYSTEM TESTS

Oil Injection Fittings Flow Test

Static Test Remove oil distribution hose from fitting at crankcase. Squeeze oil supply primer bulb to provide oil to injection pump.

1

WARNING To prevent accidental starting while servicing, disconnect battery cables at the battery. Confirm that the oil injection fittings of the cylinder and crankcase assembly allow fluid to move. Remove oil distribution hose from fitting. Connect 1/8 in. I.D. (3 mm) clear vinyl tubing to the fitting. Use a syringe filled with isopropyl alcohol to force fluid through the fitting.

TYPICAL 1. Fitting at crankcase

005348

Use the oil injector test of the Evinrude Diagnostics Software program to activate injector. Confirm that a small amount of oil is discharged while injection pump is activated.

LOW OIL Sending Unit Test Remove the oil from the oil tank, and turn the key switch ON. The LOW OIL light/warning of the SystemCheck gauge should activate. Once the warning has been verified, turn the key switch ON and refill the oil tank. Confirm that the LOW OIL warning stops as the oil level exceeds one-quarter of oil tank’s capacity.

8 1

Static Tests Screen 1. Oil injector test button

005146

Results: • Oil flows from distribution hose, compare to oil flow at other distribution hoses. • No oil discharge, compare to oil flow at other distribution hoses. If one or more hoses fail to discharge oil, check for a kinked or restricted hose before replacing the oil injection pump assembly.

221

OILING SYSTEM OIL COMPONENT SERVICING

OIL COMPONENT SERVICING

Once hose is removed from the manifold, make sure hose support is in the end of the hose.

2 WARNING To prevent accidental starting while servicing, disconnect the battery cables at the battery.

IMPORTANT: Access to certain oil distribution hoses requires removal of various engine components. Refer to service information in the various sections of this manual for additional information related to the removal and installation of specific components. DO NOT disassemble or replace any oiling system components until you are familiar with the entire OILING SYSTEM section.

1

1. Retainer mechanism 2. Hose support

005349

Oil Distribution Hoses The oil distribution hoses from each manifold MUST be the same length. DO NOT alter the length of any hoses. Oil Distribution Hose Length Primary oil manifold to 12 in. (305 mm) cylinder block fitting Rear oil manifold to 32 in. (812 mm) cylinder block fitting Rear oil manifold to 32 in. (812 mm) primary oil manifold* *Rear oil manifold to primary oil manifold hose has a 0.160 in. I.D. (P/N 352949)

Removal The oil distribution manifolds have oil hose retainer mechanisms incorporated into the design. Release the hose by depressing the outer ring of the hose retaining mechanism.

1

1. Hose support

DSC0290

Installation Installation is essentially the reverse of removal. Pay close attention when performing the following additional tasks. Use Replacement Oil Hose, P/N 778708, or equivalent. Insert hose support in manifold end of hose.

IMPORTANT: DO NOT reinsert the hose into manifold without the hose support. Be sure the hose is fully inserted into manifold. The insertion depth of hose into the manifold is 5/8 in. (16 mm). Visually inspect for hose supports. Hose supports are seen through hoses.

222

OILING SYSTEM OIL COMPONENT SERVICING Connect oil hoses to crankcase fittings and fasten with tie straps.

Oil Injection Pump Removal Disconnect the battery cables at the battery. Remove engine cover and air silencer. Remove the oil supply hose from the fitting (inlet) of the oil injection pump.

1

Disconnect the electrical connector.

IMPORTANT: Make sure oil distribution hose routings are noted before proceeding with disassembly. Center hose from primary oil manifold connects to oil to inlet of rear oil manifold. This hose has a 0.160 in. I.D.

1. Crankcase fitting

005348

Connect oil hose to rear oil manifold.

Remove the oil distribution hoses from the crankcase fittings. Remove oil injection pump bracket clamps and screws.

1

8 1. Oil to rear manifold

1

Oil Injector-Manifold Bracket 1. Clamp

005346

Remove the oil injection pump assembly.

005347

Install oil pump bracket and retaining screws. Torque small screw to 24 to 36 in. lbs. (3 to 4 N·m) and longer screw to 96 to 120 in. lbs. (11 to 13.5 N·m). Position the oil injection pump assembly on bracket and install 60.5 mm Oetiker clamp.

IMPORTANT: The oil injection pump and manifold is an assembly and cannot be serviced as individual components.

Installation Route oil distribution hoses from the oil distribution manifold to the crankcase oil delivery fittings as they were prior to removal. Refer to Oil Supply and Distribution Diagrams – V6 on p. 206 and Oil Supply and Distribution Diagrams – V4 on p. 208.

1

1. Clamp

005346

223

OILING SYSTEM OIL COMPONENT SERVICING Reconnect the electrical connector.

IMPORTANT: Use oil primer bulb to purge oil supply hose before reconnecting hose to oil pump. Reconnect oil supply hose to the inlet fitting of oil pump. Fasten with Oetiker clamp.

2 1

TYPICAL 1. Oil supply hose 2. Oetiker clamp

005346

Make sure oiling system is primed. Check oil flow through oil distribution hoses. Check oil system operation and routing of oil hoses. Refer to PRIMING on p. 215. Run the outboard and check for leaks. Repair any oil leaks and any kinked or misrouted hoses. Reinstall the air silencer and engine cover.

224

COOLING SYSTEM

COOLING SYSTEM TABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 IDLE OPERATING TEMPERATURE TROUBLESHOOTING (BELOW RANGE) . . . . . . . . . . . . . . . . . . . . . . . 229 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 ADAPTER/INNER EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 VAPOR SEPARATOR AND EMM COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

9

225

COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS

HOSE ROUTING AND WATER FLOW DIAGRAMS V4 MODELS

6

Hose Routing & Water Flow Diagram 115HP/60°V4

6

10

7 9

11

8 5 4

12

1. Water intake screens 1. Water intake screens 2. Water pump 2. Water pump 3. Water tube Water tube 4. Adapter 3. housing 4. Adaptor/exhaust housing 5. Cylinder block 5. 6. ThermostatCylinder block Thermostat 7. Pressure6.valve 7. Pressure valve 8. Cylinder head, water outlet 8. Cylinder head, water outlet 9. Cylinder block vent 9. Cylinder block vent 10. Water supply to EMM 10. Water supply to EMM 11. Water supply, EMM to vapor separator 11. Water supply, EMM to vapor separator 12. Vapor separator to overboard indicatorindicator 12. Vapor separator to overboard Outgoingwater water (warm/hot) Outgoing (warm/hot) Incomingwater Water(cool) (cool) Incoming

226

3

2

1

COOLING SYSTEM HOSE ROUTING AND WATER FLOW DIAGRAMS

HOSE ROUTING AND WATER FLOW DIAGRAMS V6 MODELS

6

Hose Routing & Water Flow Diagram 150-200 HP/60°V6

6

10

7 9 11 8 5 4 12

9

1. Water intake screens 1. Water intake screens 2. Water pump 2. Water pump 3. Water tube 3. Water tube 4. Adapter4.housing Adaptor/exhaust housing 5. Cylinder5.block Cylinder block 6. Thermostat 6. Thermostat 7. valve Pressure valve 7. Pressure Cylinder head, water outlet 8. Cylinder8.head, water outlet Cylinder 9. Cylinder9.block ventblock vent 10. Water 10. Water supply to supply EMM to EMM 11. Water supply, EMM to vapor separator 11. Water supply, EMM to vapor separator 12. Vapor separator to overboard indicator 12. Vapor separator to overboard indicator Outgoing (warm/hot) Outgoingwater water (warm/hot) Incomingwater Water (cool) (cool) Incoming

3

2

1

227

COOLING SYSTEM ENGINE TEMPERATURE CHECK

ENGINE TEMPERATURE CHECK IMPORTANT: The engine temperatures listed

Software Method Use the Evinrude Diagnostics Software program. Observe temperature displays for port and starboard temperature sensors.

below are based on an intake water temperature of 70° ± 10°F (21° ± 3°C).

CAUTION When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Install correct test propeller and place outboard in a test tank or in the water. Start outboard and run at 3000 RPM in FORWARD gear for at least five minutes. Reduce outboard speed and run engine at IDLE for five minutes. Check IDLE operating temperature. Increase outboard speed to 5000 RPM and check temperature. Check temperature on both sides of powerhead. If engine temperature is not within range, troubleshoot cooling system. Remember, running outboards at high speeds in test tanks may disrupt water flow to water intakes of the gearcase. Make sure the outboard has adequate water flow.

Engine Monitor Screen

005141

Typical temperature displays at IDLE speed should be 160°F ± 20°F (71°C ± 11°C). Typical temperature displays at WOT speed should be 120°F ± 20°F (50°C ± 11°C). At 5000 RPM, operating temperature must not exceed 194°F (90°C).

Pyrometer Method Use a Temperature Gun, P/N 772018, or a digital pyrometer to accurately determine the outboard’s operating temperature. Position infrared beam or pyrometer pickup on the thermostat housing at the top of cylinder head. Check temperature on both sides of powerhead.

Temperature Gun, P/N 772018

228

005389

COOLING SYSTEM ENGINE TEMPERATURE CHECK Pressure Relief Valve The pressure relief valve should be closed at IDLE speed. Water should not flow past the plunger and seal. Check for damage or debris that could prevent the valve from closing completely. Replace pressure relief valve if necessary. Refer to PRESSURE RELIEF VALVE SERVICING on p. 233. 005390

Typical pyrometer temperature displays at IDLE speed should be 150°F ± 20°F (66°C ± 11°C).

IMPORTANT: If you get low or inaccurate readings during these tests, coat the probe location of the digital pyrometer with a liberal amount of Thermal Joint Compound, P/N 322170. If engine temperature tests within range, but the SystemCheck gauge indicates a “WATER TEMP” warning, refer to WATER TEMP/ HOT Circuit Test on p. 146.

Thermostats If IDLE temperature is still below operating range, inspect thermostats and thermostat seals. Check position of thermostat seal and how thermostat seals against cylinder head. Seal must be properly fitted to flange of thermostat.

1

Idle Operating Temperature Troubleshooting (Below Range) If engine temperature is below operating range, check pressure relief valve and thermostat operation. Remember, cold running outboards prevent spark plugs from achieving proper operating temperatures and may decrease spark plug life.

1. Thermostat seal

005392

Check thermostat for cracks, heat damage, or signs of corrosion. Check for proper operation. Thermostat opens at 143°F (62°C). Refer to THERMOSTAT SERVICING on p. 233.

229

9

COOLING SYSTEM COMPONENTS

COMPONENTS General Description All models use a two-stage cooling system design. The cooling system is dependent on water pump pressure and controlled by thermostat and pressure valve operation.

2 3

IMPORTANT: Restricted or inadequate water flow through the outboard reduces cooling system performance and may lead to severe powerhead damage.

Water Pump and Intakes External water intakes mounted in the gearcase housing collect water and must supply the inlet side of the water pump with an unrestricted and unaerated water supply. Water is drawn into the water pump through a hole in the lower plate of the water pump assembly. All cooling water to the powerhead is provided by the water pump. • A nylon wedge (impeller key) is used to engage the impeller bushing and driveshaft. • The nylon impeller housing with stainless steel liner must seal against a separate stainless steel water pump plate. • The pump operates as a positive displacement pump at LOW speeds (below 1500 RPM) and as a centrifugal pump at HIGHER speeds. • The bottom plate MUST seal to gearcase housing. Refer to WATER PUMP on p. 311 for water pump servicing.

5

4 1

(Impeller key removed for clarity) 1. Water inlet 2. Water outlet 3. Seal 4. Plate 5. O-ring

000697 DSC02328

Water Supply Tube The water pump outlet connects with the water supply tube located in the outboard’s midsection. Grommets seal the water tube to the water pump housing and the inner exhaust housing. Water supplied to the water tube provides all cooling water to the adapter housing and cylinder block.

230

COOLING SYSTEM COMPONENTS

Adapter/Inner Exhaust Housing • Adapts the cylinder/crankcase assembly (pow-

Overcooling: Debris may prevent the valve from closing completely.

erhead) to the exhaust housing and the water tube. • Provides water passages which route incoming and outgoing cooling water. • Provides exhaust passages which connect to the lower inner exhaust.

1 Pressure Relief Valve Components

005391

Thermostats 20 in. models

Thermostats are used to control water flow and operating temperature at lower speeds (below 2500 RPM).

25 in. models

2

Overheating: Restricted or faulty thermostats typically result in LOW SPEED overheating. Overcooling: Debris may prevent the thermostat from closing completely.

9 25 in. models

1. Adapter/inner exhaust housing 2. Water tube(s)

005396

Pressure Relief Valve A pressure relief valve is used to control water flow and operating temperature at higher speeds (above approximately 2500 RPM / 21 PSI). Pressure relief valve activates or “blows-off the seat” as water pressure increases. Spring tension is used to set the “blow off” pressure. Overheating: A restricted or faulty valve typically results in HIGH SPEED overheating. (Minimum water pressure at 3000 RPM is 21 PSI.)

Thermostat

005392

Refer to THERMOSTAT SERVICING on p. 233.

Block Venting A fitting and hose from the top of the block allows the constant movement of water and/or air from the center water passage (top) of the block. Circulated water flows through the EMM to the Vapor Seperator and then overboard through the water outlet fitting in the rear exhaust grommet.

231

COOLING SYSTEM OPERATION

OPERATION Cylinder Block / Cylinder Head Cooling The flow of water through the cylinder block and cylinder heads is controlled by two thermostats and one external pressure valve. The pressure valve is connected by hoses to the top of the block and each cylinder head.

1

2

1

At higher speeds, water pressure increases. The pressure valve opens, or lifts off the seat, at approximately 2500 RPM. Water flows through the pressure valve and bypasses the thermostats. Hoses route the water flow from the pressure valve to the vertical water passages below the thermostats. All water flows through the cylinder heads to the outlet passages of the block and then exits through the adapter housing. This pressure controlled water outlet circuit provides a “high flow” discharge of water during high speed operation. This cooling system configuration provides “balanced cooling” at higher RPM by utilizing one pressure valve to control the discharge of water through both cylinder heads. Refer to HOSE ROUTING AND WATER FLOW DIAGRAMS on p. 226.

1. Thermostats 2. Pressure valve assembly

005393

The thermostats and pressure valve control the flow of water entering the vertical water passages of the cylinder heads. Water outlet passage at the bottom of each cylinder head aligns with a water outlet passage in the cylinder block. Water flows through the block to the adapter housing and then out of the outboard. At low speed, the pressure valve is against the seat and the thermostats are closed. Warm water from the top of the cylinder block gradually migrates to the thermostat pocket at the top of each cylinder head. Water movement is the result of water “bleeding” past the pressure valve and thermostats. The thermostat eventually opens as the water temperature in the system reaches 143°F (62°C). When thermostat opens, increased water flow is directed down the cylinder head water passage to the water outlet passage of the block. Water then exits through the adapter/exhaust housing.

232

Vapor Separator and EMM Cooling Cooling water is routed from the top of the cylinder block to the inlet fitting of the EMM and through the EMM water cavity. Cooling of the EMM minimizes the temperatures of internal components. Cooling water from the EMM is routed to the water inlet fitting of the vapor separator water cavity. Cooling the vapor separator fuel chamber minimizes fuel vaporization. Cooling water from the vapor separator is routed to the water outlet fitting in the rear exhaust grommet.

IMPORTANT: Improper EMM cooling will activate service codes (code 29 and 25) and initiate S.A.F.E. or SHUTDOWN. Refer to EMM DIAGNOSTICS on p. 104 for specific service code information.

COOLING SYSTEM THERMOSTAT SERVICING

THERMOSTAT SERVICING

PRESSURE RELIEF VALVE SERVICING

Disassembly

Pressure relief valve assembly should be serviced at the same time as the thermostats.

Remove the thermostat cover and O-ring from each cylinder head. Remove each thermostat.

Disassembly Remove the EMM. Refer to EMM SERVICING on p. 153. Remove the four screws holding the electrical harness base.

1 005394

1

Inspection Inspect all components for cracks, heat damage, or signs of corrosion. Replace damaged components. Clean debris from all housings and thermostat components.

1. Harness base screws

005378

Loosen electrical harness connections as necessary to lift harness base away from the pressure relief valve. Remove screws and cap from pressure valve assembly.

000756

Assembly

1

1

Assembly is essentially the reverse of disassembly. Pay close attention when performing the following additional tasks. Coat threads of each cylinder head thermostat cover with Gasket Sealing Compound. Install and tighten the cover to a torque of 120 to 144 in. lbs. (13.6 to 16.3 N·m). 1. Pressure valve cap screws

005395

Remove the pressure valve housing.

233

9

COOLING SYSTEM PRESSURE RELIEF VALVE SERVICING Remove the pressure valve components.

Inspection Inspect all components for cracks, heat damage, or signs of corrosion. Replace damaged components. Clean all debris from pressure relief valve components.

Assembly Assembly is essentially the reverse of disassembly. Pay close attention when performing the following additional tasks. Torque cap screws to 60 to 84 in. lbs. (7 to 9.5 N·m). 005391

234

POWERHEAD

POWERHEAD TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 CYLINDER COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 RETAINING RING PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 UPPER MOUNT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 V4 STARBOARD – HOSE ROUTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 V4 PORT – HOSE ROUTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 V4 STARBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 V4 PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 V4 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 V4 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 TOP – HOSE ROUTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 V4 – V6 TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 V6 STARBOARD – HOSE ROUTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 V6 PORT – HOSE ROUTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 V6 STARBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 V6 PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 V6 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 V6 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

235

10

POWERHEAD SERVICE CHART

SERVICE CHART 60-84 In. lbs. (7-9.5 N·m)

L M

B

B

120-144 In. lbs. (14-16 N·m)

Q H

A 168-192 In. lbs. (19-21.7 N·m)

B

40-50 In. lbs. (5-6 N·m)

J

L

A

60-84 In. lbs. (7-9.5 N·m)

A

IMPORTANT See - Spark Plug Indexing Procedure

L

15-30 Ft. lbs. (20-41 N·m)

40-50 In. lbs. (4.5-5.5 N·m)

L 40-50 In. lbs. (4.5-5.5 N·m)

H

T

31-35 Ft. lbs. (42-47.5 N·m)

60-84 In. lbs. (7-9.5 N·m)

B A 60-84 In. lbs. (7-9.5 N·m)

A 60-84 In. lbs. (7-9.5 N·m)

F

P F

120-144 In. lbs. (14-16 N·m)

F

120-144 In. lbs. (14-16 N·m)

A

120-144 In. lbs. (14-16 N·m)

20-22 Ft. lbs. (27-30 N·m)

B A

A

60-84 In. lbs. (7-9.5 N·m)

A A B D E F H J L M Q T

Triple-Guard Grease Gasket Sealing Compound Moly Lube

E 18-20 Ft. lbs. (24-27 N·m)

D

15-20 Ft. lbs. (20-27 N·m)

Red Ultra Lock Blue Nut Lock Outboard Engine Lubricant Thermal Grease Pipe Thread Sealing Compound RTV Sealant

A 110-130 Ft. lbs. (149-176 N·m)

Gel Seal II Liquid Neoprene

236

005230

POWERHEAD SERVICE CHART

A E

48 In. lbs. (5.5 N·m)

Must use Rod Alignment Tool. 30-32 Ft. lbs. (41-43 N·m)

H

H H

G

H H

H

A A B

10 A

005229 DSS135

A B E G H

Triple-Guard Grease Gasket Sealing Compound Red Ultra Lock Needle Bearing Grease Outboard Engine Lubricant

237

POWERHEAD GENERAL

GENERAL

Retaining Ring Pliers

Cylinder Compression Testing Start and run outboard until it achieves operating temperature, then shut OFF. Disconnect crankshaft position sensor (CPS) connector. Remove all spark plugs. Advance throttle linkage to WOT. Install compression tester’s hose attachment into spark plug hole (14 mm threads). While cranking outboard with starter, note maximum pressure reading on gauge. Repeat procedure for each cylinder. If engine shows a variation greater than 15 psi (100 kPa) between cylinders, check for: • damaged cylinder head • damaged pistons • broken or stuck piston rings • scored cylinder walls Return throttle to idle position and reconnect CPS connector. Replace spark plugs. Refer to Spark Plug Indexing on p. 160.

238

Retaining Ring Pliers

DRC2523

POWERHEAD REMOVAL Remove flywheel cover and rear shroud.

REMOVAL WARNING Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 189. To prevent accidental starting while servicing, disconnect the battery cables at the battery.

005248

Disconnect the power trim/tilt switch connector.

Remove air temperature sensor from air silencer. Remove the air silencer.

005246

Remove lower engine cover screws and port and starboard covers.

005272

Remove screw and washer from shift rod lever to release the lower shift rod.

10

1 1

1

1. Shift rod screw 1. Lower cover screws

005253

005242

239

POWERHEAD REMOVAL Disconnect power trim connectors.

ALL MODELS Disconnect water overflow hose from vapor separator. Remove clamps and muffler assembly from rear of powerhead.

1 1 2 2

1. Tilt limit switch connector 2. Sending unit connector

005254

1. Overflow indicator hose 2. Muffler clamps

1

Remove the four small powerhead screws, seven large powerhead screws, and the upper mount screws.

2 1. Tilt relay connector

005243

005255

3 2

V4 MODELS Disconnect electrical harness from exhaust valve actuator. It is not necessary to remove actuator from exhaust housing.

1 1. Large powerhead screws 2. Small powerhead screws 3. Upper mount screws

005273

Install Lifting Tool, P/N 342672, on crankshaft. Tighten mounting screw securely using an

1

1. Actuator connector

240

005247

POWERHEAD DISASSEMBLY Allen 1/4 in. hexagonal wrench. Attach suitable chain hoist to lifting tool.

DISASSEMBLY General To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location. Remove the electric starter. Refer to Starter Removal on p. 161. Remove fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 189.

005260

With weight of powerhead supported by hoist, use a suitable tool to carefully separate the powerhead from exhaust housing.

IMPORTANT: Do not damage the powerhead adapter mating surfaces when separating. Remove the powerhead.

Remove EMM, then remove electrical harness with flywheel cover base, starter solenoid, and trim relay module. Remove flywheel and stator. Refer to FLYWHEEL AND STATOR SERVICING on p. 154. Remove oil pump, rear oil manifold, and oil circulation hoses. Refer to OIL COMPONENT SERVICING on p. 222. Remove ignition coils and fuel injectors. Refer to Fuel Injectors on p. 193.

IMPORTANT: Mark injectors for proper cylinder location before removal. All injectors must be reinstalled in their original location. Improper injector installation can result in powerhead failure. Remove throttle cam screw and throttle lever screw.

10

005259

1

1. Throttle cam screw 2. Throttle lever screw

2

005293

241

POWERHEAD DISASSEMBLY Remove shoulder screw from shift arm and retaining screw from shift rod lever. Slide entire shift linkage assembly from crankcase.

Loosen in stages and remove the main bearing screws.

1

1

1

2 1. Main bearing screws (6 on V4; 8 on V6) 1. Shift arm screw 2. Shift lever screw

005313

005294

Remove the throttle body and reed plate assemblies. Refer to INTAKE MANIFOLD on p. 196. Remove pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on p. 233.

Using a 1/8 in. diameter pin punch, push crankcase taper pin toward intake manifold side.

IMPORTANT: Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin.

Crankcase Remove crankcase flange screws.

1

1 005305

Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to loosen. 1. Flange screws (12 on V4; 16 on V6)

242

005306

POWERHEAD DISASSEMBLY Carefully remove the crankcase from the cylinder block to avoid damaging the crankshaft seal rings.

Connecting Rods and Pistons Use a permanent marker to identify each connecting rod cap, connecting rod, and piston by cylinder number. Number 1 is closest to the flywheel.

005304

Cylinder Head

005292

Loosen in stages and remove cylinder head retaining screws. Remove the cylinder heads. Discard thermostat seals.

1

Use Torquing Socket, P/N 331638, to loosen in stages the rod cap retaining screws. DO NOT remove the screws.

1

005303 1. Cylinder head screws (28 on V4; 40 on V6)

10

005302

243

POWERHEAD DISASSEMBLY Using one hand to support the piston, remove the rod cap screws with your other hand. Remove each piston and rod assembly.

Use Retaining Ring Pliers, or equivalent, to remove wrist pin retaining rings. Discard retaining rings.

WARNING Wear safety glasses to avoid injury.

005301

IMPORTANT: Reattach each rod cap to its rod as soon as the piston is removed. Each cap is unique and can only be installed on its mated rod. Do not allow rod to contact inside surface of cylinder or crankshaft.

IMPORTANT: Identify all internal components so that if reused, they can be reinstalled in their original positions.

46524

The wrist pin fit is loose on both sides. Push the wrist pin through to free the piston from the connecting rod. If necessary, use Wrist Pin Pressing Tool, P/N 326356, to remove the wrist pin bearing.

Repeat steps for each remaining piston and connecting rod. Use an appropriate ring expander to remove all piston rings from pistons. Discard the rings.

WARNING Wear safety glasses to avoid injury.

46520

Be careful not to lose any of the 28 needle bearings or the two wrist pin washers. If any of the bearings are worn or lost, replace all 28 bearings during reassembly.

002054

244

POWERHEAD DISASSEMBLY If the lower crankshaft is to be resealed or the lower bearing replaced, remove the lower bearing seal housing.

Crankshaft WARNING Wear safety glasses to avoid injury. Carefully lift crankshaft straight up and remove from crankcase.

005280

Remove the housing O-ring. Discard O-ring.

005285

Remove upper seal from crankshaft. Discard the seal. A new upper seal must be installed on assembly.

002044

To remove the housing seal, use a punch as shown. Discard seal.

10 49068

1

1. Punch

002053

Inspect housing and replace if necessary.

245

POWERHEAD DISASSEMBLY Remove O-ring from crankshaft sleeve and inspect it. Replace the O-ring if it is not in good condition.

Using an appropriate bearing separator, support the bearing, place separator flats against the bearing, and press off the crankshaft.

29019

24383

Inspect the crankshaft sleeve and replace if necessary. To remove, use Slide Hammer, P/N 432128, and Large Puller Jaws, P/N 432129.

Remove and inspect crankcase seal rings. Identify each ring for installation in original location.

Remove the lower main bearing only if it needs to be replaced. Use external retaining ring pliers to remove the lower bearing retaining ring.

49069

Remove center main bearings and split sleeves for inspection. Do not mix parts. Note location of bearings for reassembly. 24384

24381

246

POWERHEAD CLEANING

CLEANING IMPORTANT: Before inspecting or assembling

Use Gel Seal and Gasket Remover to remove all traces of gaskets, adhesives, and Gel-Seal II™ sealant from the cylinder block and crankcase.

powerhead, all internal components must be completely clean and free of contaminants. Remove any carbon accumulation from exhaust port areas. Remove any carbon accumulation from cylinder head combustion chambers. If cylinder walls are glazed from extended use, use a rigid, medium grit cylinder hone to resurface walls. Use slow RPM for best oil retention and ring sealing. When finished, a cross hatch pattern of 22 to 32° should be visible in the cylinder wall. The pattern should be uniform in both directions.

IMPORTANT: To avoid piston or cylinder block damage, restore the chamfer to all port edges using a ball hone or other suitable tool.

2 1

005296

WARNING To avoid personal injury, wear eye protection and rubber gloves when using Gel Seal and Gasket Remover. Carefully remove any carbon accumulation from the tops and ring grooves of the piston using Engine Tuner. A ring groove cleaning tool can be made by breaking an old ring and grinding its end to an angle. DO NOT damage ring grooves while cleaning. Thoroughly wash entire cylinder block and crankcase with warm, soapy water to remove all traces of contaminants.

1. Crosshatch pattern in cylinder wall 2. Chamfered port edge

002067

Air dry cylinder block and crankcase. Blow all holes and passageways with compressed air.

WARNING To avoid personal injury, wear eye protection and set compressed air pressure at less than 25 psi (172 kPa). Cover the cylinder walls with a liberal amount of outboard lubricant to prevent corrosion.

247

10

POWERHEAD INSPECTION

INSPECTION

Crankshaft

For powerhead dimensions, refer to TECHNICAL DATA on p. 18.

IMPORTANT: Before any inspection process

Measure the diameter of each crankpin and main bearing journal. The lower main bearing journal would only be measured if the bearing was removed for another reason.

can begin, all internal components must be completely clean and free of contaminants. Visually inspect all parts. Check for unusual wear patterns, scuffing, or deterioration of aluminum parts, heat-related discoloration of bearings and bearing surfaces, and broken components.

Cylinder Head Check for cylinder head warpage using a piece of bar stock or machinist’s straightedge and a feeler gauge set. Cylinder head warpage must not exceed 0.003 in. (0.08 mm) per inch of measurement. Replace head if warpage exceeds this dimension.

005281

Visually inspect crankcase seal rings for wear, grooves, or chipping. If rings appear worn, use a micrometer to measure ring thickness. Replace rings that are less than 0.154 in. (3.9 mm) thick. Install seal rings in their original positions on crankshaft after inspection.

46517

1936

248

POWERHEAD INSPECTION

Cylinder Bore Use Cylinder Bore Gauge, P/N 771310, to inspect each cylinder bore for an out-of-round, oversize, or tapered condition. Be sure the gauge is perfectly square in the bore when measuring.

IMPORTANT: If any cylinder is outside these tolerances, it must be bored oversize. It is permissible to have one or more oversize pistons in an engine.

Pistons Visually inspect pistons for signs of abnormal wear, scuffing, cracks, or burning.

Piston Rings For new ring sets, place each ring separately in its respective bore. Use a piston to square the ring in the cylinder. Use a feeler gauge to measure the ring end gap.

Measure as shown

46528

Measure each cylinder in at least two areas. Each area should be measured twice. The difference between the two measurements in each area is the cylinder out-of-round dimension. • The cylinder must not be out-of-round by more than 0.004 in. (0.10 mm). The dimensional difference between the two areas is cylinder taper. • The cylinder taper must not exceed 0.002 in. (0.05 mm).

002143

Ring End Gap Specification Standard or Oversize rings

IMPORTANT: Ring end gap increases approximately 0.003 in. (0.08 mm) for each 0.001 in. (0.025 mm) increase in cylinder bore diameter. DO NOT exceed cylinder oversize dimension.

1

1. Cylinder taper

0.011 to 0.023 in. (0.28 to 0.58 mm)

DR3482

Use a machinist’s straightedge to check for proper ring clearance. Position piston rings on piston. Push rings into groove and hold straightedge against the side of the piston. Rings must be even

The difference between the measurements and standard bore is cylinder oversize. For dimensions, refer to TECHNICAL DATA on p. 18. • The cylinder must not be oversized by more than 0.004 in. (0.10 mm).

249

10

POWERHEAD ASSEMBLY or just below the surface of piston. Rings must move freely in piston ring groove.

ASSEMBLY IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant.

IMPORTANT: Use new wrist pin retaining rings, gaskets, seals, and O-rings during assembly.

Crankshaft 31796

Bearings

Oil the end of the crankshaft. Use Crankshaft Bearing/Sleeve Installer, P/N 338647, and place a new lower main bearing onto crankshaft with lettered side facing the tool. Install bearing until it seats on the crankshaft.

Inspect center main bearing and split sleeves for excess wear, nicks, or scratches. Replace, if necessary.

29020

24381

Inspect crankshaft rod bearings for excess wear, nicks, or scratches. Replace, if necessary.

Oil the end of the crankshaft. Place a new sleeve in the Crankshaft Bearing/Sleeve Installer, P/N 338647, and drive the sleeve onto the crankshaft until the installer contacts the lower main bearing.

29021 24377

250

POWERHEAD ASSEMBLY If the installer sticks on the sleeve after installation, thread Slide Hammer, P/N 391008, into installer and pull it off.

facing down. The seal lip faces the bottom of the crankshaft.

IMPORTANT: Inspect sleeve after installation. Sleeve must not be used if surface is damaged. Using retaining ring pliers, install bearing retaining ring with sharp edge facing away from bearing.

1

Lubricate a new driveshaft O-ring and lightly lubricate crankshaft splines with Moly Lube. Install O-ring in sleeve. 1. Extended lip

002036

1

1 2

1. Bearing retaining ring 2. O-ring

29022

Lubricate the center main bearings and split sleeves with outboard lubricant and install them in their original positions. The split sleeve ring grooves must face toward driveshaft (lower) end of crankshaft when installed.

1. Seal lip

002037

Lubricate a new lower seal housing O-ring with Triple-Guard grease and place the O-ring on the lower housing. Lubricate seal lip with Triple-Guard grease and place lower seal housing on crankshaft.

1

005282

Lightly coat the metal case of a new lower housing seal with Gasket Sealing Compound. Press against outer metal case of the seal and install seal in the lower housing with extended lip of seal

1. O-ring

005280

251

10

POWERHEAD ASSEMBLY Align bearings with Wrist Pin Bearing Tool, P/N 336660.

Pistons and Connecting Rods IMPORTANT: It is very important that the pis-

2

tons in this engine are oriented correctly. New pistons are stamped “PORT” or “STBD,” and “EXH.” These markings should be oriented to the exhaust side (center) of the block. As another reference, the splash bowl on the dome of the piston will be located toward the flywheel and opposite the exhaust port.

1

1. Wrist pin bearings 2. Tool, P/N 336660

31794

Place the two wrist pin thrust washers on the tool with flat side of the washers facing out.

1 1. Stamped markings

1

1 005283

IMPORTANT: It is also very important that the connecting rods are installed with the alignment dots and the diagonal oil hole facing up, toward the flywheel. 1

1. Wrist pin thrust washers

DR3480 31793

Oil the wrist pin bore and wrist pin. Place connecting rod, with bearings, washers, and tool, into the piston with the alignment dots facing the top of the piston.

2

1. Oil hole 2. Raised dots

002055

Apply Needle Bearing Grease to the wrist pin bearings. Install the bearings in the wrist pin bore.

252

46521

POWERHEAD ASSEMBLY Install wrist pin through piston and connecting rod, pushing bearing tool out through the piston. Use Wrist Pin Cone, P/N 318600, and Driver, P/N 318599, to install new wrist pin retaining rings in each wrist pin hole. Gap of retaining ring faces up, away from notch in piston.

Installing Pistons When all pistons and connecting rods are assembled, install piston ring sets. Be sure rings are installed in the cylinder used to test ring end gap.

IMPORTANT: Be sure gap of ring fits squarely around dowel pin.

002048 46522

IMPORTANT: Before continuing, make sure that all Gel-Seal II has been removed from the cylinder block and crankcase mating flanges. If traces of hardened Gel-Seal II are left, main bearings could be misaligned. Refer to CLEANING on p. 247. Coat pistons, rings, cylinder walls, and Ring Compressor, P/N 336314 (P/N 336313 for oversize pistons), with outboard lubricant.

1

2 1. Gap of retaining ring 2. Notch in piston

46523

Center connecting rod in piston and locate piston rings on dowel pins. Place appropriate ring compressor on piston.

10

Repeat steps for each piston.

253

POWERHEAD ASSEMBLY Slide piston and rod assembly into the correct cylinder, as marked during disassembly. Guide connecting rod through cylinder block to avoid scratching cylinder wall.

If it has been removed, apply soapy water to water dam and insert into block.

1 1

1. Water dam 1. Ring compressor

005284

Repeat steps for each piston.

Cylinder Head

Apply a 1/16 in. (2 mm) bead of RTV adhesive around each water passage on the block and cylinder head as shown. Apply adhesive with a brush around thermostat seat area on block.

Install a new thermostat seal in cylinder head with side marked “TO CYL HEAD” facing toward thermostat. Refer to THERMOSTAT SERVICING on p. 233 prior to installing cylinder heads.

005287

2

1

1

Lightly lubricate new cylinder head O-rings with Triple-Guard grease and install in cylinder block.

1 1. RTV adhesive (24 locations) 2. Thermostat seat area

005288

Install cylinder head. Apply outboard lubricant to threads and install the cylinder head screws. Following sequence on cylinder head, torque all 1. O-Ring

254

005286

POWERHEAD ASSEMBLY screws in stages to 168 to 192 in. lbs. (19 to 21.7 N·m).

1

1. Cylinder head screws (28 on V4; 40 on V6)

Thoroughly clean upper seal area of the crankshaft. Install new upper seal on crankshaft. Do not apply sealer to outside diameter of the seal.

1

005289 49068

Repeat steps for opposite cylinder head. Push all pistons to the top of cylinders. Remove numbered connecting rod caps.

Crankshaft and Connecting Rods

Gently lower crankshaft into place.

Rotate cylinder block so crankcase mating flange is facing up.

• Orient all crankcase seal ring gaps facing up. • Align tab on lower bearing seal housing with

Apply Gasket Sealing Compound to lower oil seal groove in cylinder block. DO NOT put any sealer in upper seal groove.

hole in crankcase. • Align upper oil seal in groove. • Locate each main bearing on its dowel pin. A mark placed on the bearing race opposite the dowel pin hole will help in the alignment process.

Check that main bearing alignment dowel pins are seated in the block.

1 2 1 3

1. Gasket Sealing Compound 2. Dowel pins 3. No sealer here

005290

2

3

4 1. 2. 3. 4.

Gaps (up) Lower seal housing Upper oil seal Alignment marks

005291

255

10

POWERHEAD ASSEMBLY Lubricate each crankpin and bearing assembly with outboard lubricant. Slowly pull connecting rod up to crankshaft and install bearing halves.

IMPORTANT: Be sure alignment dot on rod cap matches dot on rod and that both dots face flywheel.

1

1. Alignment dots 005298

Lubricate rod cap screw threads and under screw head mating surface with outboard lubricant. Align dot on rod cap with dot on the connecting rod. Install rod cap screws finger tight (NO MORE than 6 in. lbs. (1 N·m) maximum).

53628

IMPORTANT: Torquing

the screws without Alignment Fixture, P/N 396749, or using an incorrect procedure could cause permanent damage to the connecting rod and crankshaft. To maintain accurate torque values, keep torque wrench extension length to a minimum. Install Rod Cap Alignment Fixture, P/N 396749, before tightening rod cap screws. Align the flat marked “SET” on the rod engagement stop with the arrow on the frame. Position stop at the center setting (one line showing). Rotate adjustment knob 180° to lock in position.

1

49080

1. Center position, one line showing

256

002484

POWERHEAD ASSEMBLY Secure restraining jaw “C” and forcing jaw “D” to frame.

• Tighten the forcing screw to a torque of 14 to 16 in. lbs. (1.6 to 1.8 N·m).

1 2

3

Restraining Jaw “C”

21591c

1. Forcing screw 2. Adjustment stop 3. Groove line

005297

IMPORTANT: Make sure that frame is squarely in position and that rod and cap are aligned. Loosen both rod cap screws one-quarter turn.

Forcing Jaw “D”

21594c

Apply a light coat of outboard lubricant to the corners of the connecting rod and rod cap. Place frame on connecting rod using the following procedure: • Position frame onto the connecting rod so the contact area of the jaw is centered on the side of the rod. • Tighten forcing screw until jaws contact connecting rod. • Slide frame down until adjustment stop contacts the rod cap. The groove lines on the jaws must be centered on the rod/crankpin diameter.

Use Torquing Socket, P/N 331638, to tighten rod cap screws in three stages: • Apply an initial torque of 40 to 60 in. lbs. (5 to 7 N·m) to both rod cap screws. • Torque screws to 14 to 16 ft. lbs. (19 to 21.7 N·m). • Apply a final torque of 30 to 32 ft. lbs. (41 to 43 N·m).

10

005299

Loosen forcing screw and remove the frame.

257

POWERHEAD ASSEMBLY Test at least three corners of the rod and cap joint with a pick. Joint must be smooth with no step.

IMPORTANT: Gel-Seal II has a shelf life of at least one year when stored at room temperature. Test the Gel-Seal II or replace it if the age of the tube cannot be determined. Using old Gel-Seal II could cause crankcase air leaks. IMPORTANT: If Locquic Primer is used, crankcase halves must be assembled and tightened within ten minutes after the Gel-Seal II has been applied. Lower the crankcase into place. Confirm that upper oil seal and lower seal housing are seated correctly in grooves.

005300

Repeat steps for remaining connecting rods.

Apply outboard lubricant to the main bearing screws and install screws finger tight.

Crankcase Thoroughly clean and degrease the mating flanges of the crankcase and cylinder block with a non-petroleum based solvent, such as isopropyl alcohol or acetone, and let air dry.

IMPORTANT: DO NOT allow solvent to get on internal components. Clean only the mating flanges. Apply Gasket Sealing Compound to lower oil seal groove in crankcase. DO NOT put any sealer in upper seal groove. Use a small brush to dab a thin, even coat of GelSeal II sealant to the crankcase mating flange. The application must not come within 1/4 in. (6.4 mm) of seal rings or bearings.

005308

When the crankcase is seated, install and firmly seat the crankcase taper pin.

005307

TYPICAL

258

003874

POWERHEAD ASSEMBLY Torque main bearing screws in stages to 31 to 35 ft. lbs. (42 to 47.5 N·m). Begin with the center screws and work outward in a spiral pattern.

1

1

Test that the crankshaft spins freely without binding.

IMPORTANT: After powerhead has been assembled, allow at least two hours for Gel-Seal II to cure before running outboard.

General Connect all crankcase recirculating hoses. Refer to Recirculation Hose Routings and Check Valve Diagrams – V4 on p. 213, Recirculation Hose Routings and Check Valve Diagrams – V6 on p. 211, or POWERHEAD VIEWS on p. 266.

1. Main bearing screws (6 on V4; 8 on V6)

005313

Apply Triple-Guard grease to crankcase flange screws. Install screws and torque to 60 to 84 in. lbs. (7 to 9.5 N·m).

1

1

Install pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on p. 233. Install the throttle body and reed plate assemblies. Refer to INTAKE MANIFOLD on p. 196. Lubricate shift linkage bosses at the base of the crankcase with Triple-Guard grease. Insert bushings into bosses. Apply Triple-Guard grease to the shaft of the shift lever assembly. Guide shaft through bushings in crankcase. Install shift rod lever and tighten retaining screw 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Flange screws (12 on V4; 16 on V6)

005306

Apply Triple-Guard grease to shoulder of shift arm screw and Nut Lock to threads. Install arm, screw, and washer and torque screw to 120 to 144 in. lbs. (14 to 16 N·m).

10 1

2

1. Shift arm screw 2. Shift lever screw

005294

259

POWERHEAD ASSEMBLY Apply Nut Lock to threads of throttle lever screw. Insert spring into cavity of throttle lever. Install lever, screw, and washer on crankcase and hook spring on rib as shown. Torque screw to 120 to 144 in. lbs. (14 to 16 N·m).

Install ignition coils and fuel injectors. Refer to Fuel Injectors on p. 193.

IMPORTANT: All injectors must be reinstalled in their original location. Improper injector installation can result in powerhead failure. Install oil pump, rear oil manifold, and oil injection hoses. Refer to OIL COMPONENT SERVICING on p. 222.

1

Install flywheel and stator. Refer to FLYWHEEL AND STATOR SERVICING on p. 154. Install electrical harness with flywheel cover base, starter solenoid, and trim relay module, then install EMM.

1. Throttle lever spring

005259

Apply Nut Lock to threads of throttle cam screw. Install cam, screw, and washer and torque screw to 120 to 144 in. lbs. (14 to 16 N·m).

Install fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 189. Install the electric starter. Refer to Starter Installation on p. 167.

WARNING To prevent fire and explosion hazard, make sure all electrical and ignition wiring is routed and clamped in original positions.

1

1. Throttle cam screw

005293

IMPORTANT: Do not lubricate throttle levers or shoulder screws.

260

POWERHEAD UPPER MOUNT SERVICING Dislodge mount assemblies and remove.

UPPER MOUNT SERVICING Removal Remove mount retainer screw.

005312

1

Inspect mounts and replace if necessary.

IMPORTANT: The motor mount, washer, and 005309

1. Mount retainer screw

screw are serviced as an assembly. Do not disassemble.

.

WARNING Wear safety glasses to avoid injury. Tap the edge of one of the mount housings with a large, blunt punch to loosen the mount retainer.

39820

10 005311

261

POWERHEAD INSTALLATION

Installation Place mount assemblies in position, with flats facing away from each other. Apply Moly Lube to all sides of retainer and install between mounts.

INSTALLATION Apply Permatex No. 2 to both sides of a new base gasket around the exhaust ports only. Install gasket on adapter. To ensure proper sealing, mating surfaces must be clean.

1

005310

Install the retainer screw and torque to 15 to 20 ft. lbs. (20 to 27 N·m).

1. Permatex No. 2

005258

IMPORTANT: V4 and V6 base gaskets are NOT interchangeable. Be sure to use the correct part. Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.

1

1. Mount retainer screw

Use Lifting Tool, P/N 342672, and hoist to slowly lower powerhead onto exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines.

005309

005276

262

POWERHEAD INSTALLATION Install pins from Alignment Pin Kit, P/N 5007167, as shown. Tighten pins until fully seated.

With alignment pins in place, loosely install remaining powerhead screws and upper mount screws.

2

3

1

2

4 1 005274 1. 2. 3. 4.

005277

Large powerhead screws Small powerhead screws Upper mount screws Alignment pin tool

• Torque the large powerhead screws 1 through 4 to 20 to 22 ft. lbs (27 to 30 N·m).

• Remove Alignment Pins and torque screws 5

005275

Apply Triple-Guard grease to the threads, and Gasket Sealing Compound to the shank of the powerhead screws. Apply Triple-Guard grease to upper mount screw threads.

through 7 to 20 to 22 ft. lbs (27 to 30 N·m). • Torque the four small powerhead screws to 60 to 84 in. lbs. (7 to 9.5 N·m). • Torque upper mount screws to 110 to 130 ft. lbs. (149 to 176 N·m). Confirm that screw heads are tight against steering arm.

Alignment Pin here

C

D

6

4

1

2

3

5 Alignment

10 Pin here

A

B 7

Large screw torque sequence, 1–7 Small screw torque sequence, A–D

005244

IMPORTANT: Retorque powerhead mounting screws after outboard has been run at full operating temperature.

263

POWERHEAD INSTALLATION Position the shift rod in the shift rod lever. Install the retaining screw and washer. Torque screw to 60 to 84 in. lbs. (7 to 9.5 N·m).

ALL MODELS Connect the power trim connectors.

1 1

1. Shift rod screw

005253

2

1. Tilt limit switch connector 2. Sending unit connector

005254

IMPORTANT: Confirm that gearcase shifts solidly into both forward and reverse and that propeller shaft spins freely in neutral.

V4 MODELS Fill exhaust valve actuator electrical connector with Electrical Grease and install on actuator.

1

IMPORTANT: Leave enough slack in harness so that lower cover will not pull it away from actuator. 1. Tilt relay connector

005255

Install air silencer and air temperature sensor.

1

1. Actuator connector

005247

005272

264

POWERHEAD INSTALLATION Install rear shroud and flywheel cover.

Connect trim/tilt switch connector.

005248

005246

Install the lower engine covers and tighten the screws.

IMPORTANT: Perform the following procedures before returning outboard to service: • Index all spark plugs. Refer to Spark Plug Indexing on p. 160. • Use the Evinrude Diagnostics Software program to initiate powerhead break-in. Refer to Powerhead Break-In on p. 109. • Prime fuel system. Refer to Fuel System Priming on p. 66. • Prime oiling system. Refer to Oiling System Oil Supply Priming on p. 68. • Adjust timing pointer and check engine timing. Refer to TIMING ADJUSTMENTS on p. 157.

1 1

1. Lower cover screws

005242

10

265

POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS

V4 Starboard – Hose Routings

005249

266

POWERHEAD POWERHEAD VIEWS

V4 Port – Hose Routings

10

005250 02406

267

POWERHEAD POWERHEAD VIEWS

V4 Starboard

005225

268

POWERHEAD POWERHEAD VIEWS

V4 Port

10

005224 02406

269

POWERHEAD POWERHEAD VIEWS

V4 Front

005226

270

POWERHEAD POWERHEAD VIEWS

V4 Rear

10

005227

271

POWERHEAD POWERHEAD VIEWS

Top – Hose Routings

005245

272

POWERHEAD POWERHEAD VIEWS

V4 – V6 Top

10

005228

273

POWERHEAD POWERHEAD VIEWS

V6 Starboard – Hose Routings

005324

274

POWERHEAD POWERHEAD VIEWS

V6 Port – Hose Routings

10

005325

275

POWERHEAD POWERHEAD VIEWS

V6 Starboard

005256

276

POWERHEAD POWERHEAD VIEWS

V6 Port

10

005257

277

POWERHEAD POWERHEAD VIEWS

V6 Front

005252

278

POWERHEAD POWERHEAD VIEWS

V6 Rear

10

005251

279

POWERHEAD NOTES

NOTES Technician’s Notes

Related Documents Bulletins

Instruction Sheets

Other

280

MIDSECTION

MIDSECTION TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 STERN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 EXHAUST RELIEF MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

11

281

MIDSECTION SERVICE CHART

SERVICE CHART 8-12 In. lbs. (0.9-1.5 N·m)

40-50 In. lbs. (4.5-5.7 N·m)

A 110-130 Ft. lbs. (149-176 N·m)

A

10-16 In. lbs. (1.1-1.8 N·m)

A

30-50 In. lbs. (3.5-5.5 N·m)

U

60-84 In. lbs. (7-9.5 N·m)

A

40-50 In. lbs. (4.5-5.7 N·m)

A

28-30 Ft. lbs. (38-41 N·m)

50-54 Ft. lbs. (68-73 N·m)

See Text

40-50 In. lbs. (4.5-5.7 N·m) 216-240 In. lbs. (24.5-27 N·m)

IMPORTANT Use Triple-Guard grease on all pivot points 40-50 In. lbs. (4.5-5.7 N·m)

216-240 In. lbs. (25-27 N·m)

A 170-190 In. lbs. (19-22 N·m)

38-45 Ft. lbs. (52-61 N·m)

40 Ft. lbs. (54 N·m) Marine Sealant See "Installation & Predelivery" in manual

120-144 In. lbs. (14-16 N·m)

A

004105a

282

B 130-150 Ft. lbs. (176-204 N·m)

A B F U

Triple-Guard Grease Gasket Sealing Compound Blue Nut Lock Instant Bonding Adhesive

MIDSECTION SERVICE CHART

A 60-84 In. lbs. (7-9.5 N·m)

P A

A 216-240 In. lbs. (24.5-27 N·m)

A

A

60-84 In. lbs. (7-9.5 N·m)

60-84 In. lbs. (7-9.5 N·m)

A 60-84 In. lbs. (7-9.5 N·m)

A Q A/B 20-22 Ft. lbs. (27-30 N·m)

156-180 In. lbs. (18-20 N·m)

11 A C

A B C D E F L P Q

Triple-Guard Grease Gasket Sealing Compound

C

Adhesive 847 Moly Lube

A

Red Ultra Lock Blue Nut Lock Pipe Thread Sealing Compound Permatex #2 Gel Seal II

005203

283

MIDSECTION SERVICE CHART

284

MIDSECTION TILT TUBE Remove the nut from the starboard side.

TILT TUBE The tilt tube may be serviced without major disassembly of the outboard using Tilt Tube Service Kit, P/N 434523.

Removal WARNING Support the outboard with a suitable hoist. Pull the locking tabs on the tilt limit cam loose from the collar.

30747

Thread the spacer from Tilt Tube Service Kit, P/N 434523, onto the starboard end of the tilt tube.

1

1. Locking tabs

30749 30746

Remove the cam and collar from the tilt tube.

Remove steering cable wiper nut from tilt tube. Thread the adapter from Tilt Tube Service Kit, P/N 434523, onto the port end of the tilt tube.

11 30748

30745

285

MIDSECTION TILT TUBE Thread Slide Hammer, P/N 432128, into the adapter until at least 2 in. (51 mm) of thread are engaged.

Install the starboard locknut.

WARNING Replace locknut if definite resistance is not felt. Torque starboard tilt tube nut to 50 to 54 ft. lbs. (68 to 73 N·m), then loosen nut 1/8 to 1/4 turn.

30744

Pull tilt tube from stern bracket with the slide hammer. When tilt tube clears the port stern bracket, remove tilt tube from the spacer.

Installation Thread starboard end of tilt tube into the spacer. Thread the adapter onto port end of tilt tube. Use a wood or leather mallet to tap the tilt tube into position.

30741

Replace steering cable wiper nut on port end of tilt tube. Apply one drop of instant bonding adhesive in receiving channels of tilt limit switch collar and install collar and tilt cam on tilt tube. Be sure locating tab on collar fits in hole on tilt tube.

30743

Make sure the lock tab is in correct position.

1 30750

1. Lock tab

286

30742

MIDSECTION EXHAUST HOUSING Remove the exhaust housing.

EXHAUST HOUSING Removal Before removing the midsection: • The gearcase must be removed. Refer to Gearcase REMOVAL AND INSTALLATION on p. 308. • The powerhead must be removed. Refer to Powerhead REMOVAL on p. 239. Remove and discard four lower mount screws.

005223

Remove lower mount covers and inspect the lower mounts. If replacement is necessary, lubricate mount with soapy water and carefully pry at both ends to remove. 20” Models



23036

32578

25” Models



32590

11

287

MIDSECTION EXHAUST HOUSING Remove the water tube. Inspect water tube grommet and replace if necessary.

Disassembly V4 MODELS Remove three screws and exhaust valve actuator.

1 1 1

1. Water tube grommet 1. Actuator screws

005206

ALL MODELS Remove the front and rear screws retaining the adapter/inner exhaust housing to the exhaust housing.

005210

V4 MODELS Remove circlip and washers from exhaust valve shaft on starboard side of inner exhaust housing.

1 1

1

1. Circlip

1. Adapter retaining screws

005205

005211

Remove exhaust valve shaft and washer from port side of inner exhaust housing.

Lift the adapter/inner exhaust housing out of the exhaust housing.

005212

005207

288

Remove exhaust valves from inside the inner exhaust housing.

MIDSECTION EXHAUST HOUSING Inspect the water tube for obstructions or kinks, which may restrict water flow.

Cleaning and Inspection WARNING

Assembly

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa). Clean all parts with parts cleaning solvent and dry with compressed air. All nut and screw threads coated with thread locking material must be thoroughly cleaned before assembly. When using a thread locking product, be sure to prime the threads with Locquic Primer.

V4 MODELS Assemble linkage to exhaust valve shaft as shown. Be sure the word “OUT” on the lever is facing away from the shaft.

1

Examine the upper and lower thrust mounts, and replace if deteriorated or damaged. Before checking the exhaust housing for distortion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion. Check the exhaust housing for distortion. Place the housing on a surface plate. Using a dial indicator, check flatness by measuring the run-out on the top edge of housing. The maximum allowable run-out is 0.009 in. (0.228 mm). If you do not have access to a dial indicator and surface plate, seek the services of a machine shop. DO NOT attempt to straighten a distorted housing. Replace it.

1. “OUT” mark

005213

Place rear of inner exhaust housing on bench. Arrange exhaust valves and linkage as shown.

IMPORTANT: A distorted exhaust housing will cause the upper driveshaft splines to wear excessively and will damage the crankshaft splines.

005214

11

DR2223

289

MIDSECTION EXHAUST HOUSING Place exhaust valves in inner exhaust housing.

Secure shaft with spring washer, flat washer, and circlip.

2 1 005215

Push valves into housing until they drop into notch.

1. Circlip 2. Spring washer

005211

ALL MODELS Apply Adhesive 847 to the bottom flange of the inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.

2

1 005216

Insert exhaust valve shaft and washer through port side of inner exhaust housing with lever angled toward top of housing.

1. Adhesive 847 2. Triple-Guard grease

005217

Install the water tube.

1

005212

1. Water tube grommet

290

005210

MIDSECTION EXHAUST HOUSING Clean and degrease the adapter housing and outer exhaust housing mating surfaces with Cleaning Solvent. Apply Gel-Seal II sealant to the adapter flange of the exhaust housing.

216 to 240 in. lbs. (24.5 to 27 N·m) and rear screw to 60 to 84 in. lbs. (7 to 9.5 N·m).

1 1

1. Adapter retaining screws 13692

Place the adapter/inner exhaust housing into the exhaust housing. Guide the water tube through the hole in the outer housing.

005205

If removed, coat the lower mounts with soapy water and press into the exhaust housing with the “OUT” mark facing outward.

IMPORTANT: On V4 models, be sure that exhaust valve linkage is oriented as shown.

23033

Position the mount covers. Install washers and screws, and torque to 156 to 180 in. lbs. (18 to 20 N·m). 005218

Apply Triple-Guard grease to threads of adapter retaining screws. Tighten two forward screws to

11

32579

291

MIDSECTION EXHAUST HOUSING V4 MODELS Check that exhaust valve linkage is oriented as shown. “OUT” marking on lever must be visible.

Rotate and push actuator into position. Apply Triple-Guard grease to screw threads and install screws and washers. Tighten screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

1 1 1

1. “OUT” mark

005208 1. Actuator screws

Apply a small amount of Triple-Guard grease to the actuator shaft and o-ring.

005206

IMPORTANT: Fill actuator electrical connectors with Electrical Grease before installation.

Installation 1 2

Bring the exhaust housing into position with the stern bracket. Install four new lower mount screws. These screws have lock-patch pre-applied. Torque screws to 38 to 45 ft. lbs. (52 to 61 N·m).

1. Shaft 2. O-ring

005209

Carefully engage actuator shaft in linkage lever.

23036

Install powerhead. Refer to Powerhead INSTALLATION on p. 262. Install gearcase. Refer to Gearcase REMOVAL AND INSTALLATION on p. 308. 005219

292

MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer. It may be necessary to tap the steering shaft out using a wood dowel and mallet.

STERN BRACKET Removal Before servicing the stern bracket: • The gearcase must be removed. Refer to Gearcase REMOVAL AND INSTALLATION on p. 308. • The powerhead must be removed. Refer to Powerhead REMOVAL on p. 239. • The exhaust housing must be removed. Refer to Exhaust Housing Removal on p. 287. • The power trim/tilt unit must be removed. Refer to TRIM AND TILT section.

30735

Disassembly Remove and discard steering shaft locknut.

Pry out upper and lower steering shaft seals and discard. Remove the upper and lower steering shaft bushings.

30738 30765 / 30764

Remove the lower mount bracket and keeper.

Remove the tilt tube. Refer to TILT TUBE on p. 285. Remove the two tilt tube washers.

11

30736 30763

293

MIDSECTION STERN BRACKET Remove the anode.

Remove the tilt limit switch and retainer from the swivel bracket.

1 1

2 1. Anode

30762

Remove the swivel bracket. Inspect and, if necessary, replace the tilt tube bushings.

1. Tilt limit switch 2. Retainer

30758

Disconnect the trail lock spring and remove it from the swivel bracket. Remove trail arm retainer.

1

2 1 1. Tilt tube bushing

30761

Remove the trim sender unit from the port stern bracket and pull its wires through the braided tube.

1. Trail lock spring 2. Trail arm retainer

30756

Remove the trail lock arm and bushings from the swivel bracket.

1

30760 1. Trail lock bushing

294

30755

MIDSECTION STERN BRACKET Remove the two trim rod rollers from the swivel bracket.

Assembly IMPORTANT: Before proceeding, make sure all components have been thoroughly cleaned. Replace any seals that have been removed. Inspect all thrust washers and bushings for evidence of deterioration. Install the detent roller and spring and the tilt support with bushing in the swivel bracket. Torque bushing to 28 to 30 ft. lbs. (37.9 to 40.7 N·m).

1

1. Trim rod roller

30754

Remove the tilt support and bushing from the swivel bracket and inspect the detent roller and spring.

30752

1

1. Tilt support bushing

1

30753

1. Tilt support bushing

30753

295

11

MIDSECTION STERN BRACKET Install the two trim rod rollers on the swivel bracket. Torque to 216 to 240 in. lbs. (25 to 27 N·m).

Install the tilt limit switch and retainer on the swivel bracket. Torque screws to 40 to 50 in. lbs. (4.5 to 5.7 N·m).

1

1 2 1. Trim rod roller

30754

Install the trail lock and bushings in the swivel bracket. Torque to 216 to 240 in. lbs. (25 to 27 N·m).

1. Tilt limit switch 2. Retainer

30758

Route the trim sender wires through the braided tube, and install the sender unit in the port stern bracket.

1

1. Trail lock bushing

30755 30760

Install the trail lock spring in the swivel bracket and connect the spring to the trail lock.

2 1

1. Trail lock spring 2. Trail arm retainer

296

30756

Install the upper and lower steering shaft bushings and new seals in the swivel bracket. Both seal lips face out. • Coat the outside surfaces of seals with Gasket Sealing Compound.

MIDSECTION STERN BRACKET • Coat the bushings and seal lips with TripleGuard grease.

Install the steering shaft keeper. Apply Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount bracket.

30765 / 30764

Coat tilt tube bushings with Triple-Guard grease and, if removed, install them in the swivel bracket. 30736

Install the lower mount bracket and a new locking nut with its unstaked side facing the mount bracket. Align the bracket with the steering arm and torque the nut to 130 to 150 ft. lbs. (176 to 204 N·m).

30761

Place the swivel bracket between the stern brackets and install the anode. Install the tilt tube and tilt limit cam. Refer to TILT TUBE on p. 285. Install the steering shaft and thrust washer.

30767

Fill the swivel bracket with Triple-Guard grease through the grease fitting on the bracket’s port side. Lubricate the tilt tube, swivel bracket, and stern brackets through the two forward grease fittings. Install the exhaust housing. Refer to TILT TUBE on p. 285.

30735

297

11

MIDSECTION EXHAUST RELIEF MUFFLER ASSEMBLY

EXHAUST RELIEF MUFFLER ASSEMBLY The exhaust relief muffler is located at the rear of the powerhead and concealed by the lower motor covers. The exhaust relief grommet connects directly to the muffler assembly.

The overboard indicator and flush port in the exhaust relief grommet connect to the vapor separator with a hose. This hose is not connected to the muffler assembly.

1

1

1. Overboard indicator hose

005222

Periodically inspect hoses and connections for condition. Replace muffler or hoses as needed. 1. Exhaust relief grommet

005220

The muffler assembly connects to the exhaust relief hoses at the base of the powerhead.

1

1. Exhaust relief hoses

298

005221

GEARCASE

GEARCASE TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 GEARCASE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 SHIFT INTERRUPT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 BEARING AND SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 PINION GEAR BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 DRIVESHAFT BEARING HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 PROPELLER SHAFT BEARING HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 BEARING AND SEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 PINION GEAR BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 DRIVESHAFT BEARING HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 PROPELLER SHAFT BEARING HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 COUNTER ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 PROPELLER SHAFT BEARINGHOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 SHIFT HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 PROPELLER SHAFT BEARING HOUSING AND FORWARD GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 PROPELLER SHAFT BEARING HOUSING SEALS AND BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

299

12

GEARCASE SERVICE CHART

SERVICE CHART V4 20 IN. MODELS

“S2”–TYPE GEARCASE A B 120-144 In. lbs.

B (13.6-16.3 N·m) C

60-84 In. lbs. (6.8-9.5 N·m)

A

B

24-36 In. lbs. (2.7-4.1 N·m)

D

60-84 In. lbs. (6.8-9.5 N·m)

F

F

26-28 Ft. lbs. (35-38 N·m)

B See Water Pump Assembly instructions

C

A

B A

37-41 Ft. lbs. (50-56 N·m)

Ft. lbs. F 20-24 (27-33 N·m)

B A Ft. lbs. B 45-50 (61-68 N·m)

A

60-84 In. lbs. (6.8-9.5 N·m)

B

C

215-240 in. lbs. (24-27 N·m)

F 60-84 In. lbs. (6.8-9.5 N·m)

Ft. lbs. B 26-28 (35-38 N·m)

G

B

B

35-40 Ft. lbs. (47-54 N·m)

A 60-84 In. lbs. (6.8-9.5 N·m)

B

18-20 Ft. lbs. (24-27 N·m)

E B A B 120-144 In. lbs. (13.6-16.3 N·m) 108-132 In. lbs. (12.2-14.9 N·m)

B

A

DSS133-2

300

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

GEARCASE SERVICE CHART V6 20 IN. MODELS

“O”–TYPE GEARCASE

A F

B

60-84 In. lbs. (6.8-9.5 N·m)

120-144 In. lbs. (13.6-16.3 N·m)

C

A

B

60-84 In. lbs. (6.8-9.5 N·m)

24-36 In. lbs. (2.7-4.1 N·m)

F B

B

A

26-28 Ft. lbs. (35-38 N·m)

A See Water Pump Assembly instructions

C

B

D 45-50 Ft. lbs. (61-68 N·m)

A

B

A

B

C

60-84 In. lbs. (6.8-9.5 N·m)

G

B

60-84 In. lbs. (6.8-9.5 N·m)

26-28 Ft. lbs. (35-38 N·m)

F 100-110 Ft. lbs. (136-149 N·m) Use Outboard Lubricant on threads only, taper must be clean and dry.

E

15-20 In. lbs. (1.7-2.3 N·m)

B

A B

B

35-40 Ft. lbs. (47-54 N·m)

B

60-84 In. lbs. (6.8-9.5 N·m)

18-20 Ft. lbs. (24-27 N·m)

E

A B B B 70-80 Ft. lbs. (95-109 N·m) 108-132 In. lbs. (12.2-14.9 N·m)

12 A

DSS152

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

301

GEARCASE SERVICE CHART PERFORMANCE MODELS

“L”-TYPE GEARCASE

F

A

60-84 In. lbs. (6.8-9.5 N·m)

B

B

120-144 In. lbs. (13.6-16.3 N·m)

C

A

60-84 In. lbs. (6.8-9.5 N·m)

F

24-36 In. lbs. (2.7-4.1 N·m)

B

See Water Pump Assembly instructions

C

B

B

40-50 Ft. lbs. 26-28 Ft. lbs. (54-68 N·m) (35-38 N·m)

A

A

B

D 40-50 Ft. lbs. (54-68 N·m)

B

A A

B

C

60-84 In. lbs. (6.8-9.5 N·m) 26-28 Ft. lbs. (35-38 N·m)

60-84 In. lbs. (6.8-9.5 N·m)

B

G

B

B

F

35-40 Ft. lbs. (47-54 N·m)

E

15-20 In. lbs. (1.7-2.3 N·m)

100-110 Ft. lbs. (136-149 N·m) Use Gearcase Lubricant on threads only, taper must be clean and dry.

A

60-84 In. lbs. (6.8-9.5 N·m)

E

B

18-20 Ft. lbs. (24-27 N·m)

B

A

B

70-80 Ft. lbs. (95-109 N·m) 108-132 In. lbs. (12.2-14.9 N·m)

A

DSS151

302

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

GEARCASE SERVICE CHART V4/V6 25 IN. MODELS, STANDARD ROTATION

“M”–TYPE GEARCASE

A B

B

10-12 Ft. lbs. (13.6-16.3 N•m)

A

60-84 In. lbs. (6.8-9.5 N•m)

E

E

60-84 In. lbs. (6.8-9.5 N•m)

24-36 In. lbs. (2.7-4.1 N•m)

B 18 In. lbs. (2.0 N•m) Then 10-12 In. Lbs (Then 1.1-1.4 N•m)

B

F See Water Pump Assembly instructions

A

C

B

D

D

40-50 Ft. lbs. (54-68 N•m)

26-28 Ft. lbs. (35-38 N•m)

B

B A

26-28 Ft. lbs. (35-38 N•m)

B 60-84 In. lbs. (6.8-9.5 N•m)

C

F

60-84 In. lbs. (6.8-9.5 N•m)

G

B

26-28 Ft. lbs. (35-38 N•m)

B 100-110 Ft. lbs. (136-149 N•m) Use Gearcase Lubricant on threads only, taper must be clean and dry.

35-40 Ft. lbs. (47-54 N•m)

A

B

60-84 In. lbs. (6.8-9.5 N•m)

15-20 In. lbs. (1.7-2.3 N•m)

E E B18-20 Ft. lbs. (24-27 N•m) B A B 70-80 Ft. lbs. (95-109 N•m)

B 108-132 In. lbs. (12-15 N•m)

12 A

DSS131

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

303

GEARCASE SERVICE CHART V6 COUNTER ROTATION

“M”-TYPE GEARCASE

A B

B

10-12 Ft. lbs. (14-16 N•m)

A

E

B

E

24-36 In. lbs. (2.7-4.1 N•m)

60-84 In. lbs. (6.8-9.5 N•m)

60-84 In. lbs. (6.8-9.5 N•m)

87

A

D See Water Pump Assembly instructions

F

C B

40-50 Ft. lbs. (54-68 N•m)

26-28 Ft. lbs. (35-38 N•m)

B

B

D

26-28 Ft. lbs. (35-38 N•m)

B

A C

60-84 In. lbs. (6.8-9.5 N•m)

F

F

B

26-28 Ft. lbs. (35-38 N•m)

B

60-84 In. lbs. (6.8-9.5 N•m)

144-168 In. lbs. (16-19 N•m) See Gearcase Assembly Instructions.

B

18 In. lbs. (2.0 N•m) Then 10-12 In. Lbs (1.1-1.4N•m)

G 100-110 Ft. lbs. (136-149 N•m) Use Gearcase Lubricant on threads only, taper must be clean and dry.

35-40 Ft. lbs. (47-54 N•m)

60-84 In. lbs. (6.8-9.5 N•m)

B

100 Ft. lbs. (136 N•m) Gearcase Lubricant on threads.

E

18-20 Ft. lbs.(24-27 N•m)

B

B

A 15-20 In. lbs. (1.7-2.3 N•m)

E

B B A

70-80 Ft. lbs. (95-109 N•m) 108-132 In. lbs. (12-15 N•m)

A

DSS132

304

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

GEARCASE GEARCASE TYPES

GEARCASE TYPES Outboard Model

Housing Type

V4 20 in.

“S”

V4 20 in.

“S2”

V4 25 in

“O”

V6 20 in. V6 20 in. V6 25 in. V6 25 in Counter Rotation

Similar Housings

“L”

Unique Housing

“M”

Comparative Information

Gear Ratio

standard gearset

13:26 (.500)

unique shafts, “large” gearset

13:26 (.500)

special gear ratio, uses V6 style prop

12:27 (.444)

standard gearset

high speed profile, standard gearset

14:26 (.538)

standard gearset

13:24 (.542)

“CR” shafts, bearings and gearset

13:24 (.542)

12

305

GEARCASE PROPELLER

PROPELLER Inspection Carefully examine propeller and outboard for the following: • Damaged blades and signs of propeller cavitation (burned paint, etc.) • Spun or overheated inner hub • Worn or twisted splines and inadequate lubricant • Damaged or missing converging ring (if applicable) • Damage to outer hub area • Worn, missing, or incorrect thrust washer and spacer • Correct size and style • Check for bent or damaged propeller shaft and twisted splines. Refer to Propeller Hardware Installation on p. 74.

SHIFT INTERRUPT SWITCH IMPORTANT: The shift interrupt switch signal is not utilized on 60°V4 or 60°V6 Evinrude ETEC models. Low idle speeds do not require shift interrupt function. The shift switch function is used on V4 models when an accessory tiller conversion kit is added. Refer to tiller handle kit installation instructions for details. The shift interrupt switch is in contact with the shift lever (positioned at the base of the powerhead). The switch is normally open and activates momentarily as the shift linkage moves. Excessive shift loads activate the switch. Typically the switch is depressed when the linkage moves from the FORWARD or REVERSE position into the NEUTRAL position.

WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and disconnect the battery positive (+) cable so the outboard cannot be started accidentally.

1

1. Switch, shift interrupt

306

005404

GEARCASE LUBRICANT Overheated lubricant will have a black color and burned odor.

LUBRICANT Draining

Internal gearcase inspection is recommended when lubricant is contaminated or shows signs of failure.

WARNING Gearcase lubricant may be under pressure and/or hot. If plug is removed from a recently operated outboard, take precautions to avoid injury. Remove the lubricant level plug, then the lubricant drain/fill plug, and drain the lube from the gearcase into a container. Inspect the lube and the magnets on the plugs for metal chips.

1

Filling Secure the gearcase in a vertical position. Remove the lubricant level plug and the lubricant drain/fill plug. Slowly fill the gearcase with HPF XR gearcase lube through the drain/fill hole until it appears at the oil level hole. Filling the gearcase too quickly can cause air pockets and the gearcase may not fill completely. Clean plug seal area and install the lubricant level plug and new seal, then the lubricant drain/fill plug and new seal. Tighten them to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1 2 2 1. Lubricant level plug 2. Lubricant drain/fill plug

39514

The presence of metal fuzz can indicate normal wear of the gears, bearings, or shafts within the gearcase. Metal chips can indicate extensive internal damage.

1. Lubricant level plug 2. Lubricant drain/fill plug

002386

Inspection Inspect the lubricant for water contamination. Water can make the lubricant milky in appearance. However, normal aeration can also cause the same appearance. To check for water contamination, drain lubricant into a suitable glass container. Allow the drained oil to settle for a minimum of one hour to determine if there is an abnormal amount of water in the oil. Some gearcase lubricants are designed to mix with a small amount of water from normal water vapor condensation within the gearcase.

12

Refer to LEAK TEST.

307

GEARCASE LEAK TEST

LEAK TEST

REMOVAL AND INSTALLATION

Drain lubricant before testing. STEP 1 Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant level hole. Pressurize 3 to 6 psi (21 to 42 kPa). If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leak. If the gearcase pressure gauge does not indicate leakage, increase pressure to 16 to 18 psi (110 to 124 kPa). Check for leakage. Make necessary repairs and repeat test. STEP 2 Complete successful STEP 1 before proceeding.

Removal WARNING To prevent accidental starting while servicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. Remove screw from shift lever to release the lower shift rod.

Install vacuum test gauge. Apply 3 to 5 in. of vacuum (76 to 127 mm) Hg. with pump.

1

Check for leakage. If leakage occurs, apply oil around suspected seal. If leak then stops or oil is drawn in, that seal is defective. Repeat test. Gearcase must hold minimum of 15 in. (381 mm) Hg.

1. Shift rod screw

004241

Note where the index mark on the gearcase aligns with the index number of the adjustable trim tab so the trim tab can be installed in the same position. Remove the trim tab retaining screw, gasket and trim tab from the gearcase.

3

2

002388

1 1. Index mark 2. Trim tab 3. Trim tab retaining screw

308

COA3663

GEARCASE REMOVAL AND INSTALLATION Remove the forward screw with the washer, and remove middle screw.

Installation WARNING During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

2 1

1. Forward screw 2. Middle screw

COA3139

IMPORTANT: Before installation of gearcase on motor, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 314. Coat the driveshaft splines with Moly Lube. DO NOT coat top surface of the driveshaft because lubricant may prevent seating of the driveshaft in the crankshaft.

Remove the four gearcase retaining screws.

1 1. Gearcase retaining screws

30385

001990

Remove the gearcase assembly from the exhaust housing, being careful not to bend the shift rod or damage the water tube. The lower inner exhaust housing may come out with the gearcase.

Apply Adhesive 847 to the lower exhaust housing seals’ inner surfaces. Position two new seals on the housing. Apply Triple-Guard grease to the seals’ outer surfaces and position the housing on the gearcase.

1

12 TYPICAL 1. Lower exhaust seals

001985

309

GEARCASE REMOVAL AND INSTALLATION Apply Gel-Seal II to gearcase mating surface pads on exhaust housing. Slide the gearcase into place, making sure: • Driveshaft engages the crankshaft. • Water tube enters the water pump. • Lower inner exhaust housing installs correctly. • Shift rod does not turn and is positioned properly in shift shaft connection area. Use Gearcase Alignment Kit, P/N 5007231, to accurately align gearcase housing to exhaust housing. Position alignment bolts (2) as indicated.

Apply Gasket Sealing Compound to threads of the gearcase retaining screws. Torque the screws: • 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N·m) • 7/16 in. screws – 40 to 50 ft. lbs. (54 to 68 N·m)

2

1 1. Alignment screw 2. 3/8 in. screw

005403

005401

Alignment Bolt(s)

2 1

1

1. 7/16 in. screw 2. 3/8 in screw

1 1. Position of alignment bolts (2)

005402

IMPORTANT: Remove and replace alignment screws with appropriate 3/8 in. mounting screws after all other gearcase mounting screws are installed and tightened.

310

COA3139

Apply Gasket Sealing Compound to threads of the trim tab screw. Install gasket on “M”-type gearcases. Install and align the trim tab (cover on “L”type) with the index marks noted prior to disassembly. Torque the trim tab screw to 35 to 40 ft.

GEARCASE WATER PUMP lbs. (47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment on p. 77.

WATER PUMP Disassembly Rotate the driveshaft counterclockwise to unlock the impeller cam. Remove the four impeller housing screws.

1

2

1

1

COA3663

1. Trim tab screw 2. Index mark

1

IMPORTANT: Standard rotation and counter rotation trim tabs must not be interchanged. This would result in inadequate cooling water supply to the propeller hub. Position the shift rod in the connector. Install and torque shift rod screw to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Screws

31998

Slide the water pump off the driveshaft. Remove the impeller drive cam, O-ring, impeller plate, and gasket. Discard the gasket.

2 1

1

004241

1. Shift rod screw

1. O-ring 2. Impeller plate

DSC02328

WARNING To prevent loss of operator control, check for proper shifting operation and adjust, if necessary.

IMPORTANT: During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.

Remove all the parts from the housing.

Inspection Check impeller for overheating, hub separation, and other wear or damage. Check liner and wear plate for scoring, distortion, and impeller material transfer. Inspect the housing for cracks or melting.

311

12

GEARCASE WATER PUMP

Assembly Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs.

Install the water tube grommet with the inside taper facing up.

1

IMPORTANT: Do not allow any adhesive to get into the air bleed groove in the impeller housing. If this groove is blocked by adhesive, the pump will lose its prime and will not pump water. 1

1. Water tube grommet

3

32000

Install the impeller housing cover and torque two screws to 24 to 36 in. lbs. (2.7 to 4.1 N·m). Apply Adhesive 847 to flat side of the impeller housing grommet. Install the grommet, flat side down.

2 2311 DR1185

1

Install the O-ring in groove in the impeller housing.

2

1. Seal ring groove 2. Ribs 3. Air bleed groove

1 1. Impeller housing cover 2. Impeller housing grommet

1. O-ring

34814

Lightly coat the exterior of the impeller cup with Gasket Sealing Compound. Install the cup in the impeller housing.

312

32001

Lightly coat the liner with Triple-Guard grease. With a counterclockwise rotation, install the impeller into the liner with the slot for the impeller cam facing out.

GEARCASE WATER PUMP Run a thin bead of Adhesive 847 in the seal groove, and install the special shaped O-ring seal.

impeller, and slide water pump down over cam. Be sure impeller cam does not fall out of position.

2 1 1

1. Sharp edge of drive cam 2. Direction of driveshaft rotation 1. O-ring

CO2995

34815

Apply Gasket Sealing Compound to both sides of a new impeller plate gasket. Install the gasket and impeller plate. Apply Triple-Guard grease to a new impeller Oring. Slide the O-ring down the driveshaft and slide half way over installed drive cam to temporarily hold cam in place.

IMPORTANT: Make sure the impeller engages the impeller cam properly. Serious powerhead damage will result if impeller cam is displaced. Align the impeller housing with the gearcase. Apply Gasket Sealing Compound to threads of the four impeller housing screws. Install the screws and torque to 60 to 84 in. lbs. (7 to 9.5 N·m).

25 IN. MODELS Place water tube spacer with grommet on the impeller housing cover.

3 2

1 2 4

1 1. 2. 3. 4.

Impeller plate gasket Impeller plate O-ring Drive cam

DSC02326

The sharp edge of the cam is the leading edge in clockwise rotation. Triple-Guard grease or Adhesive 847 can be used to retain the drive cam during water pump installation. Slide the water pump down the driveshaft. Align impeller slot with the impeller cam. Rotate the driveshaft to engage the impeller cam with the

TYPICAL 1. Spacer 2. Grommet

32728

12

IMPORTANT: Before installation of gearcase on motor, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT.

313

GEARCASE SHIFT ROD ADJUSTMENT

SHIFT ROD ADJUSTMENT

DISASSEMBLY WARNING

Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

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

IMPORTANT: Clean and inspect all components during disassembly. Replace any damaged components, seals, O-rings, and gaskets upon assembly. Remove the propeller and mounting hardware. Drain and inspect oil as described in LUBRICANT on p. 307. Remove gearcase as described in REMOVAL AND INSTALLATION on p. 308. COA6166

With the shift rod and detent lever in NEUTRAL, rotate the shift rod up or down as necessary for correct adjustment. Once correct height is achieved, rotate rod one half turn or less to face offset forward.

IMPORTANT: The NEUTRAL detent is a twostep design. Make sure the NEUTRAL detent ball is in the center step before checking shift rod height. Shift Rod Heights Model

Type

Height

20 in. (L)

“S2” (V4) “O” (V6) “L” (V6)

20 15/16 in. (20.945 in./ 532 mm) ± 1/2 Half Turn

25 in. (X)

“O” (V4) “M” (V6)

25 15/16 in. (25.945 in./659 mm) ± 1/2 Turn

314

Remove water pump as described in WATER PUMP on p. 311.

Pre-Disassembly Inspection Before disassembling the gearcase, examine the following: • Gearcase Housing — Check for visible damage to skeg, strut, anti-ventilation plate, bullet, and mating surface. Check seal areas for visible signs of lubricant leakage. • Propeller Shaft — Check for bent or damaged shaft. Check for twisted splines and damaged threads. • Shift Rod — Check for misadjusted, bent, or binding rod. A misadjusted shift rod height can cause shift difficulty, loss of boat and outboard control, and gearcase damage.

GEARCASE DISASSEMBLY • Hydrostatic Seal Grooves — Must be in good condition to help prevent propeller ventilation.

Propeller Shaft Bearing Housing Removal IMPORTANT: This procedure is for standard rotation gearcases only. For counter rotation gearcases, refer to COUNTER ROTATION on p. 341.

1

Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.

1. Hydrostatic seal grooves

1

4557

• Gearcase Anodes — If anodes have eroded to two-thirds their original size, they must be replaced.

1. Retainer tab screws

1

1. Gearcase anode

001989

Remove wedge, screw, and washer (except “S2” type).

14161

• Drive Shaft — Check splines for visible damage, twisting and wear. Severe spline wear indicates the exhaust housing or gearcase has been distorted, possibly by impact damage. • Water Intake Screens — Check for damage and blockage. If screens cannot be cleaned, they must be replaced. Different screens are available and should not be mixed. Refer to correct model parts manual for listing and description.

DSM02291 DSC02361

Remove the propeller shaft bearing housing from the gearcase using the following: • Puller body, screw, and handle from Universal Puller Set, P/N 378103. • Two 5/16-18 x 11 in. (279 mm) threaded rods, two large 5/16 in. I.D. flat washers, and two 5/16-18 nuts (obtain locally).

315

12

GEARCASE DISASSEMBLY Assemble components and pull the bearing housing from the gearcase. Remove the thrust washer, thrust bearing, and reverse gear from gearcase.

Use the required tools to remove the pinion screw and gear from the lower driveshaft.

3 4

1 2

22775

Pinion Gear and Driveshaft Removal

1. 2. 3. 4.

Lower Driveshaft Spline Tool, P/N 5007052 Lower driveshaft Wrench, P/N 352877 Pinion gear and screw Lower driveshaft

005406

With driveshaft bearing housing and screws in place, insert Lower Driveshaft Spline Tool, P/N 5007052, into lower driveshaft.

“S2” TYPE GEARCASE Remove upper driveshaft. Refer to Driveshaft Service on p. 320 for upper driveshaft removal and installation. Remove propeller shaft bearing housing and reverse gear, thrust bearing and thrust washer. Push down on shift rod to move the clutch dog to reverse position. Pull propeller shaft aft to disengage from forward gear and shift housing. Allow shaft to drop against lower gearcase housing. This will assist in the removal of the pinion gear.

1

1

1. Lower Driveshaft Spline Tool

005407

Insert Lower Driveshaft Wrench, P/N 352877, through Lower Driveshaft Spline Tool and lower driveshaft. Seat hex tip of wrench in head of pinion screw.

1 1. Propeller shaft

005405

1. Wrench, hex tip

316

GEARCASE DISASSEMBLY IMPORTANT: Make sure Lower Driveshaft Wrench is fully seated in head of pinion screw.

Remove shims, thrust washer, and thrust bearing with the lower driveshaft.

1

Use a long 3/4 in. combination wrench to hold lower Driveshaft Spline Tool and a 1/2” drive wrench to turn the Lower Driveshaft Wrench in a counterclockwise direction. Loosen screw completely

2 3

1. Shims 2. Thrust bearing 3. Thrust washer

005410

Remove pinion gear from gearcase housing. 005409

Remove the four driveshaft bearing housing screws with washers and then the bearing housing.

005420

1

1. Driveshaft bearing housing

005426

12

317

GEARCASE DISASSEMBLY “O,” “L,” AND “M” TYPE GEARCASES Position the shift rod to move the clutch dog as far forward as possible. This will assist in the removal of the pinion nut. Loosen the pinion nut from the bottom of the driveshaft using Driveshaft Holding Socket, P/N 311875, Pinion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438. Pad the handle of holder to prevent damage to gearcase.

The bearing housing, shims, thrust bearing, and thrust washer will come out with the driveshaft.

1

2 4 3

1 1. 2. 3. 4.

Bearing housing Shims Thrust bearing Thrust washer

COA3558

Reach inside the gearcase and remove the pinion gear and pinion nut.

3 2 1. Holding socket 2. Pinion holder 3. Retainer

42229

Remove the four driveshaft bearing housing screws with washers.

COA3159

If driveshaft cannot be removed, refer to (Special) Driveshaft Removal Procedures on p. 319.

1 1

1. Driveshaft bearing housing screws

318

COA3153

GEARCASE DISASSEMBLY (Special) Driveshaft Removal Procedures “O,” “L,” AND “M” TYPE GEARCASES 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. Install the tools as shown by clamping them around the driveshaft. Alternately tighten the two vertical screws against the backing plate inserted between the puller and the gearcase until the driveshaft pops loose from the pinion.

If upper driveshaft becomes separated from lower driveshaft, use Lower Driveshaft Puller, P/N 342681, to remove. Install puller into lower driveshaft and turn 90° to position hook under pin in driveshaft. Thread Slide Hammer, P/N 391008, into puller and remove driveshaft.

1

2 46905

3 1. Drive shaft 2. Puller 3. Backing plate

41177

12

319

GEARCASE DISASSEMBLY

Driveshaft Service “S2” TYPE GEARCASE Removal IMPORTANT: To separate the upper driveshaft from the lower driveshaft, the upper retainer must be removed and upper driveshaft must slide down into lower driveshaft. Remove the four driveshaft bearing housing screws with washers and bearing housing.

005424

Force upper driveshaft into lower driveshaft. This moves lower retainer on stepped groove of lower driveshaft. Refer to diagram below.

1 1

1. Driveshaft bearing housing screws

005422

Remove upper retainer

1

1. Retainer

005423

Upper Driveshaft Removal

005411

Lift and remove upper driveshaft from lower driveshaft.

320

GEARCASE DISASSEMBLY Installation To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown.

1

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

1

1. Retainer(s)

005412 1. Seal protector

Hold lower retainer in place and align upper driveshaft with lower driveshaft. Force upper driveshaft down until seated. Make sure upper driveshaft is locked in place.

COA3130

Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N·m).

1

1. Driveshaft bearing housing screws

1

005425

005413

12

321

GEARCASE DISASSEMBLY “O,” “L,” AND “M” TYPE GEARCASES Refer to DISASSEMBLY on p. 314 for driveshaft removal.

Install the upper driveshaft into the lower driveshaft, aligning the holes in the driveshaft retainer and the lower driveshaft.

To separate the upper driveshaft (if needed) from the lower driveshaft, remove the roll pin. Replace the damaged component.

29330

Install the roll pin to the specified dimension.

29337

To assemble the driveshaft, install new driveshaft retainer into the groove of the upper driveshaft.

1 1. Roll pin

29338

322

0.125 in. (3.2 mm) DR4610

GEARCASE GEARCASE HOUSING INSPECTION

Shift Housing, Gear and Propeller Shaft Removal Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out. Unthread the shift rod from the detent lever. Remove the six screws, shift rod, and cover from the gearcase. Discard the cover gasket. Remove and discard the shift rod O-ring from inside of cover.

GEARCASE HOUSING INSPECTION Thoroughly clean gearcase housing to remove all dirt and debris prior to inspection. Inspect pinion bearing and forward thrust surface of gearcase housing. Use Gearcase Alignment Gauge Kit, P/N 5006349 to check the condition of gearcase housing prior to reassembly. Refer to instructions provided with kit. Use Gauging Head, P/N 352879, for “S” Type gearcase housings.

1

1. Cover gasket

COA3141

Remove propeller shaft assembly from gearcase. 004315 005072

IMPORTANT: DO NOT force gauging shaft into

COA3149

alignment hole. Shaft MUST slide easily into hole of gauging head. If shaft does not slide into hole, gearcase housing is damaged and must be replaced.

Water Intake Screens Remove and clean water intake screens. Replace if damaged.

1

12 1 1. Gauging shaft

1. Water intake screen

004347

001991

323

GEARCASE BEARING AND SEAL REMOVAL Remove the gear, thrust bearing, and thrust washer from the shift housing.

BEARING AND SEAL REMOVAL Shift Housing

1

WARNING Wear safety glasses to avoid injury.

2

IMPORTANT: The shift housing and forward gear bearing are serviced as an assembly. If either are worn or damaged, replace the complete assembly. Disassembly Insert a suitable tool under one end of the clutch dog spring and remove it from its groove by unwrapping it from around the clutch dog. Discard the spring.

3

COA3562

1. Gear 2. Thrust bearing 3. Thrust washer

Remove the shift lever pin from the housing. Remove shift shaft, cradle and shift lever. Move shifter detent accordingly to assist in removal of components.

5

4

1 3 1 2

1. Clutch dog spring

COA3560

Push the pin out of the clutch dog. Remove all components.

1. 2. 3. 4. 5.

DSC02449 DSC02489

Shift lever pin Shift shaft Cradle Shift lever Shifter detent

WARNING Wear safety glasses to avoid personal injury. The detent ball and spring and come out with great force.

1 1. Pin

324

COA3561

GEARCASE BEARING AND SEAL REMOVAL Wrap the housing with a shop cloth to catch ball and spring. Rotate the shifter detent 90° in either direction, then pull the detent out of the housing.

“S” TYPE GEARCASES Use a mallet to drive the bearing from the housing.

1 2 2 3

1

4

1. Shifter detent 2. Ball and spring

5

DSC02518

6

Remove the detent ball and spring. Remove needle bearings from bearing housing for cleaning and inspection (“O,” “L,” and “M” Type).

Pinion Gear Bearing If the pinion bearing must be replaced, assemble Pinion Bearing Remover and Installer, P/N 391257, in the gearcase as follows: Remove pinion bearing retaining screw.

1. 2. 3. 4. 5. 6.

1/4-20 x 1/2 in. Hex Head Screw 1 in. O.D. Flat Washer Plate, P/N 391260 Rod, P/N 326582 Installer/Remover, P/N 326574 1/4-20 x 1 1/4 in. Hex Head Screw

824163

“O”, “L,” AND “M” TYPE GEARCASES Use a 7/8 in. wrench to hold the remover in place. Use a 3/4 in. wrench to turn flange nut clockwise. Draw the bearing up from the housing.

1 2

2 1

3

4 3 1. Pinion bearing retaining screw 2. Water screen pocket 3. Seal

DSC02370 DRC7416 DSC02313

12 1. 2. 3. 4.

Flange nut, P/N 326586 Plate, P/N 391260 Rod, P/N 326582 Remover, P/N 326579

DR3419

325

GEARCASE BEARING AND SEAL REMOVAL

Driveshaft Bearing Housing

Propeller Shaft Bearing Housing

The driveshaft bearing is not serviceable. Replace the bearing housing assembly if the bearing is worn or damaged. Also, inspect the driveshaft bearing surface if the bearing is damaged.

Rear Seal Removal

Seal Removal

Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.

Remove the driveshaft bearing housing seals using Puller Bridge, P/N 432127, and Large Puller Jaws, P/N 432129. Discard the seals.

13520

Bearing Removal 14155

Remove the O-ring from the bearing housing and discard. Clean the bearing housing in solvent to remove sealer from the seal bore and the O-ring groove.

Rear seals must be removed if bearing replacement is needed. See Rear Seal Removal.

IMPORTANT: Inspect bearings in place. If a bearing is removed for any reason, it must be discarded. Remove either bearing using Puller Bridge, P/N 432127, and Large Puller Jaws, P/N 432129. Rest the puller plate on top of the housing to support the bridge, and tighten the jaws securely behind the bearing.

13522

326

GEARCASE BEARING AND SEAL INSTALLATION Inspect the bearing housing anode. Replace anode if it is reduced to two-thirds of original size.

1

BEARING AND SEAL INSTALLATION Shift Housing IMPORTANT: Clean and inspect all components before beginning assembly procedures. Replace any damaged components. Lightly coat the detent ball and spring with Needle Bearing grease. Insert the spring in the housing, then the ball.

1. Anode

001220

Discard the bearing housing O-ring. Clean the housing and bearings in solvent and dry thoroughly. If bearings were not replaced, rotate the needles to check for freedom of movement. Inspect O-ring groove, and sand off any sharp edges that would cut O-ring and prevent its sealing. Check for and remove any nicks or burrs on front of bearing housing.

1

4518

Insert shifter detent at 90° angle into the housing as shown, while depressing the ball and spring with a suitable tool. Once the shifter detent is past the ball, remove the tool and position detent to engage NEUTRAL position. 1. O-ring groove

DSC02291

12 DSC02506

327

GEARCASE BEARING AND SEAL INSTALLATION Thoroughly grease 25 needle bearings with Needle Bearing grease and place in the bearing case (except “S” Type).

Position the shift lever arms into the recesses of the shift cradle. Pull shifter detent back up to NEUTRAL position to hold the cradle and shaft in place.

4520

With shifter detent in NEUTRAL, install arms of shift lever into detent slots. Align the pivot holes and insert the retaining pin. Push shifter detent down.

001219

Coat thrust bearing and thrust washer with Needle Bearing grease. Place the bearing on the back of the gear. Set the washer on top of the thrust bearing. Insert the gear, bearing, and washer into the bearing housing.

IMPORTANT: Bearing and washer must be installed in the correct order. 1

3

2

2 1 1. Shifter detent 2. Shift lever 3. Pin, shift lever

DSC02449

Rest the cradle on the shift shaft.

1. Thrust bearing 2. Thrust washer

1 2

TYPICAL 1. Cradle 2. Shift shaft

328

4512

DSC02297

GEARCASE BEARING AND SEAL INSTALLATION Align holes in the clutch dog with slot in the propeller shaft. Install the clutch dog on the shaft with “PROP END” facing rear of the shaft.

IMPORTANT: The clutch dog is not symmetrical. If installed backward, it will not fully engage and will immediately damage itself and the gears.

Pinion Gear Bearing Assemble the following components of Pinion Bearing Remover and Installer, P/N 391257, as shown:

1 2 3 4 5

6 1 1. “PROP END”

7

COB7581

Slide the propeller shaft onto the shift shaft, align the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring. Position three coils over each end of the pin, MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE.

“S” Type Gearcases 1. 1/4-20 X 1/2 in. Hex head screw 2. 1 in. O.D. Flat washer 3. Spacer, P/N 341437 4. Plate, P/N 391260 5. Rod, P/N 326582 6. Installer/Remover, P/N 326574 7. 1/4-20 X 1 1/4 in. Hex head screw

824182

1 2 3* 4

5 1 1. Retaining spring

6

COB3101

7 “O,” “L,” and “M” Type Gearcases 1. 1/4-20 X 1/2 in. Hex head screw 2. 1 in. O.D. Flat washer 3. Spacer; P/N 350932 “M” and “XP”, P/N 326584 “L” 4. Plate and Bearing P/N 391260 5. Rod P/N 326582 6. Installer/Remover, P/N 350958 7. 1/4-20 X 1 1/4 in. Hex head screw

824182

IMPORTANT: Spacers are different sizes and cannot be interchanged.

329

12

GEARCASE BEARING AND SEAL INSTALLATION Apply Needle Bearing grease to the needle bearings and insert them into the bearing case (except “S” Type). Place the bearing on the installer tool with the lettered side of the bearing facing the top of the gearcase. Use Needle Bearing grease to hold the bearing on the tool.

IMPORTANT: The pinion bearing is tapered so

Driveshaft Bearing Housing Lightly apply Gasket Sealing Compound to a new O-ring. Install the O-ring in top groove of the bearing housing. Do not allow sealant in oil passage.

IMPORTANT: Do not install the O-ring in the bearing housing’s bottom groove. The bottom groove is an oil passage. Gearcase damage could result.

that, when installed correctly, its shape compensates for stresses in the gearcase and allows full bearing contact. Whenever a gearcase is disassembled, the pinion bearing should be checked to ensure that it has been installed with the lettering facing up.

1

2

Insert the tool with the bearing into the gearcase. Drive the bearing into the gearcase until the washer on the tool contacts the spacer. 1. O-ring (top groove) 2. Oil passage

Remove the tool. Position new O-ring on the pinion bearing retaining screw. Apply Gasket Sealing Compound to Oring. Apply Nut Lock to screw threads. Install the screw and torque to 60 to 84 in. lbs. (7 to 9.5 N·m).

14156

Install new seals back to back in bearing housing using Seal Installation Tool, P/N 330268. Apply Gasket Sealing Compound to metal casings of the seals before installing. Install inner seal with lip facing toward bearing housing, then the outer seal with lip facing away from bearing housing. Apply Triple-Guard grease to seal lips.

1

1 1. O-ring

DRC7416

2 1. Inner seal 2. Outer seal

330

DR2061 DR2062

GEARCASE BEARING AND SEAL INSTALLATION

Propeller Shaft Bearing Housing

Rear Seal Installation

Bearing Installation Oil, then install new bearings in bearing housing. Place the lettered end of the bearing case on the bearing installer, then press the bearing into the housing until the tool seats. When installed, the lettered end of the bearing should be visible. Bearing Installation Tool: • P/N 326562 – “S” Type gearcases • P/N 339750 – “O,” “L,” and “M” Type gearcases

Install new seals back to back in bearing housing using Seal Installation Tool. Apply Gasket Sealing Compound to metal casings of the seals before installing. Install inner seal with lip facing toward the bearing housing, then outer seal with lip facing away from the bearing housing. Seal Installation Tool: • P/N 326551 – “S” Type gearcases • P/N 336311 – “O,” “L,” and “M” Type gearcases

1

1

Forward Bearing 1. Bearing installation tool

29967

2

1 1. Inner seal 2. Outer seal

DR2061 DR2062

Apply Triple-Guard grease to seal lips. Install bearing housing anode. Torque screws to 108 to 132 in. lbs. (12.2 to 14.9 N·m). Rear Bearing 1. Bearing installation tool

1

44237

12

1. Anode

001220

331

GEARCASE DRIVESHAFT SHIMMING

DRIVESHAFT SHIMMING IMPORTANT: If new pinion gear is needed, replace gear set before shimming. Pinion gear backlash is achieved by using shims between the driveshaft bearing housing and the thrust washer. When installing a new thrust bearing or washer, bearing housing, pinion, or driveshaft, it is necessary to properly shim the assembly to restore factory clearance. Use Driveshaft Shimming Tool, P/N 5005925 (replaces P/N 393185). Shim gauge bars are precision made and should be handled carefully. The length of each bar is stamped near the part number. This dimension is 0.020 in. (0.508 mm) shorter than the actual shimmed length of the driveshaft.

“O,” “L,” AND “M” TYPE GEARCASES IMPORTANT: Degrease pinion and driveshaft tapers prior to assembly. Check tapers for any damage or material transfer. Replace any damaged components before proceeding. Assemble the driveshaft bearing housing, thrust washer, thrust bearing, and pinion onto the driveshaft. Use Driveshaft Seal Protector, P/N 318674, whenever installing or removing the bearing housing. Lightly coat the threads of the pinion nut with outboard lubricant and torque to 100 to 110 ft. lbs. (136 to 149 N·m).

IMPORTANT: The original pinion nut may be used for shimming, but must NOT be used in final assembly. 1

2

3

4

“S2” TYPE GEARCASE IMPORTANT: Clean pinion and driveshaft prior to assembly. Assemble the driveshaft bearing housing, thrust washer, thrust bearing, and pinion onto the driveshaft. Install shimming screw, P/N 352878 and torque to 37 to 41 ft. lbs. (50 to 56 N·m).

IMPORTANT: The original pinion screw is NOT used for shimming, but is used in final assembly. Use Shimming Screw, P/N 352878 (service tool) for shimming procedure.

1. 2. 3. 4.

Driveshaft bearing housing Thrust washer Thrust bearing Pinion

COA3565

ALL GEARCASES Select collar, P/N 341440, and the correct shim gauge bar: • “M”-type: Shim gauge bar, P/N 349957 • “S,”-type: Shim gauge bar, P/N 328367 • “L,”-type: Shim gauge bar, P/N 328367 • “O”-type: Shim gauge bar, P/N 328367

1

Slide the collar onto the driveshaft with large end in contact with the bearing housing.

1. Shimming screw

332

005414

Insert the assembled driveshaft into the tool base and tighten preload screw against the driveshaft until groove on the spring-loaded plunger is flush

GEARCASE DRIVESHAFT SHIMMING with end of threads. Tighten locking ring on preload screw.

5 1 2 3

4 1. 2. 3. 4. 5.

“S2” Type Gearcase - pinion shimming bolt “O”, “L”, “M”, Type Gearcases - pinion nut Collar Tool base Groove

COA3566 DSC00326 005415

Rotate the driveshaft several revolutions to seat bearings. Lay the tool base on its side. Position the shim gauge bar against guide pins of the tool base.

Check the squareness of the pinion to the driveshaft by holding the shim gauge bar against the bearing housing (between the screw holes) while rotating just the driveshaft and pinion assembly and measuring the clearance between the shim gauge bar and the pinion. Replace the pinion or the driveshaft, as necessary, and repeat the check if variance exceeds 0.002 in. (0.050 mm). Subtract the average clearance measurement obtained from 0.020 in. (0.508 mm) to determine the correct shim thickness required. Select the fewest number of shims to achieve the correct thickness. Remove the driveshaft from the tool base. Remove the collar and bearing housing from the driveshaft, and add the required amount of shims.

IMPORTANT: Use extreme care when removing bearing housing to avoid damaging the seals. Use Driveshaft Seal Protector, P/N 318674. Check shimming by reassembling the driveshaft with shims and placing it back into the tool base. The measurement between the gauge bar and the pinion should be 0.020 in. (0.508 mm).

1

1. Shim gauge bar

005416

Check the squareness of the bearing housing mounting surface by holding the shim gauge bar against the pinion while rotating just the bearing housing and measuring the clearance between the gauge bar and the bearing housing with feeler gauges. Measure between each pair of screw holes. Replace the bearing housing and repeat check if variance exceeds 0.004 in. (0.010 mm).

005417

“S2” TYPE GEARCASE Remove the shimming screw and pinion from the driveshaft.

IMPORTANT: Make sure shimming screw is not installed in assembled gearcase. “O,” “L,” AND “M” TYPE GEARCASES Remove the nut and pinion from the driveshaft. Discard the nut.

333

12

GEARCASE ASSEMBLY

ASSEMBLY

Shift Rod Housing Installation

Water Intake Screens Install water intake screens. Torque screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

Lubricate a new shift rod cover O-ring with TripleGuard grease. Install the O-ring into the shift rod cover.

IMPORTANT: Make sure O-ring is fully seated in groove around shift rod cover’s full circumference.

1 1

1. Water intake screen

001991

Shift Housing, Gear, and Propeller Shaft Installation

12308

1. O-ring

Push shifter detent into farthest downward position. Tip the rear of the gearcase slightly downward to assist in the installation of the shaft assembly. Be sure the thrust bearing and the thrust washer are properly positioned. Insert the shaft assembly fully into the gearcase while aligning shift housing pin with hole in forward end of gearcase housing.

Place the shift rod grommet on the shift rod. Install shift rod spacer under grommet on 25 in. models.

2

1 1

1. Pin

1. Grommet 2. Shift rod spacer (25” models)

005427

COA3568

Apply Triple-Guard grease to the threaded end of the shift rod and insert it through the cover. Turn the shift rod while pushing it through the cover to avoid damaging the O-ring. Apply Gasket Sealing Compound to both sides of a new shift rod cover gasket. Position the gasket

334

GEARCASE ASSEMBLY on the gearcase. Thread the shift rod into the shifter detent about four turns.

2

Pinion Gear and Driveshaft Installation Refer to DRIVESHAFT SHIMMING on p. 332

“S2” TYPE GEARCASE Position the driveshaft thrust bearing, thrust washer, and correct shim(s) on driveshaft as shown.

1

3 2 1. Cover gasket 2. Grommet

COA3141

1

Move shift rod from side to side while pushing on the propeller shaft to ensure proper alignment of the bearing housing locator pin into the locator pin hole in the gearcase. Apply Ultra Lock to the threads of the shift rod cover screws. Install the screws. Torque the screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Thrust bearing 2. Thrust washer 3. Shim(s)

005418

Push down on shift rod to move the clutch dog to reverse position. Pull propeller shaft aft to disengage from forward gear and shift housing. Allow shaft to drop against lower gearcase housing. This will allow the installation of the pinion gear.

1 COA3569

1. Propeller shaft

005405

IMPORTANT: Forward gear and thrust bearing and washer can become misaligned. Make sure forward thrust washer and thrust bearing and forward gear are properly aligned with shift housing before continuing gearcase assembly.

335

12

GEARCASE ASSEMBLY Install pinion gear in gearcase housing

IMPORTANT: Temporarily install bearing housing for support during pinion torque procedure.

005420

Install driveshaft with thrust bearing, thrust washer, and correct shim(s) in gearcase housing. Position pinion on lower driveshaft.

005426

Insert Lower Driveshaft Spline Tool, P/N 5007052, into lower driveshaft.

1

1. Lower Driveshaft Spline Tool

005407

005410

Position pinion screw in lower driveshaft and thread into pinion.

Insert Lower Driveshaft Wrench, P/N 352877, through Lower Driveshaft Spline Tool and lower driveshaft. Seat hex tip of wrench in head of pinion screw.

1

005421 1. Wrench, hex tip

005408

IMPORTANT: Make sure Lower Driveshaft Wrench is fully seated in head of pinion screw. 336

GEARCASE ASSEMBLY Use a long 3/4 in. combination wrench to hold Driveshaft Spline Tool and a 1/2” drive torque wrench to turn the Lower Driveshaft Wrench in a clockwise direction. Torque pinion screw to 37 to 41 ft. lbs. (50 to 56 N·m).

Hold lower retainer and align upper driveshaft with lower driveshaft. Force upper driveshaft down until seated. Driveshaft should lock in place.

005413 005409

Temporarily remove the four driveshaft bearing housing screws with washers and bearing housing.

005421

To install upper driveshaft into lower driveshaft, position new retainers (circlip type) on upper driveshaft as shown.

1

12

1. Retainer(s)

005412 Upper Driveshaft Installation

0054

337

GEARCASE ASSEMBLY Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

1

“O,” “L,” AND “M” TYPE GEARCASES Refer to DRIVESHAFT SHIMMING on p. 332 before proceeding. Position the driveshaft thrust bearing, thrust washer, and shim(s) (selected earlier) on the driveshaft, exactly in order shown.

3 1 2

1. Seal protector

COA3130

Install washers on the driveshaft bearing housing screws. Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N·m).

1

1. Driveshaft bearing housing screws

1. Thrust bearing 2. Thrust washer 3. Shim(s)

COA3168

Install new seals in driveshaft bearing housing. Refer to Driveshaft Bearing Housing on p. 326. Using Driveshaft Seal Protector, P/N 318674, slide the driveshaft bearing housing onto the driveshaft.

1

1

005425

1. Seal protector

COA3130

Move shift rod to position clutch dog as far forward as possible. Be sure excess grease is removed from the pinion bearing.

338

GEARCASE ASSEMBLY Washer must be snapped into recess of pinion gear.

1

Install washers on the driveshaft bearing housing screws. Apply Gasket Sealing Compound to the threads of the screws. Install screws and torque to 120 to 144 in. lbs. (13.6 to 16.3 N·m).

1 1. Washer

1

DSC02293

IMPORTANT: The inside taper of the pinion gear and the driveshaft taper MUST be completely free of grease. Clean the tapers with Cleaning Solvent. Use a shop towel free of grease and lint. Lightly coat the threads of a new pinion nut with outboard lubricant and install on the driveshaft using Pinion Nut Starting Tool, P/N 342216. Turn the driveshaft by hand to engage the nut. Hand tighten pinion nut and remove the pinion nut starting tool. Proceed to next step and then torque procedure.

1. Driveshaft bearing housing screws

COA3153

Use Driveshaft Holding Socket, P/N 311875, Pinion Nut Holder, P/N 334455, and Wrench Retainer, P/N 341438, to torque the pinion nut to 100 to 110 ft. lbs. (136 to 149 N·m).

1

3 2 1. Holding socket 2. Pinion holder 3. Retainer

42229

42230

12

339

GEARCASE ASSEMBLY

Propeller Shaft Bearing Housing and Gear Installation Oil and install thrust bearing and thrust washer on hub of reverse gear. Slide the reverse gear assembly onto the propeller shaft until it engages the pinion gear.

1

2 1. Retainer tab screws

1

001989

“O,” “L,” AND “M” TYPE GEARCASES Loosen retainer screws 1/4 turn. Install wedge, screw, and washer. Apply Ultra Lock to threads and torque screw 15 to 20 in. lbs. (1.7 to 2.3 N·m).

1. Thrust bearing 2. Thrust washer

DSC02295

Lightly apply Gasket Sealing Compound to a new bearing housing O-ring. Install O-ring in groove in the housing. Install housing into gearcase, aligning screw holes with retainer slots in gearcase. Housing must be completely seated to install retainer tabs. DSM02291 DSC02361

Re-torque two retainer screws to 18 to 20 ft. lbs. (24 to 27 N·m). Confirm that torque on the wedge screw is 15 to 20 in. lbs. (1.7 to 2.3 N·m).

Retainer Tab Notch

50106a

Install two retainers, washers and screws. Apply Ultra Lock to threads and torque screws 18 to 20 ft. lbs. (24 to 27 N·m).

340

To complete gearcase assembly, refer to: • LEAK TEST on p. 308 • WATER PUMP on p. 311 • SHIFT ROD ADJUSTMENT on p. 314 • REMOVAL AND INSTALLATION on p. 308 • LUBRICANT on p. 307 • Propeller Hardware Installation on p. 74 • Trim Tab Adjustment on p. 77 During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.

GEARCASE COUNTER ROTATION

COUNTER ROTATION IMPORTANT: Counter rotation model gearcases use unique components and require different service procedures. Use care when working on counter rotation gearcases. DO NOT interchange parts between standard and counter rotation models. Pay particular attention to these procedures when working on counter rotation gearcases.

To remove the propeller shaft, bearing housing and forward gear from a counter rotation gearcase, thread Propeller Shaft Adapter, P/N 432398, onto Slide Hammer, P/N 432128, until it seats. Thread adapter completely onto propeller shaft and pull propeller shaft, bearing housing, and forward gear assembly out of gearcase.

1

Propeller Shaft Bearing Housing Removal Remove the two screws, washers, and retainers holding the propeller shaft bearing housing.

2

1

1. Adapter, P/N 432398 2. Hammer, P/N 432128

13501

Shift Housing, Gear and Propeller Shaft Removal

1. Retainer tab screws

001989

Remove wedge, screw, and washer.

Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaft assembly is pulled out. Unthread the shift rod from the detent lever. Remove the six screws, shift rod, and cover from the gearcase. Discard the cover gasket. Remove the shift rod Oring from inside of cover and discard.

1

12 1. Cover gasket DSM02291 DSC02361

COA3141

Use an appropriate tool to apply downward pressure on the detent while pulling on the propeller

341

GEARCASE COUNTER ROTATION shaft assembly. Remove propeller shaft assembly from the gearcase.

Push the pin out of the clutch dog. Remove all components.

1

1 1. Pin

Counter Rotation Models 1. Tool

14038 13489

COA3561

Remove the gear, thrust bearing, and thrust washer from the shift housing.

Shift Housing Service

1

WARNING 2

Wear safety glasses to avoid injury.

3

Disassembly IMPORTANT: The shift housing and forward gear bearing are serviced as an assembly. If either are worn or damaged, replace the complete assembly. Insert a suitable tool under one end of the clutch dog spring and remove it from its groove by unwrapping it from around the clutch dog. Discard the spring.

1

1. Clutch dog spring

342

COA3560

1. Gear 2. Thrust bearing 3. Thrust washer

COA3562

IMPORTANT: The shift housing supports the reverse gear on counter rotation gearcases. Remove the shift lever pin from the housing. Remove shift shaft, cradle and shift lever. Move

GEARCASE COUNTER ROTATION shifter detent accordingly to assist in removal of components.

Assembly IMPORTANT: Clean and inspect all components before beginning assembly procedures. Replace any damaged components. Lightly coat the detent ball and spring with Needle Bearing grease. Insert the spring in the housing, then the ball.

DSC02421

WARNING Wear safety glasses to avoid personal injury. The detent ball and spring and come out with great force. 4518

Wrap the housing with a shop cloth to catch ball and spring. Pull the shifter detent straight out of the housing.

2

Insert shifter detent into the housing as shown, while depressing the ball and spring with a suitable tool. Once the detent is past the ball, remove the tool and position detent to engage NEUTRAL.

1

1 1. Ball and spring 2. Shifter detent

DSC02436

1. Pin, shift lever (used as tool)

DSC02442

Remove the detent ball and spring.

12

Remove needle bearings from bearing housing for cleaning and inspection.

343

GEARCASE COUNTER ROTATION Thoroughly grease 25 needle bearings with Needle Bearing grease and place in the bearing case.

Position the shift lever arms into the recesses of the shift cradle. Pull shifter detent back up to NEUTRAL to hold the cradle and shaft in place.

001219

4520

With shifter detent in NEUTRAL, install arms of shift lever into detent slots. Align the pivot holes and insert the retaining pin. Push shifter detent down.

Inspect clutch shaft detent balls, retainer and spring. These parts should not require removal under normal servicing.

WARNING Wear safety glasses to avoid injury.

1

3

If these parts are damaged or removed, a new service kit should be installed. Refer to correct model parts catalog for kit part number.

1 2 1. Shifter detent 2. Shift lever 3. Pin, shift lever

DSC02449

2

Rest the cradle on the shift shaft.

TYPICAL 1. Clutch Shaft Retainer Kit 2. Clutch Shaft

Coat thrust bearing and thrust washer with Needle Bearing grease. Place the bearing on the back of the gear. Set the washer on top of the thrust bearing. Insert the gear, bearing, and washer into the bearing housing.

1 2

TYPICAL 1. Cradle 2. Shift shaft

344

0000

4512

GEARCASE COUNTER ROTATION IMPORTANT: Bearing and washer must be installed in the correct order.

end of the pin, MAKING SURE NONE OF THE COILS OVERLAP OR ARE LOOSE.

2

1

1 1. Thrust bearing 2. Thrust washer

DSC02297

Align holes in the clutch dog with slot in the propeller shaft. Install the clutch dog on the shaft with “PROP END” facing rear of the shaft.

IMPORTANT: The clutch dog is not symmetrical. If installed backwards, it will not fully engage and will immediately damage itself and the gears.

1. Retaining spring

COB3101

Propeller Shaft Bearing Housing and Forward Gear Disassembly Remove and discard the bearing housing O-ring. Remove the anode and discard if more than twothirds deteriorated. Clamp the bearing housing by the anode bosses in a vise, as shown. Remove the forward gear assembly by unscrewing it with Spanner Wrench, P/N 432400.

1 1. “PROP END”

COB7581

Slide the propeller shaft onto the shift shaft, align the hole in the shaft with the hole in the clutch dog, install the pin and then, a new clutch dog retaining spring. Position three coils over each 13491

345

12

GEARCASE COUNTER ROTATION Remove gear housing retaining ring.

Remove the thrust bearing.

1

1. Retaining ring

DSC02486 31963

Remove the set screws and remove the flange.

Remove the bearing housing from the forward gear.

31965

Remove the shim from either the flange or forward gear.

31961

Remove the thrust bearing from the forward gear. Inspect the forward gear for excessive wear or damage.

31964

31960

346

GEARCASE COUNTER ROTATION Remove the forward gear bearing only if it needs to be replaced. If removal of the bearing is necessary, use Large Puller Jaws, P/N 432129, and Puller Bridge, P/N 432127, with an appropriate base. Leave the rollers in to allow for good contact with the puller jaws.

Install the thrust bearing on the forward gear.

31960

Place the bearing housing on the forward gear.

31958

If removed, install a new forward gear bearing. Apply Needle Bearing grease to 25 new rollers. Install the rollers in the bearing. Using Bearing Installation Tool, P/N 339778, install the bearing, lettered side facing tool.

31960

Install 0.030 in. (0.7 mm) of shims and the thrust bearing in the flange. Install the thrust bearing on the forward gear.

31956

12

31955

347

GEARCASE COUNTER ROTATION Install set screws and torque to 144 to 168 in. lbs. (16.3 to 19 N·m). Use no thread sealant.

31968 31967

Anchor a dial indicator gauge to a flat, level surface. Position the gear assembly so the indicator needle makes contact with the flange on the housing. The indicator needle must be parallel with the side of the gear housing and perpendicular to the table surface. Zero the dial indicator.

Remove the 0.030 in. (0.7 mm) of shims from the assembly. Reassemble the gear assembly using a combination of shims to achieve the required thickness. Apply Nut Lock to the threads of the set screws and torque to 144 to 168 in. lbs. (16.3 to 19 N·m). Push propeller shaft out of the bearing housing.

13479

Remove the thrust washer and thrust bearing. 31953

Grip the bearing housing 180° apart and pull up to get a reading on the indicator. To determine thickness of shims; use the following example: 0.030 in. of shims in the assembly – 0.020 in. reading on the dial indicator = 010 in. difference + 0.001 in. necessary end play = 0.011 in. required shims

348

2

1

1. Thrust washer 2. Thrust bearing

13593

GEARCASE COUNTER ROTATION For seal and bearing service, refer to Propeller Shaft Bearing Housing Seals and Bearings on p. 350.

Install gear housing retaining ring as shown.

Assembly Apply Needle Bearing grease to the thrust bearing. Position bearing around shoulder on the propeller shaft.

1

1

Apply Needle Bearing grease to the thrust washer. Place washer in recess of bearing housing.

1. Retaining ring

Apply gearcase lubricant to the threads of the forward gear.

1 2

1. Thrust bearing 2. Thrust washer

14214

IMPORTANT: To prevent damage to threads, install forward gear by hand until fully seated against propeller shaft bearing housing. Use Spanner Wrench, P/N 432400, to tighten the gear assembly to a torque of 100 ft. lbs. (136 N·m).

Coat bearing surfaces of propeller shaft with gearcase lubricant. Slide the propeller housing onto the propeller shaft.

13529

Inspect the anode. Replace if necessary. Torque screws to 108 to 132 in. lbs. (12.2 to 14.9 N·m). 14159

12

IMPORTANT: Use caution when assembling the propeller shaft in the bearing housing. Thrust bearing must remain around shoulder on the propeller shaft.

349

GEARCASE COUNTER ROTATION port the bridge, and tighten the jaws securely behind the bearing.

Propeller Shaft Bearing Housing Seals and Bearings Rear Seal Removal Remove seals using Puller Bridge, P/N 432127, and Small Puller Jaws, P/N 432131. Position the plate on top of the housing to support the bridge, and tighten jaws securely behind the inner seal.

13522

Inspect the bearing housing anode. Replace anode if it is reduced to two-thirds of original size.

1 13520

Bearing Removal Rear seals must be removed if bearing replacement is needed. See Rear Seal Removal on p. 326.

IMPORTANT: Inspect bearings in place. If a bearing is removed for any reason, it must be discarded. Remove either bearing using Puller Bridge, P/N 432127, and Large Puller Jaws, P/N 432129. Rest the puller plate on top of the housing to sup-

1. Anode

001220

Discard the bearing housing O-ring. Clean the housing and bearings in solvent and dry thoroughly. If bearings were not replaced, rotate the needles to check for freedom of movement. Inspect O-ring groove, and sand off any sharp edges that would cut O-ring and prevent its sealing. Check for and remove any nicks or burrs on front of bearing housing.

1

1. O-ring groove

350

DSC02291

GEARCASE COUNTER ROTATION Bearing Installation

Rear Seal Installation

Oil, then install new bearings in bearing housing.

Install new seals back to back in bearing housing using Seal Installer. Apply Gasket Sealing Compound to metal casings of the seals before installing.

Place the lettered end of the bearing case on the bearing installer, then press the bearing into the housing until the tool seats. When installed, the lettered end of the bearing should be visible. Bearing Installation Tool: • P/N 339750 – rear (counter rotation only) • P/N 432401 – forward (counter rotation only)

Install inner seal with lip facing toward the bearing housing, then outer seal with lip facing away from the bearing housing. Seal Installation Tool: • P/N 326551 – “S” Type gearcases • P/N 336311 – “O,” “L,” and “M” Type gearcases

1

1 Forward Bearing – Counter Rotation 1. Forward bearing installation tool

13519

1

2 1. Inner seal 2. Outer seal

DR2061 DR2062

Apply Triple-Guard grease to seal lips. Rear Bearing 1. Bearing installation tool

44237

Install bearing housing anode. Torque screws to 108 to 132 in. lbs. (12.2 to 14.9 N·m).

1

1. Anode

001220

351

12

GEARCASE COUNTER ROTATION Housing must be completely seated to install retainer tabs.

Propeller Shaft Bearing Housing and Gear Installation Oil and install thrust bearing and thrust washer on the hub of reverse gear. Slide the gear assembly onto the propeller shaft until it engages the pinion gear.

2

1

1. Thrust bearing 2. Thrust washer

DSC02295

Lightly apply Gasket Sealing Compound to a new bearing housing O-ring. Install O-ring in groove in the housing.

Retainer Tab Notch

50106a

Install two retainers, washers and screws. Apply Ultra Lock to threads and torque screws to 18 to 20 ft. lbs. (24 to 27 N·m).

Install housing into gearcase, aligning screw holes with retainer slots in gearcase.

1

IMPORTANT: The propeller shaft must engage the clutch shaft and the forward gear must fully engage the pinion gear.

1. Retainer tab screws

Loosen retainer screws 1/4 turn.

13586

352

001989

GEARCASE COUNTER ROTATION Install wedge, screw, and washer. Apply Ultra Lock to threads and torque screw 15 to 20 in. lbs. (1.7 to 2.3 N·m).

DSM02291 DSC02361

Re-torque two retainer screws to 18 to 20 ft. lbs. (24 to 27 N·m). Confirm that torque on the wedge screw is 15 to 20 in. lbs. (1.7 to 2.3 N·m). To complete gearcase assembly, refer to: • LEAK TEST on p. 308 • WATER PUMP on p. 311 • SHIFT ROD ADJUSTMENT on p. 314 • REMOVAL AND INSTALLATION on p. 308 • LUBRICANT on p. 307 • Propeller Hardware Installation on p. 74 • Trim Tab Adjustment on p. 77 During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.

12

353

GEARCASE NOTES

NOTES Technician’s Notes

Related Documents Bulletins

Instruction Sheets

Other

354

TRIM AND TILT

TRIM AND TILT TABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 MANUAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 TRAILERING BRACKET AND TILT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 MODES OF OPERATION (THREE PISTON SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 TRIM-OUT / TILT-UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 TILT-DOWN / TRIM-IN MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 IMPACT RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 SHALLOW WATER DRIVE TILT RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 THERMAL EXPANSION RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 MANUAL RELEASE – UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 MANUAL RELEASE – DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 ROUTINE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 RESERVOIR FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 MANUAL RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 STERN BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 THREE PISTON SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 SINGLE PISTON SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 ELECTRICAL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 RELAY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 TRIM AND TILT MOTOR CURRENT DRAW TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 TRIM AND TILT MOTOR NO LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 TRIM GAUGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 TRIM SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 SERVICING – THREE PISTON SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 TILT PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 TILT PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 TILT PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 TILT ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 TRIM ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 TRIM ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 MANIFOLD AND RESERVOIR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 TRIM ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 TILT ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 SERVICING–SINGLE PISTON SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

355

13

TRIM AND TILT SERVICE CHART

SERVICE CHART 20” 115 HP MODELS

(SINGLE PISTON SYSTEM)

30-50 In. lbs. (4-6 N·m)

A 45-55 In. lbs. (5.1-6.2 N·m)

W

45-55 In. lbs. (5.1-6.2 N·m)

A

005002

356

A Triple-Guard Grease W Biodegradable TNT Fluid

TRIM AND TILT SERVICE CHART

25” MODELS

(FASTRAK - THREE PISTON SYSTEM)

35-52 In. lbs. (4.0-5.9 N·m)

A

12-24 In. lbs. (1.4-2.7 N·m) 84-108 In. lbs. (9.5-12 N·m)

58-87 Ft. lbs. (79-118 N·m)

60-84 In. lbs. (6.8-9.5 N·m)

60-70 Ft. lbs. (81-95 N·m)

F

DO NOT OVER TIGHTEN 45-55 In. lbs. (5.1-6.2 N·m)

58-87 Ft. lbs. (79-118 N·m)

60-84 In. lbs. (6.8-9.5 N·m)

35-52 In. lbs. (4.0-5.9 N·m)

DSS130

A B C D E F G

Triple-Guard Grease Gasket Sealing Compound

13

Adhesive 847 Moly Lube Red Ultra Lock Blue Nut Lock Needle Bearing Grease

357

TRIM AND TILT SYSTEM DESCRIPTION

SYSTEM DESCRIPTION The power trim/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

Trailering Bracket And Tilt Support Use the trailering bracket to support the outboard when trailering in the tilted position. This bracket protects the hydraulic system from damage. Tilt the outboard up fully, engage the bracket, then tilt the outboard down until the bracket is firmly in position.

Optimal boat and outboard performance can be achieved by adjusting (trimming) the angle of outboard propeller thrust. The first 15° of outboard movement is considered trim range.

1

Outboard movement beyond the trim range is considered tilting. Tilting of the outboard may be desired for shallow water drive and for trailering/storage. The tilt cylinder moves the outboard through the tilt range (final 50°). A tilt relief valve limits the propeller thrust load that will be supported by the unit in tilt range. As pressure increases, the outboard will tilt down to the top of the trim range.

IMPORTANT: When in tilt range, make sure water is available to gearcase water pickups.

1. Trailering Bracket

001987

For mooring or storing the boat with the outboard tilted, a tilt support is provided to support the outboard.

Manual Adjustment The outboard can be manually raised or lowered through the entire trim and tilt range by opening the manual release valve a minimum of three turns. The manual release valve must be closed and torqued 45 to 55 in. lbs. (5 to 6 N·m) to hold the outboard in position and before normal operation can be resumed.

1

1. Tilt support

002279

IMPORTANT: The tilt support must not be used to support the outboard while trailering.

1

1. Manual release valve

358

001988

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

MODES OF OPERATION (Three Piston System) The three piston trim/tilt hydraulic assembly achieves trim and tilt movement through the following modes of operation.

2

Trim-OUT / Tilt-UP Mode

3

1

When the UP switch is pressed, the trim/tilt motor rotates clockwise (as viewed from pump end) and turns the pump gears.

7

Fluid pressure passes through the UP shuttle valve to the DOWN shuttle valve, mechanically opening the DOWN check valve.

4

Fluid pressure pushes the UP check valve off its seat, and fluid passes through the valve to the bottom of all cylinders, pushing the pistons UP.

5

Fluid is pushed from the top of the tilt cylinder by the piston and returns to the pump through the open DOWN check valve. In the trim range, fluid is pushed from the top of the trim cylinders by the pistons and returns to the reservoir. Only fluid from the top of the tilt cylinder is returned to the pump. Because the cylinder rod displaces some fluid, that volume is less than the volume of the bottom of the tilt cylinder. So, additional fluid is drawn into the pump from the reservoir. When all the cylinders are completely extended, the pressure increases until the UP relief valve opens at the tilt-up stall pressure (approximately 1500 psi (10342 kPa)).

6

1. 2. 3. 4. 5. 6. 7.

Up shuttle valve Down shuttle valve Down check valve Up check valve Tilt cylinder Trim cylinders Up relief valve

DRC3462

13

359

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

Tilt-DOWN / Trim-IN Mode When the DOWN switch is pressed, the trim/tilt motor rotates counterclockwise (as viewed from pump end) and turns the pump gears. Fluid pressure passes through the DOWN shuttle valve to the UP shuttle valve, which mechanically opens the UP check valve. Fluid pressure pushes the DOWN check valve off its seat and fluid passes through the valve to the top of the tilt cylinder, moving the tilt piston DOWN.

2

1

5 4 3

When the swivel bracket contacts the top of the trim rods, the mechanical force of the tilt cylinder pulling the outboard down also pushes the trim pistons down. Fluid is pulled from the reservoir to the top of the trim cylinders. Fluid from the bottom of the cylinders returns through the open UP check valve to the pump. In the tilt range, all of the fluid from the bottom of the tilt cylinder returns through the UP check valve to the pump. Since more fluid is returning to the pump than is required to fill the top of the cylinder, the excess fluid is vented through the DOWN relief orifice to the reservoir. In the trim range, fluid from the bottom of all the cylinders is routed to the pump, which feeds only the top of the tilt cylinder. All of the excess fluid vents through the DOWN relief orifice to the reservoir. When all cylinders are completely retracted, all of the pump output vents through the DOWN relief orifice to the reservoir at stall pressure (approximately 800 psi (5516 kPa)).

360

1. 2. 3. 4. 5.

Down shuttle valve Up shuttle valve Up check valve Down check valve Down relief orifice

DRC3463

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

Impact Relief Should the gearcase hit an underwater object and the outboard suddenly tilts up, the tilt cylinder extends. The fluid above the piston is compressed, producing high pressure. This high pressure fluid passes through the impact relief valves in the tilt piston, dissipating much of the energy of the impact. To return the outboard to its original position, the hydraulic unit must be operated in the DOWN direction.

1

1. Impact relief valves

1

DRC3467

13

361

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

Shallow Water Drive Tilt Relief If the outboard exceeds idle RPM while operating in shallow water drive mode (tilted up beyond the trim range), increased pressure beneath the tilt piston forces fluid through the tilt relief valve built into the manual release valve. Fluid flows from below the tilt piston, through the tilt relief valve, and to the reservoir.

2

As the tilt piston moves down, the filter valve opens and allows fluid to flow from the reservoir to the top of the tilt cylinder. The outboard will tilt down to the top of the trim range.

Thermal Expansion Relief Ambient air temperature increase can cause fluid expansion within the hydraulic assembly. If the fluid expands when stored in the tilt range, the fluid under all of the pistons (and above the tilt piston) cannot expand, so its pressure increases.

3 1

If the pressure gets high enough to push the ball of the tilt relief valve off its seat, the excess pressure is vented to the reservoir.

1. Tilt relief valve 2. Manual release valve 3. Filter valve

362

DRC3465

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

Manual Release – UP The outboard can be positioned manually by first opening (loosening) the manual release valve.

2

Open the manual release valve (turn it slowly counterclockwise) with a screwdriver, about 3 1/2 turns, until it lightly contacts its retaining ring.

1 1

1. Manual release valve

001988

When the manual release valve is opened and the outboard is manually raised, fluid flows from the top of the tilt cylinder to the manual release valve. The fluid may pass through the manual release valve to the bottom of the tilt cylinder, or return to the reservoir. Additional fluid may be drawn from the bottom of the trim cylinders, which retract and draw additional fluid from the reservoir to the tops of the cylinders.

Trimming Outboard OUT Pull gearcase out farther than the desired final position (up into the tilt range, if necessary). Close the manual release valve. Manually, push the gearcase in (or down) until it is supported by the trim system. Open the manual release valve only enough to let the outboard trim in to desired position.

DRC3464

1. Manual release valve 2. Reservoir

Tilting Outboard UP Tilt outboard up and hold it with a suitable hoist or engage either its tilt support or trailering bracket.

WARNING Do not attempt to hold the outboard up by closing the manual release valve. The outboard must be held manually, and lowered to the trim range manually, after it has been tilted up manually. The outboard can drop to the trim range if the support is removed. Close the manual release valve firmly. The manual release valve must be closed to enable the trim/tilt unit to function.

363

13

TRIM AND TILT MODES OF OPERATION (THREE PISTON SYSTEM)

Manual Release – DOWN When the manual release valve is opened and the outboard is manually tilted down or trimmed in, fluid flows from the bottom of the tilt cylinder (in the tilt range), or from the bottom of all of the cylinders (in the trim range), and past the manual release valve. Fluid flows from the bottom of the tilt cylinder (in the tilt range) to the top of the tilt cylinder. The excess fluid, equal to the volume of the piston rod, is vented to the reservoir.

1

In the trim range, the fluid from the bottom of all three cylinders is vented to the reservoir, except for the amount required to fill the top of the tilt cylinder. After opening the manual release valve, close it firmly. The manual release valve must be closed to enable the trim/tilt unit to function.

1. Manual release valve

364

DRC3465

TRIM AND TILT ROUTINE INSPECTIONS

ROUTINE INSPECTIONS General Check for external signs of fluid leakage. Correct causes as necessary.

1

Check the battery and make sure it is in good operating condition.

Reservoir Fluid Check reservoir fluid level every three years or every 300 operating hours. System capacity is approximately 20 fl. oz. (620 ml). • Tilt the outboard and engage the tilt support. • Remove the fill plug. • FasTrak Three Piston System–Add Power Trim/Tilt Fluid or GM Dexron II, as needed, to bring level to the bottom of the fill plug threads. • Single Piston System–Add Evinrude/Johnson Biodegradable TNT Fluid, as needed, to bring level to the bottom of the fill plug threads. • Install the fill plug and torque 45 to 55 in. lbs. (5 to 6 N·m). • Disengage tilt support. • Cycle the unit at least five complete cycles to purge all air from the system. When cycling the unit, hold the trim switch ON an additional 5 to 10 seconds after the unit reaches the end of its travel before activating the switch in the opposite direction.

Single Piston System 1. Reservoir cap

004278

Manual Release Valve Check the manual release valve with a torque wrench.

IMPORTANT: The valve must be torqued 45 to 55 in. lbs. (5 to 6 N·m).

Stern Brackets Inspect the stern brackets for binding with the swivel bracket in the thrust rod area. Retorque the tilt tube nuts as follows: • Tighten the tilt tube nuts to a torque of 40 to 45 ft. lbs. (54 to 60 N·m). • Loosen one nut 1/8 to 1/4 turn after torquing.

1

Three Piston System 1. Reservoir cap

004277

13

365

TRIM AND TILT TROUBLESHOOTING

TROUBLESHOOTING FasTrak - Three Piston System If the power trim/tilt system has malfunctioned and the cause has not been determined, the Symptoms Chart should help locate the problem. Keep a manual release valve and a valve body in stock for troubleshooting. Use these parts when the Service Procedures call for the substitution of known good parts. If the trim/tilt does not work, and its motor neither runs nor hums, troubleshoot the problem by referring to TILT/TRIM RELAY TEST on p. 151. If the outboard tilts part way up but not smoothly, or with a constant sound, there is probably air in the system due to low fluid. Fill reservoir and bleed (purge air from) the system. To test for mechanical binding, open the manual release valve and manually tilt the motor up and down. If parts are binding, refer to MIDSECTION section. If a V4 model will not lower from shallow water drive position at any throttle setting, or if a V6 model will not stay in shallow water drive and drops down at fast idle, the wrong manual release valve may be installed. Check for the identification groove in the face of the valve.

If the outboard does not tilt as high as it should, and the tilt motor TURNS OFF at maximum tilt (does not sound like it is stalled at the maximum tilt position), adjust the tilt limit switch higher and retest. Refer to Tilt Limit Switch Adjustment on p. 75. If any of the symptoms in the Symptoms Chart describe the unit, follow the indicated Service Procedures, in the order listed, to locate and correct the problem.

Symptoms Chart Symptom Unit will not move in either direction. Unit runs slowly in one direction, normal speed in other direction. Unit runs slowly. (if low hours) (if high hours) Unit leaks DOWN and/or will not hold trim position against thrust in forward. Unit leaks both UP and DOWN – Leaks down in tilt range and/or will not hold trim position against thrust in forward or reverse. Unit will not trim/tilt one way, but works the other way. Unit will not run DOWN, but runs UP; or it runs DOWN, but will not run UP.

Service Procedures 1, 2, 3, 4, 6 1, 2, 6 1, 2, 7 1, 2, 5, 7 1, 2, 6

1, 2, 7

2, 3, 6

Service Procedures STEP 1 Be sure the manual release valve is closed. If NOT, torque to 45 to 55 in. lbs. (5 to 6 N·m).

1

2 1. Grooves (V4 Models) 2. No grooves (V6 Models)

366

30959

STEP 2 Temporarily install a known good manual release valve and retest. If symptoms remain, original valve is not the problem. Reinstall original valve. If symptoms disappear, the original valve was faulty. Remove temporary valve and replace with correct new valve.

TRIM AND TILT TROUBLESHOOTING STEP 3 Go to TILT/TRIM RELAY TEST on p. 151 to determine if problem is power supply. STEP 4 Remove trim motor and check condition of drive coupling. If coupling is damaged, replace it.

• The “B” adapter, P/N 336659, checks operation of the DOWN circuit.

1

2

STEP 5 Temporarily install a known good pump manifold assembly and retest. If symptoms remain, original assembly is not the problem. Reinstall original assembly. If symptoms disappear, the original pump manifold assembly was faulty. Remove temporary assembly and replace it with correct one. STEP 6 Install replacement pump manifold assembly and retest. If all symptoms are not corrected, reconsider the problem using the new symptoms. STEP 7 Install O-ring kit. Look for any cylinder damage. Look for chips in fluid or impact valves. Look for other abnormal conditions. If all symptoms are not corrected, reconsider the problem using the new symptoms.

1. A Adapter 2. B Adapter

27340

This kit does not include a gauge and collar assembly. Gauge and collar assembly shipped with Power Trim/Tilt Service Kit, P/N 390010, will work. Gauge and Collar Assembly, P/N 983975, is also available. Be sure to use a fully charged battery. STEP 1 Screw the manual release valve in the hydraulic unit until it is seated. Place a large drain pan under the unit to catch hydraulic fluid.

Pressure Leakdown Test Before servicing a hydraulic unit, it should be pressure tested to determine the unit's malfunction. This test must be performed with the hydraulic unit removed from the outboard and mounted in a vise or holding fixture. Power Trim/Tilt Service Kit, P/N 434524, allows testing of trim/tilt operation and component condition. • The “A” adapter, P/N 336658, checks operation of the UP circuit.

1

1. Manual release valve

41736

Operate the unit to the full UP position, then run the unit down momentarily to reduce pressure. Loosen the reservoir cap one full turn. Loosen the manual release valve three turns. Some fluid will

367

13

TRIM AND TILT TROUBLESHOOTING bypass the reservoir cap. These steps will relieve the pressure in the unit.

Remember that all rods must be completely extended to check fluid level.

2 1

1. Manual release valve 2. Reservoir cap

41739

Remove the manual release valve retaining ring using retaining ring pliers.

41757

Starting with the tilt cylinder fully retracted, run the unit UP. • The gauge should show 0 to 200 psi (0 to 1379 kPa) as the tilt cylinder is extending. • The gauge should show 1400 to 1600 psi (9653 to 11032 kPa) as the unit stalls. • Release the switch and watch for a pressure drop. The stall pressure reading must not drop more than 200 psi (1379 kPa) after motor stops. If results vary from the above limits, there is a problem in the UP circuit. Refer to MODES OF OPERATION (Three Piston System) on p. 359 for circuit description.

41754

Remove the manual release valve. Install pressure gauge and adapter “A” to check problems in the UP circuit.

STEP 2 Remove the manual release valve retaining ring using retaining ring pliers.

IMPORTANT: Torque gauge and adapter lightly to 5 to 10 in. lbs. (0.6 to 1.2 N·m). Excessive torque might damage adapter or O-rings. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure. Check fluid level again, and add fluid if necessary. 41754

368

TRIM AND TILT TROUBLESHOOTING Remove the manual release valve. Install pressure gauge and adapter “B” to check problems in the DOWN circuit. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure. Check fluid level again, and add fluid if necessary. Remember that all rods must be completely extended to check fluid level. Starting with the tilt cylinder fully extended, run the unit DOWN. • The gauge should show 0 to 200 psi (0 to 1379 kPa) as the tilt cylinder is retracting. • The gauge should show approximately 800 psi (5516 kPa) as the unit stalls. • Release the switch and watch for a pressure drop. The stall pressure reading must not drop more than 200 psi (1379 kPa) after motor stops. If results vary from the above limits, there is a problem in the DOWN circuit. Refer to MODES OF OPERATION (Three Piston System) on p. 359 for circuit description.

CAUTION After tests are complete, run the unit up, then down momentarily. Cycle the unit down and up several times to purge air. With all rods fully extended, run the unit down momentarily to reduce pressure.

Single Piston System Use the following guidelines to check a single piston trim/tilt unit that is not working correctly. Cylinder Leakdown: • Manual release valve seals • External leaks No reverse lock:

• External leaks No operation, motor runs: Manual release valve open Fluid level low Pump coupler Hydraulic pump

• • • •

No tilt down:

• Manual release valve • Fluid level Slow performance: Manual release valve Fluid level low Mechanical binding Electric motor Hydraulic pump

• • • • •

Unit locked in tilt up:

• Mechanical binding • Hydraulic pump

Check fluid level again and add fluid, if necessary.

13

369

TRIM AND TILT ELECTRICAL CIRCUIT TESTS

ELECTRICAL CIRCUIT TESTS

Connect a 0 to 100 A DC ammeter in series between the battery side of the starter solenoid and the red lead to the trim/tilt relay module.

1

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. The green trim motor wire remains grounded. When the button is released, the blue trim motor wire returns to a grounded position. When the trim-DOWN button is pressed, the DOWN relay is energized and connects the green trim motor wire to the battery positive (+) terminal. The blue motor wire remains grounded. When the button is released, the green trim motor wire returns to a grounded position. Refer to TILT/TRIM RELAY TEST on p. 151 for relay testing procedure.

Trim and Tilt Motor Current Draw Tests Careful analysis of the electric motor's current draw and trim/tilt unit operating speed aids evaluation of the electric motor and certain mechanical components. Use a battery rated at 360 CCA (50 Ah) or higher that is in good condition and fully charged to perform this test.

IMPORTANT: The specifications contained in the Performance Chart are for static hydraulic tests. DO NOT attempt to perform the following tests while the boat is moving.

370

005441

1. Red lead

Observe ammeter and a stopwatch while running hydraulic unit through several complete cycles. Compare test results to the values listed:

Performance Chart – FasTrak Three piston system Mode Trim-OUT (Trim range) Tilt-UP Stall Trim-IN (Trim range) Trim-IN Stall

Normal Time in Current Draw Seconds 22 A

9

60 to 75 A

N/A

16 A

9

35 to 45 A

N/A

Performance Chart – Single piston system Mode

Normal Time in Current Draw Seconds

Full Range UP

<30 A

12-18

Full Range DOWN

<30 A

<18

Stall

<40 A



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 • Relief valve springs weak • Pump damaged • O-rings leaking • Check valves fouled or damaged • Manual release valve damaged B. High current draw – Check for: Pump binding Motor binding Cylinder binding Valves sticking

• • • •

C. Normal current draw, slow operating speed – Check for: • Impact valves damaged • Check valve or shuttle valve malfunctioning • Manual release valve damaged

Trim and Tilt Motor No Load Test IMPORTANT: Securely fasten motor in a suitable fixture before proceeding with this test.

30957

The motor shaft must rotate clockwise, as viewed from the pump end, when positive (+) is applied to the blue lead, and negative (–) is connected to green lead. The motor shaft must rotate counterclockwise, as viewed from the pump end, when positive (+) is applied to the green lead, and negative (–) is applied to the blue lead. Blue lead (+) Green lead (-)

Green lead (+) Blue lead (-)

Use a battery rated at 360 CCA (50 Ah) or higher that is in good condition and fully charged to perform this test. Connect a 0 to 50 A ammeter in series with the battery positive (+) terminal, ammeter red lead toward battery. Attach or hold a vibration or mechanical tachometer to the motor while performing this test.

DR4238r

If test results vary, replace the motor.

13

371

TRIM AND TILT ELECTRICAL CIRCUIT TESTS

Trim Gauge Test

Trim Sender Test

STEP 1 Turn key switch ON. Using a voltmeter, check for voltage between the trim gauge “I” and “G” terminals. • If no voltage, check condition of instrument harness, key switch, and engine 20 A fuse. • If voltage, go to STEP 2.

IMPORTANT: To avoid immediate meter damage, never apply a multimeter to an electrical circuit where voltage is present. Disconnect the 3-pin Deutsch connector between the instrument harness and engine trim harness. Connect an ohmmeter between the white/tan wire, terminal “C,” of the engine harness and a clean engine ground. With the outboard fully DOWN, meter must show a reading above 80 Ω. With the outboard fully UP, meter must show a reading below 10 Ω. • If results agree, refer to Trim Gauge Test on p. 372. • If results are different, replace trim sender.

DRC6245

STEP 2 Remove the white/tan lead from the trim gauge “S” terminal. With key switch ON, gauge should indicate full-trim DOWN position. Now connect a jumper wire between terminals “S” and “G.” Gauge should indicate full-trim UP position. • If results are different, replace the trim gauge. • If results agree, refer to Trim Sender Test. DRC6247

DRC6246A

372

TRIM AND TILT REMOVAL AND INSTALLATION Separate the trim/tilt unit wires in the braided tube to permit removal through the hole in the stern bracket.

REMOVAL AND INSTALLATION Removal Remove port lower engine cover and disconnect the trim/tilt connectors. Refer to Powerhead REMOVAL on p. 239. Remove the rubber grommet from the blue/green trim/tilt cable connector.

25078

Unscrew the manual release valve, raise the unit, and lock it in place with the tilt support.

000686

Remove the terminals from the connector by using a suitable tool to depress the tab. While the tab is depressed, pull on the wire from the rear of the connector to release it from the connector. 27381

Remove the ground wire from the trim/tilt unit.

1 000687

1. Ground wire

25057

373

13

TRIM AND TILT REMOVAL AND INSTALLATION Remove the external snap rings from the upper pin.

Use a punch to remove the lower pin and remove the trim/tilt unit from the stern brackets.

25064

25076

Use a punch to remove the upper pin.

Installation Place trim/tilt unit into position. Apply Triple-Guard grease to the lower pin and install the pin. If loosened, torque the tilt tube nut to 50 to 54 ft. lbs. (68 to 73 N·m), then loosen the nut by 1/8 to 1/4 turn. Install external snap rings on lower pin with sharp edge of ring facing out. 25065

Retract the tilt cylinder rod. Remove the external snap rings from the lower pin.

25077

Extend tilt cylinder rod to match with holes in swivel bracket. Apply Triple-Guard grease to upper pin and install the pin. 25077

374

TRIM AND TILT REMOVAL AND INSTALLATION Install external snap rings onto upper pin with sharp edge facing out.

Release the tilt support and lower the outboard. Torque the manual release valve to 45 to 55 in. lbs. (5.1 to 6.2 N·m).

25064 27381

Place trim/tilt wires in braided tube and install through hole in the stern bracket.

Install connector on trim/tilt cable and reconnect trim connectors to engine wire harness.

25079 002152

Attach the ground wire to the trim/tilt unit. Install port lower engine cover. Refer to Powerhead INSTALLATION on p. 262.

1

1. Ground wire

25057

13

375

TRIM AND TILT SERVICING – THREE PISTON SYSTEM

SERVICING – THREE PISTON SYSTEM

Screw the manual release valve in. Remove the retaining ring using retaining ring pliers. Remove the manual release valve.

Disassembly WARNING Before removing the manual release valve, operate the unit to the full UP position, then run the unit down momentarily and loosen the reservoir cap one full turn. To avoid personal injury, always wear eye protection when servicing the hydraulic unit. Since there might be significant residual pressure behind some components, cover each component with a shop cloth as you remove it. Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from contaminating internal parts.

41739

Inspect O-ring and two plastic split rings on the manual release valve for nicks and cuts. Inspect tip of valve for damage. The two plastic split rings are not available separately. If rings are damaged, replace the manual release valve.

2

CAUTION

1

Do not apply heat to the cylinder body or cylinders. Excessive heat can cause high pressure leaks or failure of parts. Always use a lint free shop cloth when handling power trim/tilt components. If painting the unit is required, paint it after it is completely assembled. Painting of individual components may cause flakes of paint to enter the hydraulic passages during assembly. Tape the trim/tilt piston rods before painting.

1. O-ring 2. Plastic split rings

Remove reservoir cap and drain the fluid into a container. Inspect the O-ring in the cap.

1

1. Reservoir cap

376

22863

41736 41751

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the three Pozidriv screws securing the reservoir to cylinder body. Remove reservoir.

Remove the four screws securing motor to pump manifold assembly.

41753

41760

Remove the reservoir O-ring from the cylinder body. Check machined surfaces for nicks and scratches.

Remove the wire shield from the pump manifold. Remove the motor and inspect the motor O-ring and the O-ring on the cable connector.

1

1. O-ring

41759

Use a 6 mm hex wrench to remove the plug from the cylinder body. Inspect the O-ring and the filter. Replace, if necessary.

22878

Remove and inspect the coupler. Remove the filter screen from the pump manifold. Check the machined surfaces on the manifold for nicks and scratches. The pump manifold is not serviceable. Do not remove the pump or any control valves from the manifold. Clean the screen with a mild

13 41787

377

TRIM AND TILT SERVICING – THREE PISTON SYSTEM solvent and inspect it for tears, clogging, or other damage.

Remove the manifold. Remove five O-rings from cylinder body. Check machined surfaces for nicks and scratches.

2 1

1. Coupler 2. Filter screen

41763 41799

Remove the three Allen head screws securing the pump manifold assembly to cylinder body.

Tilt Piston Removal Use Tilt Cylinder End Cap Remover/Installer, P/N 326485, or Universal Spanner Wrench, P/N 912084, and a breaker bar, to unscrew the tilt rod end cap.

41798

IMPORTANT: Individual parts in the pump manifold assembly are not available separately. Do not remove pump or any control valves from the body.

41788

Drain the fluid from above the piston.

41789

378

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Slowly pull the piston out with a rag wrapped around the rod and the top of the cylinder. Drain the remaining fluid from the cylinder.

Remove the washer. Slide the tilt piston off the rod. Be careful not to lose the springs, plungers, or small check valves in the piston assembly.

41784 41765

Inspect the bore of the tilt cylinder for excessive scoring. If the bore of the tilt cylinder is scored or damaged, the hydraulic assembly must be replaced.

Remove and discard the small inner O-ring and large outer O-ring.

1 2

41819

1. Small inner O-ring 2. Large outer O-ring

Tilt Piston Identification WARNING 41767

Clamp the rod eye tightly in a soft jaw vise. Remove the nut from the piston end of the rod.

Different tilt pistons are used on hydraulic units for various outboard models. All plungers and check balls are identical. The tilt piston assemblies contain valving specific to certain models. To provide impact protection, it is important the correct piston assembly be installed.

13 1 1. End cap

41781

379

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Three of the four springs are one length, and the fourth spring is shorter. On assembly, the shorter spring can be positioned in any hole in the piston.

Use a screwdriver to carefully pry the scraper out of the end cap. Discard the scraper. Remove and discard the large outer O-ring.

41791

41882

Remove and discard inner O-ring of the end cap.

Tilt Piston Assembly Piston check balls and plungers are identical. Lubricate and install a new outer O-ring on the tilt piston. Place one ball, one plunger, and one spring in each hole in the piston as indicated. Three of the four springs are one length, and the fourth spring is shorter. On assembly, the shorter spring can be positioned in any hole in the piston. Set piston aside.

41792

Tilt Rod Assembly Clean the end cap thoroughly, then lubricate and install a new O-ring in the end cap. Lubricate and install a new scraper. The scraper is installed with the lip facing out. Lubricate and install a new O-ring on the outside of the end cap.

1

2

41818

3 1. Inner O-ring 2. Lip 3. Outer O-ring

380

41795

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Use a wire brush to clean all thread-locking material from the threads on the tilt rod.

Clean any thread-locking material from the threads on the inside of the nut. Spray threads of with Locquic Primer and let dry. Apply a small amount of Nut Lock to the threads. Slide the washer over the threads and install the nut. Torque to 58 to 87 ft. lbs. (79 to 118 N·m).

41821

Lubricate the inside surface of the end cap. Lubricate and install Tilt Cylinder Seal Protector, P/N 326005. Use a deep-well socket and a plastic mallet to drive the end cap onto the rod, then remove the seal protector. Slide the end cap down the tilt rod.

41783

To ensure that the tilt piston has been properly assembled and the impact relief balls are properly seated, apply Power Trim/Tilt & Steering Fluid on top of the tilt piston. Fluid should not leak past the impact relief balls while seated. If fluid does leak, disassemble the piston assembly and inspect the relief ball seats. Set the tilt rod assembly aside.

1

1. Tilt Cylinder Seal Protector

41824

Remove any lubricant from the threads on the tilt rod, prime with Locquic Primer, and let dry. Slide the piston assembly onto the tilt rod. Place a new rod O-ring over the threads.

41828

1

13 1. O-ring

41816

381

TRIM AND TILT SERVICING – THREE PISTON SYSTEM

Trim Rod Removal Unscrew trim cylinder end caps using Trim Cylinder End Cap Remover/Installer, P/N 436710, or Universal Spanner Wrench, P/N 912084, and a breaker bar. Small pins must be used in the spanner wrench.

Drain the remaining fluid from the cylinders. Inspect both bores of the trim cylinders for excessive scoring. If one or both trim bores are scored or damaged, the hydraulic assembly must be replaced.

41840 41829

Slide the caps to the end of the rods. Drain the fluid from the top of the pistons.

Remove and discard both back-up rings and the O-ring from each trim rod piston.

41841

41837

Using Hydraulic Cylinder Rod Holder, P/N 983213, clamp the rod tightly in a vise. Remove the thrust pad from the trim rod, then remove the end cap.

Slowly pull each piston out with a rag wrapped around the rod and the top of the cylinder.

41842 41838

382

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Remove the rod from the vise. Use a small screwdriver to carefully pry the scraper out of the end cap. Discard the scraper.

Lubricate and install a new O-ring and two new back-up rings on the trim rod piston. Place one back-up ring on each side of the O-ring. Position the open end of the back-up rings 180° apart.

41843

Use a suitable tool to remove the inner quad-ring and the outer O-ring. Discard the quad-ring and O-ring.

2 1. O-ring 2. Back-up rings

1 41847

Using Hydraulic Cylinder Rod Holder, P/N 983213, clamp the rod tightly in a vise and lubricate the cap and rod. Slide the end cap onto the rod and install thrust pad. Torque thrust pad 84 to 108 in. lbs. (9.5 to 12 N·m).

41844

1

Trim Rod Assembly Lubricate and install a new quad-ring and scraper in the end cap. Install the scraper with the bevel facing out. Lubricate and install a new O-ring on the outside of the end cap.

1. Thrust pad

41848

1 2

1. Bevel 2. O-ring

41845

13

383

TRIM AND TILT SERVICING – THREE PISTON SYSTEM removed later for the Pressure Leakdown Test on p. 367.

Manifold and Reservoir Installation Lubricate five new manifold body O-rings. Place them in the cylinder body.

41851

41849

Attach the valve pump assembly to the cylinder body with three Pozidriv screws. Torque screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

Install the reservoir filter screen in the cylinder body. Make sure the screen is seated. Install the plug, using a 6 mm Allen wrench, and tighten securely.

41863

41850

Lubricate and place a new reservoir O-ring in the cylinder body.

Oil and install the manual release valve. Thread the valve just past the snap ring groove. Do not install the snap ring at this time. The valve will be

1

1. O-ring

384

41865

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Attach the reservoir to the cylinder body with three Pozidriv screws. Torque the screws to 35 to 52 in. lbs. (4.0 to 5.9 N·m).

Spanner Wrench, P/N 912084. Torque caps to 60 to 70 ft. lbs. (81 to 95 N·m).

41868 41866

Tilt Rod Installation

Trim Rod Installation Lubricate the trim rod pistons. Place the rod assemblies into the body. Push them in until the end caps just clear the tops of the cylinders. Fill the cylinders with Power Trim/Tilt & Steering Fluid. Failure to fill the cylinders could cause difficulty in purging air from the unit.

Lubricate the tilt rod piston. Slide the end cap all the way up on the rod assembly. Place the piston end of the rod assembly into the cylinder body. Push it in until the end cap just clears the cylinder top. Leave enough room to pour fluid into the cylinder. Fill the cylinder with Power Trim/Tilt & Steering Fluid. Failure to fill the cylinder could cause difficulty purging air from the unit.

41867 41869

Screw the trim rod end caps into the cylinder body. Use Trim Cylinder End Cap Remover/Installer, P/N 436710, or Universal

Screw tilt cylinder end cap into cylinder body. Use Tilt Cylinder End Cap Remover/Installer, P/N 326485, or Universal Spanner Wrench,

13

385

TRIM AND TILT SERVICING – THREE PISTON SYSTEM P/N 912084. Torque cap to 58 to 87 ft. lbs. (79 to 118 N·m).

Install the filter screen.

1

1. Filter screen

41856

41870

Motor Installation Position the pump manifold so the pump mounting surface is level. Install the coupler into the pump.

Lubricate and place a new O-ring on the motor. Make sure the cable is on the transom side of the unit; align the coupler slot with the motor shaft. Place the motor on the pump manifold assembly.

1 1 2

1. Coupler

41852

Fill the pump cavity with Power Trim/Tilt & Steering Fluid up to the top of the two bosses. Rotate the coupler clockwise and then counterclockwise until no more air bubbles come out of the pump.

1. O-ring 2. Cable

41857

Install the four motor screws. Torque the screws to 35 to 52 in. lbs. (4.0 to 5.9 N·m).

1

41858 1. Bosses

386

41854

TRIM AND TILT SERVICING – THREE PISTON SYSTEM Fill the reservoir to the bottom of the fill hole with Power Trim/Tilt & Steering Fluid. Install and tighten the reservoir cap. Turn the manual release valve in until it seats. Cycle the unit up and down several times to purge air.

Check the tilt rod bushings. Replace them if they are worn excessively.

41888

Check the bushings on the bottom of the manifold body. Replace them if they are worn excessively. 41859

Operate the unit to the full UP position, then run down momentarily to release pressure. Check the fluid level again and add fluid, if necessary. Remember that all rods must be completely up to check the fluid level. Test the unit by performing the Pressure Leakdown Test on p. 367.

41878

Check system operation in both trim and tilt range.

41885

13

387

TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Slowly remove the manual release valve. There may be pressure behind the valve—wear safety glasses.

SERVICING–SINGLE PISTON SYSTEM Disassembly Thoroughly clean the unit before disassembling. Scrub all outside surfaces with a stiff brush and hot, soapy water to prevent surface dirt from contaminating internal parts. Always use a lint free shop cloth when handling power trim/tilt components. If painting the unit is required, paint it after it is completely assembled. Painting of individual components may cause flakes of paint to enter the hydraulic passages during assembly. Tape the trim/tilt piston rods before painting.

004285

Inspect the manual release valve. Discard the O-rings on the housing.

WARNING There may be high pressure behind some power trim valves. To avoid injury when removing manual release valve, be sure to cover valve with a shop cloth until the pressure is released. Wear safety glasses.

IMPORTANT: Before removing manual release

004284

valve, relieve pressure by fully extending cylinder. Screw the manual release valve in. Remove the retaining ring using a small pick or screwdriver. Discard the retaining ring.

Remove the four large motor flange retaining screws. Remove the motor and discard O-ring, screws, and washers.

004279

004282

388

TRIM AND TILT SERVICING–SINGLE PISTON SYSTEM Remove drive coupler from either the motor or the pump assembly.

Position the motor on the manifold and install four new screws and lock washers. Tighten the screws 35 to 50 in. lbs. (4 to 6 N·m).

004281 004282

Assembly IMPORTANT: Use only Evinrude/Johnson Biodegradable TNT Fluid to fill the hydraulic system. Install drive coupler in pump assembly.

Oil O-rings and install them on the manual release valve. Oil and install the manual release valve. Tighten the valve to a torque of 45 to 55 in. lbs. (5 to 6 N·m).

Install a new motor O-ring.

004285

004280

Install new retaining ring in groove.

1

13 1. Retaining ring

004283

389

TRIM AND TILT ADJUSTMENTS Fill the oil reservoir up to the fill plug with Evinrude/Johnson Biodegradable TNT Fluid. Install and tighten the fill plug. Do not torque the plug at this time.

ADJUSTMENTS Refer to Trim Sending Unit Adjustment on p. 76. Refer to Tilt Limit Switch Adjustment on p. 75.

1

1. Reservoir cap

004278

Run the motor, then recheck oil level. Cycle the unit several times and check the oil level when the cylinder is fully extended. Oil should be level with bottom of fill port. Install and tighten the fill plug to a torque of 45 to 55 in. lbs. (5 to 6 N·m).

390

SAFETY

SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM . . . . . . . . . . . . . . . . . . . . . S–3 OUTBOARD SHIFT SYSTEMS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–4 OUTBOARD SPEED CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–5 OUTBOARD STEERING CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–6 OUTBOARD FUEL, ELECTRICAL SYSTEM, AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–8 OUTBOARD MOUNTING SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–11 OUTBOARD HYDRAULIC TILT/TRIM SHOCK ABSORPTION SYSTEM AND SAFETY . . . . . . . . . . . . . . . . S–13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–14 SUMMING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–16 MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM . . . . . . . . . . . . . . . . . . . . . S–17 HANDLING OUTBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–17 HANDLING LEAD/ACID BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–21 GASOLINE – HANDLE WITH CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–22 HAZARDOUS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–23 SAFETY AWARENESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24

S–1

S–2

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 service boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so not only to protect yourself, but also to protect the people around you. It is impossible for this manual to cover every potentially hazardous situation you may encounter. However, your understanding and adherence to the recommendations contained in this manual and use of good judgment when servicing outboards will help promote safety. Always be alert and careful: a good foundation for safety. Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure:

• Product user is informed; and • Products are safe and reliable. It is up to you, the people who...

• Rig boats; • Fix machinery; and • Maintain equipment

...to keep the products safe and reliable.

This section talks about safe boating and how you can help make it safe. Some of these safety issues you will know, others you may not.

First! A word about parts... Plain parts; special parts; all parts!

DO NOT SUBSTITUTE PARTS “They look the same, but are they the same?”

• • • •

Same size? Same strength? Same material? Same type?

Don’t substitute unless you know they are the same in all characteristics.

Second! • Special locking bolts and nuts are often used to hold steering, shift, and throttle remote control cables to the outboard.

• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with other parts. Store them on the outboard, then they are there when you need them.

• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steering, shift, and throttle cables to the outboard.

S–3

SAFETY

Outboard Shift Systems and Safety The outboard Shift System starts here at the remote control lever...

...and ends here at the propeller.

When control lever is in FORWARD, NEUTRAL or REVERSE...

What is most important?

...shift linkage must match control lever position.

What could happen? IF...

IF... NEUTRAL

...propeller still powered (turning) unknown to operator, or outboard will START in gear, and boat will move suddenly.

FORWARD or REVERSE

FORWARD

...boat will move opposite to direction wanted by operator.

REVERSE

How can loss of shift control be minimized? Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. When • Assemble parts carefully. rigging • Make adjustments carefully. or after • Test your work. Do not guess. Make sure propeller does just what the operator wants servicing and nothing else. • Do not shift gears on a stopped outboard. Adjustments can be lost and parts weakened.

S–4

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... Powerhead speed must slow down to allow operator to shift into NEUTRAL. Operator must be able to STOP propeller.

What could happen? If Operator cannot slow down the outboard or shift into NEUTRAL gear (stop propeller), Operator could panic and lose control of boat.

How can loss of speed control be minimized? Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. When • Assemble parts carefully. rigging • Make adjustments carefully. or after • Test your work. Do not guess. Make sure speed control system does just what the operservicing ator wants and nothing else. • Make sure full throttle can be obtained so Operator will not overload parts.

S–5

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 • Must not be sloppy or loose.

What could happen? • If steering system comes apart, boat might turn suddenly and circle. Persons thrown into the water could be hit.

• If steering jams, operator may not be able to avoid obstacles. Operator could panic.

• If steering is loose, boat may weave while operator tries to steer a straight course. With some rigs (at high speed), loose steering could lead to loss of boat control.

S–6

SAFETY

How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets • When • rigging • or after • servicing • •

Marine Industry Safety Standards (ABYC). Read, understand, and follow manufacturer’s instructions Follow warnings marked “ ” closely. Assemble parts carefully. Make adjustments carefully. Keep parts moving freely. Lubricate parts as shown in manual. Use the bolts, nuts and washers supplied with steering attachment kits—they are a special locking type that will not loosen, rust, or weaken.

Transom Mounted Steering Systems – Check to Uncover Possible Trouble! Tilt outboard into boat, then turn it. During this procedure, steering parts: • Must not bind; and • Must not touch other boat, outboard, or accessory parts in transom area.

transom mounted steerer

Why? A hard blow to the outboard’s gearcase can result in damage to steering parts. stop

to

stop

Be aware that raising or lowering outboard on transom can change a set-up which was OK earlier. If moved up or down even one-half inch, run test again to make sure steering parts are free and clear. Check for damaged parts. Blows to the outboard like this

or this can put heavy loads on steering parts. Look for: • Cracked parts, including steering parts, swivel brackets, and transom brackets; • Bent parts; and • Loose nuts and bolts. Replace damaged parts. If weakened, parts could fail later on the water when least expected.

S–7

SAFETY

Outboard Fuel, Electrical System, and Safety The electrical system begins here at the battery...

The fuel system 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. • Stray electric sparks must be avoided.

What could happen? • When not boating, fuel leaking in car trunk or van, or place where portable tank is stored (basement or cottage), could be ignited by any open flame or spark (furnace pilot light, etc.).

• When boating, fuel leaking under the engine cover could be ignited by a damaged or deteriorated electrical part or loose wire connection making stray sparks.

How Can Fire and Explosion Be Minimized? • Read, understand, and follow manufacturer’s instructions • Follow warnings marked “ ” closely. • Do not substitute fuel or electrical systems parts with other parts which may look the same. Some electrical parts, like starter motors, are of special design to prevent stray sparks outside their cases. • Replace wires, sleeves, and boots which are cracked or torn or look in poor condition. GA

S

When mixing and refueling, always mix gas and oil outside...

Always fill the tank outside the boat

GA

S

Fumes are hard to control. They collect and hide in the bottom of the boat.

Remember: Do not use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling. If you use a funnel, it has to be metal to ground the spout to the tank.

S–8

To avoid those static electric sparks, ground (touch) the spout against the tank.

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 Sleeves, boots, shields • In position (to avoid shock hazard) • Not torn or cracked Metal Clamps – Tie Straps • Position as shown in manual Screws, Nuts, Washers • Tighten firmly–these keep

clamps in position and ends of wires from sparking • Where lock washers are called for, use them

Spark Plug Boots • Not torn or cracked • Fully pushed onto spark plug

Spark Plugs • Avoid rough handling that

could crack ceramic part of plug. (Sparks may jump across outside of plug.)

In transom area:

All Connections • Clean • Tight (Prevents sparks)

Electric Cable • Not rubbing on sharp objects • Enough slack to allow full turning without pull loads on cable (prevents sparks)

Batteries • Secure in approved battery box or battery tray

• Battery terminals insulated • No strain on cables

S–9

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 under engine cover

GASOLINE

GASOLINE

If tank cap has an air vent valve, make sure it is closed.

If gasoline tank is stored indoors, do not put it in a room having an appliance with a pilot light or where electrical appliances or switches (which may spark) will be used.

Whenever possible, remove hose from outboard and from tank. Store hose around ears of tank. This way, gasoline is trapped in tank and not in the hose, where it might leak onto the floor if the hose deteriorates.

When Running: Carburetor air intake silencer will catch and hold fuel which may flood into engine if carburetor float sticks.

• Make sure silencer and its gaskets are on engine and drain hose is in place. • Air silencer mounting screws are special lock screws. Use only the special screws. S–10

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 Boat may turn and be hard to steer.

T...I...L...T on transom Boat may turn and be hard to steer.

• If outboard hits something solid and does not stay on

the transom, boat occupants may be injured from the outboard or its parts entering the boat. Boat’s transom could break away.

Outboard may be lost overboard. Boat may SINK.

How Can Loss of Mounting Be Minimized? • Read, understand, and follow manufacturer’s instructions. • Follow warnings marked “ ” closely.

S–11

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. If transom is curved, outboard may come loose.

Mount on flat surface only. Use shims to make surface flat.

Use bolts, nuts, and washers supplied with outboard. They are usually special, and will not rust or weaken.

If owner tells you “I hit something really hard...”

Check for a high speed blow to the lower unit.

OR...

“I was backing up and I think the outboard may have hit a tree or something.” Check for a slow, heavy squash to the outboard.

• Look for damaged parts and

loosened nuts and bolts in both the steering and mounting systems. Replace damaged parts.

S–12

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.

What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat. Transom could break away and outboard may be lost overboard. Boat may SINK.

At high speeds, sudden trimming in too far may dive boat under water or spin it around.

How can possible conditions be minimized? • Read, understand, and • • • •

follow manufacturer’s instructions. Follow warnings marked “ ” closely. Test your work whenever possible. If oil leaks are seen in service areas, determine source. Keep reservoir filled. If outboard is hydraulic tilt/ trim model, always return rod to hole position determined by boat operator and make sure angle adjusting rod retain is in locked position.

Make sure manual release valve is closed tight. Torque to 45 to 55 in. lbs. (5.1 to 6.2 N·m). If left open, outboard has no shock protection. Trimming “in” too far can happen when angle adjusting rod is not in the right hole or is not in any hole (lost).

S–13

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 from the emergency stop / key switch.

What could happen? If switch fails... ...engine will keep running when clip is pulled from the switch If lanyard is caught... ...engine will keep running.

S–14

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. Operator may drown and boat WILL run into something.

How can failure of the emergency stop system be minimized? Read, understand, and follow manufacturer’s instructions Follow warnings marked “ ” closely. Assemble parts carefully. Inspect lanyard for cuts or fraying; clip for wear. Replace with original parts. Do not or after substitute. servicing • Locate control box and other items in area to keep lanyard from being caught. • ALWAYS TEST EMERGENCY STOP SYSTEM. PULL LANYARD. ENGINE MUST STOP. IF IT DOES NOT, REPAIR BEFORE NEXT USE.

• • When • rigging •

S–15

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 • Testing your work And making sure

• Worn or damaged parts are replaced • Replaced parts are like originals in every way • Customer is told of things which need attention But, do you really want the alternative?

S–16

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 Troubleshooting problems Fixing components Testing their work

Some of these safety issues you will know, others you may not.

Handling Outboards When lifting outboards Some outboards have a fixed lift bracket bolted to the powerhead. Because outboard will want to hang like this when off the floor...

Center of gravity

Stand Clear! It might hit you as it swings.

If engine does not have fixed lifting bracket and you use Universal Puller, P/N 378103, and Lifting Eye, P/N 321537, or Lifting Eye and Adapter Assembly, P/N 396748... ...use only the special hardened screws and washers from the set. Outboard can drop suddenly if hoist or engine stand are in poor shape, or too small for the job.

300 lbs. (136.1 kg)

Regular screws are not strong enough. Screws may break and outboard may drop suddenly.

V6 455 lbs. (206.4 kg)

• Make sure shop aids have extra capacity, and keep them in good repair.

S–17

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 you and may cause you to recoil into the rotating flywheel.

• Two people working together on a live outboard must look out for each other. Never, ever, use the key to start the outboard before signaling your partner. He may be leaning over the outboard with hands on the flywheel, handling a “hot” electrical part, or near the propeller.

Outboard starting at the wrong time When you do things that turn the flywheel like: • Off-season storage fogging (oiling) of outboard; • Removing propeller with a powered tool; • Electrical system checks; • Servicing the flywheel; or • Any other actions ALWAYS...

1) Turn key switch OFF 2) Twist and remove ALL spark plug leads

NO SPARK

S–18

3) Shift to NEUTRAL Check prop shaft. Is outboard really in NEUTRAL?

NO START

NO SURPRISES

SAFETY

Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily. Wear eye protectors.

2) Running with the wrong test wheel... Use the right test wheel.

This may happen if outboard runs too fast.

Running outboards: Exhaust fumes DANGER DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled, can cause serious brain damage or death.

• Whenever running the engine, assure there is proper ventilation to avoid the accumulation of carbon

monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain damage, or death if inhaled in sufficient concentrations. CO accumulation can occur while docked, anchored, or underway, and in many confined areas such as the boat cabin, cockpit, swim platform, and heads. It can be worsened or caused by weather, mooring and operating conditions, and other boats. Avoid exhaust fumes from the engine or other boats, provide proper ventilation, shut off the engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accumulation. In high concentrations, CO can be fatal within minutes. Lower concentrations are just as lethal over long periods of time.

S–19

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. Always shut off the engine when near people in the water.

Eye protection Eyes need protection when:

• Grinding

• Spraying cleaners and paints

• Chiseling Tip: When steel on steel, use plastic- or brass-type hammers. They don’t chip off as easily as steel hammers.

Wear Safety Glasses Protect eyes from:

S–20

• Acid

• Ends of cables

SAFETY

Handling Lead/Acid Batteries Strong acid solution (sulfuric acid)

If spilled or splashed on any 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. (This prevents shocks if charger is defective.) 2) Observe correct polarity when connecting these larger leads. 3) Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. Make sure vents are open. If clogged, pressure inside may build. Battery may EXPLODE.

Battery gas is explosive! While charging or discharging, remember: • No smoking • No flames • No sparks

DO NOT check battery charge by placing metal objects across posts. You will make sparks and serious burns are possible.

Never remove charger cables from battery posts. It is a sure way to make a lot of sparks in an area surrounded by battery gas.

After charging: • Shut off charger • Pull charger plug out of 110 V outlet • Take charger cables off battery posts

S–21

SAFETY

Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when mixed as shown...

1 Part Gasoline 20 Parts Air

When you smell ANY odor of gasoline, explosion is possible.

Gasoline fumes are heavy and will sink to the lowest point in the boat or room and will STAY there, WAITING...

By Volume

Gas Fumes If the air around you is calm, the pilot light in the heater could ignite the heavy fumes before your nose ever smells the fumes.

What can you do?

Store gasoline in sturdy, approved, sealed gas can and keep outside.

• • • •

Always store gasoline outside in a safe can (flame arrester and pressure relief valve in pour spout). Fill portable tanks outside of boat. Spillage will collect in bottom of boat. Use fuel as fuel ONLY, not for a cleaner or degreaser. If fumes are smelled in shop, basement, or garage, immediately: – Put out open flames, cigarettes, sparking devices; – Wipe up spill or leak; – Get towels and rags outside fast; – Open doors and windows; and – Check lowest area for fumes.

Be aware of items in and around repair area which can ignite fumes. Control them if fumes are smelled. Matches, cigarettes, blow torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights or electric ignitors (furnace, dryer, water heaters) Loose wires on running outboards Other variables which may ignite fumes

• • • • • • •

How many of these are in your repair area?

S–22

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”

It’s all on the back of the can or bottle label. And remember: Little children are very curious and will try to taste everything so keep containers away from children!

S–23

SAFETY

Safety Awareness Test The Technician’s Safety Awareness Test.... 1) Did you read this Safety section from page S–1 to page S–24? 2) Are you ready to take responsibility for the safe maintenance practices and procedures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions and instructions contained in this entire service manual? 4) Will you follow all safety warnings, precautions, instructions and recommendations outlined in this service manual? 5) Do you understand that the service manual as a whole and this Safety section, in particular, contain essential information to help prevent personal injury and damage to equipment and your customers? 6) Have you received training related to common shop safety practices to protect yourself and others around you? 7) When replacement parts are required, will you use Evinrude ®/Johnson ® Genuine Parts or parts with equivalent characteristics, including type, strength and material? 8) Are you ready to follow the recommendations in this service manual before you service any boat or outboard? 9) Do you understand that safety-related accidents can be caused by carelessness, fatigue, overload, preoccupation, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?

S–24

INDEX

INDEX A

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Abbreviations 12 Accessories Accessory Charge Kit, P/N 5006253 38 CANbus Water Pressure Transducer Kit, P/N 5006214 64 Drag Link, P/N 175125 57 Fuel Filter Assembly, P/N 174176 42 Remote Oil Fill Kit, P/N 176461 45 Rigging 46 Water Separating Fuel Filter Kit 87, 177, 190 XD100 Outboard Oil Decal, P/N 352369 67, 217 Adapter Housing 231 Service 287 Adjustments Control Cable 60, 61 Shift Rod 314 Tilt Limit Switch 75 Timing 109 Timing Pointer 157 TPS Calibration 110, 159 Trim Sending Unit 76 Trim Tab 77 Air Silencer Description 88 Air Temperature Sensor Connections 114 Description 98 Resistance Test 140 Alternator Circuit Test 143 AMP Connector Servicing 169 Anodes Anti-Corrosion 81 Continuity Check 81 Propeller Shaft Bearing Housing 327 Stern Bracket 294, 297

B

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Barometric Pressure Sensor 98

Batteries Battery Charge Isolator 38 Battery Switches 37 Cable Routing 47 Cables 37 Charging System Tests 142 Connections 36, 87 Installation 36 Multiple Batteries 37 Requirements 19, 36 Storage 92 Wiring Diagrams 39 Break-In EMM Programming 67, 72, 109 Gearcase 311, 340, 353 Oiling 67 Procedure 72

C

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Cable, Hose, and Wire Routing 35, 46, 59 CANbus Connections 63 Harness Routing 59 Ignition Harness 63 Oil Level Gauge 64 Software Activation 64 SystemCheck Functions 112 Water Pressure Gauge 64 Capacitor 126 Resistance Test 140 Connecting Rods Installation on Crankshaft 255, 256 Installation on Piston 252 Orientation 256 Removal from Crankshaft 243 Removal from Piston 244 Torquing 256 Control Cable Adjustments 60, 61 Identification 50 Installation 60 Routing 35, 46

1

INDEX Cooling System Components 230 Cylinder Block Venting 231 Engine Temperature Check 228 Flushing 82 Hose Routing and Water Flow 226, 227 Operating Temperatures 72 Operation 232 Pressure Relief Valve 231, 233 Thermostats 231, 233 Turbulence 51 Vapor Separator 178 Water Intake Screens 80, 82, 83, 334 Corrosion Anodes 81, 294, 297, 327 Metal components 81 Steering Cable 83 Counter Rotation Gearcase Service 341 Crankcase Installation 258 Removal 242 Crankshaft Assembly 250 Bearings 250 Disassembly 245 Inspection 248 Installation 255 Crankshaft Position Sensor Description 100 Operation Test 130 Resistance Test 139 Cylinder Bore Honing 247 Inspection 249 Oversize Dimension 249 Cylinder Head Inspection 248 Installation 254 Removal 243

D

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Dash Connections 138 Deutsch Connector Servicing 168 Diagnostic Procedures Overview 118

2

Diagnostic Software Break-In Programming 67, 72, 109 CANbus Activation 64 Communication with Outboard 105 Crankshaft Position Sensor 100, 130 Cylinder Drop Test 120 Description 105, 117 Diagnostic Procedures Overview 118 Engine Monitoring Screen 121 Fuel Injector Programming 110, 180, 193, 195 Fuel Injector Tests 132, 133, 184 Fuel Pump Test 131, 184 Oil Injector Test 218 Oil Priming 68, 108, 215 Oiling Rate 68, 109, 215 Reports 111 Sensor Monitoring 139 Service Codes 106 Shutdown Mode 103 Static Spark Test 128 Timing Verification 109, 159 TPC Calibration 159 TPS Calibration 110, 159 Driveshaft Installation 335 Removal 316 Service 320 Shimming 332 Special Removal Procedures 318 Driveshaft Bearing Housing Installation 330 Seal Removal 326 Dual-Outboard Alignment 78 CANbus Setup 64 Centerlines 52

E

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Electrical Circuits Ground Circuits 116 Ignition System 126 Key Switch 124 Start Circuit 122 Tests 116

INDEX Electrical Connectors 168 AMP Connectors 169 Deutsch Connectors 168 Packard Connectors 171 Electrical Harness Removal 154 Rigging 62 Emergency Stop Switch Installation 34 Operation Check 71 Test 149 Emissions Information 13 EMM 12 V Circuit Sensor 97 Connections 96, 102 Diagnostic Software 105 Diagnostics 104, 117, 118 Fuel Injector Servicing 110 Functions 96 LED Indicators 117 Map Replacement 111 Reports 111 Sensors 97, 98 Service Codes 106 Servicing 153 Timing Verification 109, 159 TPS Calibration 110 Transfer 111 Engine Temperature Check 228 Engine Temperature Sensor 140 Exhaust Housing Assembly 289 Cleaning and Inspection 289 Disassembly 288 Installation 292 Removal 287 Exhaust Pressure Fitting 90 Exhaust Valve EMM Control 101 Relays 152 Service 288, 289, 292 Tests 134 Exterior Finish Protection 81

F

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Flushing, Cooling System 82 Flywheel Installation 156 Removal 154 Servicing 154 Forward Gear, Counter Rotation Assembly 347 Disassembly 346 Fuel Filter Installation 190 Removal 190 Requirements 42 Fuel Injectors Crush Ring Replacement 194 Electrical Circuits 182 EMM Programming 110, 180, 193, 194, 195 Installation 194 Removal 193 Tests 132, 133, 184, 185, 187 Fuel System Additives 65 Components 177 Filter 42, 177, 190 Fuel Circulation Pump 131, 179 Fuel Filter 87, 190 Fuel Lift Pump 177, 188, 191 Fuel Manifolds 192 Fuel Requirements 65 Hose Routing 181 Intake Manifold 196 Minimum Octane 65 Pressure Tests 185 Priming 66 Relieving Pressure 189 Requirements 41 Troubleshooting 131, 184 Vapor Separator 178, 191 Fuse 116

G

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Gauges CANbus 63, 112 SystemCheck 35, 112 Tachometer 72, 149 3

INDEX Trim Gauge Test 372 Gearcase Assembly 334 Counter Rotation Service 341 Disassembly 314 Installation 309 Leak Test Procedure 308 Lubricant 85, 307 Removal 308 Grommet 59

L

H

M

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Hoses Fuel System 41, 47 Inspection 88 Oil Distribution 222 Oil Recirculation System 210 Oiling System 47 Routing, Fuel System 181

I

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

I-Command see CANbus Idle Controller 101 Ignition Circuits 126 Primary Circuit Resistance Test 130 Running Tests 129 Static Spark Test 128 Ignition Coil Resistance Tests 141 Instrument Harness 62, 138 Intake Manifold Assembly 197 Disassembly 196 Inspection 197 Installation 197 Removal 196

K

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Key Switch Circuit Tests 147 Operation Check 71 Start Circuit 124

4

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Lubrication Engine Oil 66 Gearcase 85, 307 Propeller Shaft 85 Swivel Bracket 84 Throttle and Shift Linkage 84 Tilt Tube 84 Trailering Bracket 84 Trim and Tilt 86 nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Maintenance and Inspection Schedule 80 Midsection Exhaust Housing Servicing 287 Stern Bracket Servicing 293 Tilt Tube Servicing 285 Models/Model Designation 7 Mounting the Engine Hull Preparation 51 Mounting Height 58

N

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Neutral Start Switch Tests 148 New Engines Fuel and Oil Priming 65 Outboard Rigging Procedure 59

O

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Oetiker Clamp Servicing 48 Oil Injector Description 201 Electrical Circuit (40 V) 202 Electrical Tests 218 Functional Test 220 Installation 223 Removal 223 Oil Pressure Sensor Description 202 Oil Tank 43, 201 Oiling Rate 67, 109, 217

INDEX Oiling System Components 201 Engine Lubricant 66 New Engine Set-Up 43, 66 Oil Distribution Hose Replacement 222 Oil Filters 88 Oil Injector Electrical Circuits 204 Oil Pressure Sensor 99 Oil Recirculation 210, 211 Oil Supply and Distribution 206, 207, 209, 210, 212, 214 Oil Tank 43 Oiling Rate 217 Priming 68, 215 Servicing 222 SystemCheck Warning Signals 205

P

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Packard Connector Servicing 171 Pinion Gear Installation 335 Removal 316 Pinion Gear Bearing Installation 329 Removal 325 Piston Rings Inspection 249 Installation 253 Removal 244 Ring Gap 253 Pistons Assembly 252 Inspection 249 Installation 253 Removal 243 Powerhead Assembly 250 Cleaning 247 Cylinder Compression Testing 238 Disassembly 241 Inspection 248 Installation 262 Removal 239 Upper Mount Servicing 261 Views 266

Predelivery Checks 70 Pre-Season Service 92 Pressure Relief Valve, Cooling System 233 Priming Fuel System 66 Oiling System 108, 215 Propeller Inspection 306 Installation 74 Selection 73 Propeller Shaft Counter Rotation 341 Installation 334 Lubrication 85 Removal 323 Propeller Shaft Bearing Housing Bearing Installation 331 Bearing Removal 326 Installation 340 Rear Seal Installation 331 Rear Seal Removal 326 Propeller Shaft Bearing Housing, Counter Rotation Assembly 349 Bearing Installation 351 Bearing Removal 350 Disassembly 345 Installation 352 Rear Seal Installation 351 Rear Seal Removal 350 Removal 341

R

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Relays Exhaust Valve 152 Trim and Tilt 151, 370 Remote Controls Cable Adjustment 60, 61 Cable Installation 60 Installation 35 Selection 34 Rigging Boat 34 Electrical Harness 62 Outboard 59 RPM Limit 96, 100, 101, 103 5

INDEX

S

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

S.A.F.E. Activating Conditions 103 Description 103 Oil Pressure 99 Temperature 97, 98 Voltage 97 Safety S–1 Sensors 139 Air Temperature Sensor 98, 140 Barometric Pressure Sensor 98 Crankshaft Position Sensor 100, 130, 139 EMM 97, 98 Engine Temperature Sensor 98, 140 Exhaust Pressure Sensor 90, 98 Oil Pressure 99, 202 Throttle Position Sensor 100, 139, 159 Serial Number Location 6 Service Charts Electrical and Ignition 136 Fuel System 174 Gearcase 300 Midsection 282 Oiling System 200 Powerhead 236 Shift Housing Assembly 327 Disassembly 324 Installation 334 Removal 323 Shift Housing, Counter Rotation Assembly 343 Disassembly 342 Removal 341 Shift Linkage Installation 259 Lubrication 84 Removal 242 Shift Rod Adjustment 314 Housing Installation 334 Shimming, Driveshaft 332 Shop Aids 28

6

Spark Plugs Indexing 160 Inspection 118, 160 Maintenance Schedule 80 Recommendation 89, 160 Replacement 89 Special Tools 21 Specifications 18 Starter Assembly 165 Circuit Description 122 Cleaning and Inspection 164 Current Draw Test 150 Disassembly 161 Installation 167 Removal 161 Solenoid Test 150 Start-In-Gear Protection 71, 148 Stator Resistance Test 141 Servicing 154 Voltage Output Test 142 Steering System Lubrication 83 Requirements 56 Steering Arm and Shaft 293, 296 Steering Torque 77 Stern Bracket Assembly and Installation 295 Disassembly 293 Removal 293 Stop Circuit 149 Storage 91 Submerged Engines 93 Switches Key Switch 147 Swivel Bracket Installation 297 Lubrication 84 Removal 294 Symbols 14

INDEX

SYSTEMCHECK CANbus Gauges 112 CHECK ENGINE Warning Signal 97, 100, 101 Dash Connections 138 Description 112 Gauges 35, 112 LOW OIL Warning Signal 221 NO OIL Warning Signal 99, 202, 205 Operation Check 71 Requirement 35 S.A.F.E. 103 Self Test 112 Service Mode 112 TEMP Warning Signal 97, 98, 99 Tests 68, 108, 145, 146, 147 Warning Horn 112 Winterization Procedure 91

T

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Tachometer Pulse Setting 72 Test 149 Technical Data 18 Temperature Operating 72, 228 Operation below freezing 66 Temperature Sensor Description 97 Resistance Test 140 Thermostat Assembly 233 Description 231 Disassembly 233 Inspection 233 Throttle Linkage Installation 260 Lubrication 84 Throttle Position Sensor Calibration 159 Description 100 Tests 139 Tilt Limit Switch Adjustment 75 Cam Installation 285, 286

Tilt Support 358 Tilt Tube Installation 286 Lubrication 84 Removal 285 Timing Pointer Adjustment 157 Timing Verification 109, 159 Tools Alignment Pin Kit, P/N 5007167 263 Backing Plate, P/N 325867 319 Bearing Installation Tool, P/N 326562 331 Bearing Installation Tool, P/N 339750 331, 351 Bearing Installation Tool, P/N 339778 347 Bearing Installation Tool, P/N 432401 351 Bootstrap Tool, P/N 586551 111 Collar, P/N 341440 332 Connector Service Tool, P/N 342667 168 Crankshaft Bearing/Sleeve Installer, P/N 338647 250 Crimping Pliers, P/N 322696 168 Cylinder Bore Gauge, P/N 771310 249 Diagnostic Interface Cable, P/N 437955 105 Diagnostics Software, Windows, P/N 763724 105 Driveshaft Holding Socket, P/N 311875 318, 339 Driveshaft Puller, P/N 390706 319 Driveshaft Seal Protector, P/N 318674 321, 332, 333, 338 Driveshaft Shimming Tool, P/N 393185 332 Electrical Test Probe Kit, P/N 342677 143, 218, 219 Flywheel Holder, P/N 771311 155 Flywheel Service Kit, P/N 434649 155, 156 Flywheel Service Kit, P/N 5007181 155, 156 Fuel Pressure Gauge, P/N 5000902 185 Fuel Pressure Gauge, P/N 5005697 187 Gauge and Collar Assembly, P/N 983975 367 Gauging Head, P/N 352879 323 Gearcase Alignment Gauge Kit, P/N 5006349 323 7

INDEX Gearcase Alignment Kit, P/N 5007231 310 Hydraulic Cylinder Rod Holder, P/N 983213 382, 383 Injector Test Fitting Kit, P/N 5005844 184 Large Puller Jaws, P/N 432129 246, 326, 347, 350 Lifting Eye, P/N 321537 S–17 Lifting Tool, P/N 342672 240, 262 Lower Driveshaft Puller, P/N 342681 319 Lower Driveshaft Spline Tool, P/N 5007052 316, 336 Lower Driveshaft Wrench, P/N 352877 336 Lower driveshaft Wrench, P/N 352877 316 Oetiker Pincers, P/N 787145 49 Pinion Bearing Remover and Installer, P/N 391257 325, 329 Pinion Nut Holder, P/N 334455 318, 339 Pinion Nut Starting Tool, P/N 342216 339 Piston Stop Tool, P/N 342679 158 Plug/Holder, P/N 329661 220 Primary Lock Tool, P/N 777077 169 Propeller Shaft Adapter, P/N 432398 341 Puller Bridge, P/N 432127 326, 347, 350 Retaining Ring Pliers 238 Ring Compressor, P/N 336313 253 Ring Compressor, P/N 336314 253 Rod Cap Alignment Fixture, P/N 396749 256 Seal Installation Tool, P/N 326551 331, 351 Seal Installation Tool, P/N 330268 330 Seal Installation Tool, P/N 336311 331, 351 Secondary Lock Installer, P/N 777079 169 Secondary Lock Tool, P/N 777078 169 Shim Gauge Bar, P/N 328367 332 Shim Gauge Bar, P/N 349957 332 Shimming Screw, P/N 352878 332 Slide Hammer Adaptor Kit, P/N 390898 194 Slide Hammer, P/N 391008 194, 251, 319 Slide Hammer, P/N 432128 246, 286, 341 Small Puller Jaws, P/N 432131 326, 350 Spanner Wrench, P/N 432400 345, 349 Stator Test Adaptor, P/N 5006211 142 Temperature Gun, P/N 772018 228 8

Terminal Release Tool, P/N 351413 170 Test Propeller 18 Thermal Joint Compound, P/N 322170 229 Tilt Cylinder End Cap Remover/Installer, P/N 326485 378, 385 Tilt Cylinder Seal Protector, P/N 326005 381 Tilt Tube Service Kit, P/N 434523 285 Timing Light 120 Torquing Socket, P/N 331638 243, 257 Transom Drill Fixture, P/N 434367 54 Trim Cylinder End Cap Remover/Installer, P/N 436710 382, 385 Trim/Tilt Service Kit, P/N 390010 367 Trim/Tilt Service Kit, P/N 434524 367 Universal Puller Set, P/N 378103 315, S–17 Universal Shift Rod Height Gauge, P/N 389997 314 Universal Spanner Wrench, P/N 912084 378, 382, 385 Wrench Retainer, P/N 341438 318, 339 Wrist Pin Bearing Tool, P/N 336660 252 Wrist Pin Cone, P/N 318600 253 Wrist Pin Pressing Tool, P/N 326356 244 Wrist Pin Retaining Ring Driver, P/N 318599 253 Torque Charts see Service Charts Standard 20 TPS Calibration 110 Trailering Bracket 358 Lubrication 84 Trim and Tilt Assembly 380, 383, 389 Circuits 151 Disassembly 376, 382, 388 Electrical Circuit Tests 152 Fluid 387 Inspection 365 Lubrication 86 Modes of Operation 359 Motor Installation 386 Pressure Leakdown Test 367 Relays 151 Removal 373

INDEX Reservoir Fluid 365 Tilt Piston Identification 379 Troubleshooting 366, 370 Trim Gauge Test 372 Trim Sender Adjustment 76 Test 372 Trim Tab Adjustment 77 Removal 308 Troubleshooting Air Temperature Sensor 140 Charging System Tests 142 Cylinder Drop Test 120 Diagnostic Procedures 118 Engine Temperature Sensor 140 Exhaust Valve 134 Fuel Injectors 132 Fuel System 131, 184, 185 Ignition 126, 127, 129 Inductive Amp Meter Test 121 Oiling System 218 Outboard Excessive Smoking T–5 Outboard Hard to Start T–3 Outboard Starts and Stalls T–4 Outboard Starts, Low Maximum RPM T–5 Outboard Surges, Runs Rough T–6 Outboard Will Not Start T–1 Outboard Won’t Shut Off T–4 Specialized Test Procedures 120 Timing Light Test 120 Trim and Tilt 366, 370 Trouble Check Chart 1 Voltage Testing 122

U

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Upper Mount Installation 262 Removal 261

V

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Vapor Separator Description 178 Installation 191 Removal 191

W

nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn

Water Intake Screens 80, 82 Inspection 83 Installation 334 Removal 323 Water Pressure Gauge 63, 64 Water Pump Assembly 312 Description 230 Disassembly 311 Inspection 311 Water Supply Tube 230 Water Temperature Sensor 98 Winterizing 91 Wiring Harness Connections 62

9

TROUBLE CHECK CHART OUTBOARD WILL NOT START

TROUBLE CHECK CHART OUTBOARD WILL NOT START OBSERVATION

POSSIBLE CAUSE

PROCEDURE

Battery switch not ON Discharged battery

Check battery switch operation Check battery, recharge or replace Clean and tighten connections. Check for voltage Battery cables and connections drop in starter circuit. Faulty connection or ground, Check all grounds, connections and wiring damaged electrical harness Outboard does not Fuse (10 A) Check wiring, then replace faulty fuse turn over Wiring harness Check for 12 V at terminal “B” of key switch Key switch Check key switch operation Starter solenoid Check wiring and test solenoid Starter or bendix/drive gears Check starter, inspect bendix/drive gears Seized powerhead or gearcase Check and repair as needed Discharged battery Check battery, recharge or replace Clean and tighten connections. Check voltage Battery cables and connections drop in starter circuit. Outboard turns slowly Powerhead hydro-locked Check cylinders for water Partially seized powerhead or Check and repair as needed gearcase Starter or bendix/drive gears Check starter, inspect bendix/drive gears

T–1

TROUBLE CHECK CHART OUTBOARD WILL NOT START

OUTBOARD WILL NOT START OBSERVATION

POSSIBLE CAUSE Stop circuit grounded No Fuel Water in fuel Contaminated or poor fuel quality Fuel supply restricted Air in fuel system

Outboard turns over

T–2

PROCEDURE Check wiring and emergency stop switch. Check the safety lanyard is installed and stop circuit is not grounded. Check for fuel in fuel tank Check fuel filter, sample fuel from fuel return manifold. Check or replace fuel supply Check primer, anti-siphon valve, and fuel pick-up. Use primer to fill vapor separator with fuel. Check for air in fuel supply manifold, refer to FUEL SYSTEM on p. 173 (vapor separator venting and fuel supply) Check fuel manifold pressure, refer to FUEL SYSTEM on p. 173

Low or no fuel pressure to injectors Incorrect, fouled, or worn spark Replace spark plugs plugs Fuel injectors not working Check voltage at injectors Check for leaking injectors, leaking fuel or oil lift Excessive fuel or oil, engine pump, or leaking vapor separator vent, refer to flooded SYSTEM ANALYSIS on p. 113 Check voltage on 55 V circuit (SAC), refer to Low or no 55 V alternator SYSTEM ANALYSIS on p. 113 and output ELECTRICAL AND IGNITION on p. 135 Check capacitor and 55 V circuits, refer to Capacitor or 55 V circuit wiring SYSTEM ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Check ignition, refer to SYSTEM ANALYSIS on Ignition p. 113 and ELECTRICAL AND IGNITION on p. 135 CPS input to EMM, no sync Check RPM reading while cranking No ignition system primary Check cranking RPM (300 minimum), refer to voltage output from EMM to SYSTEM ANALYSIS on p. 113 ignition coils Low or no compression Check compression Water in engine Check condition of spark plugs and cylinders Internal powerhead damage Check and repair as needed Leaking cylinder/crankcase, Check and repair as needed intake manifold, or reed valves EMM program, timing, or Check EMM program and timing; check injector operation information (by location and serial number)

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 fuel return manifold test port Contaminated or poor fuel Check or replace fuel supply quality Check for air in fuel supply manifold, refer to Air in fuel system FUEL SYSTEM on p. 173 (vapor separator venting and fuel supply) Incorrect, fouled, or worn spark Replace spark plugs plugs Check pressure, refer to FUEL SYSTEM on Low fuel pressure p. 173 Check primer bulb, anti-siphon valve, and fuel Fuel supply restricted pick-up, check for fuel system air leaks Check voltage on 55 V circuit, refer to SYSTEM Low or no alternator output ANALYSIS on p. 113 and ELECTRICAL AND Outboard eventually (55 V) IGNITION on p. 135 starts, may or may not run properly once Check capacitor and 55 V circuit (white/red), refer started Capacitor or 55 V circuit wiring to SYSTEM ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Restricted or leaking fuel Check injectors, refer to FUEL SYSTEM on p. 173 injector(s) Check ignition, refer to SYSTEM ANALYSIS on Weak or erratic ignition p. 113 and ELECTRICAL AND IGNITION on operation p. 135 Crankshaft Position Sensor Check CPS air gap and EMM LED indicators (CPS) Check for leaking injectors, leaking fuel or oil lift Excessive fuel or oil, engine pump, or leaking vapor separator vent. Refer to flooding SYSTEM ANALYSIS on p. 113. Check EMM program and timing; check injector EMM program, timing, or coefficients; and monitor injector circuits and operation ignition primary outputs Internal powerhead damage Check and repair as needed Low compression Check compression Leaking cylinder/crankcase, Check and repair as needed intake manifold, or reed valves

T–3

TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF

OUTBOARD WILL NOT SHUT OFF OBSERVATION

POSSIBLE CAUSE Key switch or wire harness ground

Outboard starts and runs, normal performance while running

Stop circuit wiring

EMM failure

PROCEDURE Check key switch and ground to key switch, refer to SYSTEM ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Check EMM LED indicators. Check wire harness (black/yellow) and key/stop switch(s). Check EMM LED indicators and eliminate stop circuit as possible cause. Stop wire (black/yellow) has 4.0 VDC from EMM with key on or outboard running.

OUTBOARD STARTS AND STALLS OBSERVATION

POSSIBLE CAUSE

PROCEDURE

Faulty wiring, connections, or Check all grounds, connections, and wiring grounds Incorrect, fouled, or worn spark Replace spark plugs plugs Check voltage on 55 V circuits, refer to SYSTEM Low or no alternator output ANALYSIS on p. 113 and ELECTRICAL AND (55 V) IGNITION on p. 135 Check capacitor and 55 V circuit, refer to Capacitor or 55 V circuit wiring SYSTEM ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Contaminated or poor fuel Check or replace fuel supply quality Check pressure, refer to FUEL SYSTEM on Low fuel pressure p. 173 Outboard may not run Check for air in fuel supply manifold, refer to for more than a few Air in fuel system FUEL SYSTEM on p. 173 (vapor separator seconds venting and fuel supply) Check primer bulb, anti-siphon valve, and fuel Fuel supply restricted pick-up, check for fuel system air leaks Injector electrical circuit or Check voltage at injectors, refer to SYSTEM control function ANALYSIS on p. 113 Restricted or leaking fuel Check injectors, refer to FUEL SYSTEM on p. 173 injector(s) Check EMM program and timing; check injector EMM program, timing, or coefficients; and monitor injector control wires and operation ignition primary outputs Check ignition, refer to SYSTEM ANALYSIS on Weak or erratic ignition output p. 113 and ELECTRICAL AND IGNITION on p. 135 Internal powerhead damage Check and repair as needed

T–4

TROUBLE CHECK CHART OUTBOARD STARTS, LOW MAXIMUM RPM

OUTBOARD STARTS, LOW MAXIMUM RPM OBSERVATION SystemCheck light

Setup or rigging change

POSSIBLE CAUSE Outboard is in S.A.F.E. Incorrect propeller Incorrect outboard mounting height Throttle plate opening Incorrect, fouled, or worn spark plugs Contaminated or poor quality fuel

PROCEDURE Access EMM service codes and check SystemCheck warning Refer to specifications, check recommended WOT RPM; water test and install correct pitch propeller Refer to installation guidelines Check throttle plate and WOT opening Replace spark plugs Check or replace fuel supply

Check primer bulb, anti-siphon valve, and fuel pick-up, check for fuel system air leaks Check voltage on 55 V circuits, refer to SYSTEM Low alternator output (55 V) ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Check ignition, refer to SYSTEM ANALYSIS on Weak or erratic ignition p. 113 and ELECTRICAL AND IGNITION on operation p. 135 Fuel injector electrical circuit or Check voltage at injectors, refer to SYSTEM control function ANALYSIS on p. 113 Restricted or leaking fuel Check injectors, refer to FUEL SYSTEM on p. 173 injectors Check circulation pump operation, refer to FUEL Low fuel pressure SYSTEM on p. 173 Check EMM program and timing; check injector EMM programming, timing, or coefficients; and monitor injector circuits and operation ignition primary outputs Restricted engine exhaust Check and repair as needed Fuel supply restricted

Performance of outboard at lower speeds appears normal

EXCESSIVE SMOKING OBSERVATION

POSSIBLE CAUSE Contaminated or poor fuel Excessive fuel or oil consumption Outboard in break-in mode Outboard mounted too low

May coincide with increased oil consumption (normal if occurs after Vapor separator vent winterization)

Faulty/leaking fuel injector(s) Damaged fuel lift pump

PROCEDURE Check or replace fuel supply Check fuel system for fuel supply air leaks or leaking fuel injectors Use diagnostic program to confirm Check installation height of outboard Check vapor separator assembly for proper venting/float valve operation Check injectors, refer to FUEL SYSTEM on p. 173 Check for internal leaks

T–5

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 Check and replace fuel supply quality Check pressure, refer to FUEL SYSTEM on Low or erratic fuel pressure p. 173 Check for air in fuel supply manifold, refer to Air in fuel system FUEL SYSTEM on p. 173 (vapor separator venting and fuel supply) Check primer bulb, anti-siphon valve, and fuel Fuel supply restricted pick-up, check for fuel system air leaks Restricted or leaking fuel Check injectors, refer to FUEL SYSTEM on p. 173 injector(s) May be erratic or Faulty wiring, connections, Check all grounds, connections, and wiring. inconsistent grounds, or CPS air gap Check CPS air gap. Check voltage on 55 V circuit, refer to SYSTEM Low alternator output (55 V) ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Check EMM program and timing; check injector EMM program, timing, or coefficients; and monitor injector circuits and operation ignition primary outputs Check ignition, refer to SYSTEM ANALYSIS on Weak or erratic ignition p. 113 and ELECTRICAL AND IGNITION on operation p. 135 Check capacitor and 55 V circuit (white/red), refer Capacitor or 55 V circuit wiring to SYSTEM ANALYSIS on p. 113 and ELECTRICAL AND IGNITION on p. 135 Restricted engine exhaust Check and repair as needed Propping Change propeller type or size as needed Internal powerhead damage Check and repair as needed Audible noise Damaged gearcase Inspect gearcase and lubricate

T–6

MWS Instrument Wiring Harness A B C

A B C

5 1 2 3 6 4

5 1 2 3 6 4

6 4

6 5

5

4

7 1 2

2

3 8

3 1

1 2

DRC6165R

Lanyard Switch / Emergency Stop Circuits

Single Outboard

M

A B

C

S

M 3 4 2 5 6 1

M

M

A

A B

C

S

B

C

Dual Outboards

S

M

M

3 4 2 5 6 1 3 4 2 5 6 1 000705

CANbus Keyswitch/TNT Wiring Harness

A B C

A B C

47 ohm 1/4 watt resistor

5 1 2 3 4

A. Trim down B. Trim up C. Trim sender

5. Battery + (12V) 1. Stop circuit 2. Start solenoid 3. Ground (B-) 6. Choke 4. Switched B+ (12V)

5 1 2 3 4

Switched B+ (12V) 10 Amp Fused B+ (12V) Ground (B-)

004839

MWS DASHBOARD TM

SYSTEM CHECK 6 4 5 7 1 2 3 8

TACHOMETER 5 2

SPEEDOMETER

6 4

PUL / 3 REV

PUL

+12V

GND

+ +

I

S

VOLTMETER

I

S

I

S

G G

G

TRIM/TILT

G WATER PRES.

LIGHT SWITCH

FUEL FUEL TANK SENDER

WARNING HORN

TO OUTBOARD

DRC6278R

Evinrude E-TEC EMM LED Diagnostic Indicators

1 1 2 3 4

2 3 4

Charging/55V Circuit Injection/Ignition/Fuel Sensors/5V Analog Circuits No Oil/Overheat

Key ON: LED’s illuminate to indicate circuit function 1 2 3 4

Start assist circuit (SAC), V-EMM models only Sensor circuits – TPS, CPS and 5V circuits FLASHING LED – Use Diagnostic Software and see Service Code Chart. Indicates URGENT conditon – Code 57. Stop circuit not grounded FLASHING LED – Use Diagnostic Software and see Service Code Chart. Indicates URGENT engine overheat or no oil condition.

Starting Mode: LED’s illuminate to indicate circuit function 1 2 3 4

Indicates 30V (or higher) on 55V circuit Indicates CPS function and EMM SYNC Sensor circuits functional Stop circuit not grounded

Running Mode: LED’s illuminate to indicate circuit fault 1 2 3 4

Exception: ALL LED’s ON indicates outboard running in Winterization Mode.

A

FUSE

B

3

10

18

5

4

2

7

6 CBA

1 2 3

1

5

BCA

A B C

4

3

1

B A

19

1 6

20

2 5 3 4 4 3 21

5 4 3 2 1

13

1 2 3

12

15

8 9 10 11 12 13

14 15 16 17 18 19

20 21 22 23 24 25 26

10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25

26 27 28 29 30 31 32 33 34

6

1 2 3 4 5 6 7

2

1 2 3 4 5 6 7 8 9

+

A B

2 1

3 2 1

J1-B 28

J1-A

14 1

3

2 4

5

6

16

J2 21 3 2 1

11 12 13

27

4 3 2 1

1 2

24 25 26 27 28 29

22

20 21 22 23

14 15

1 2

4 3 2 1

16 17

5 6 7 8 9 10

26

18 19

1 2

A B

30

1 2

32

2 1 1 2 1 23

12 3

1

2

1 2 33

2

1 4 3 2

8

1

A B

9

17

A B

11

12 3

23

1 3 1 22 3

24

12 3

1. Oil Injector 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12. Water Pressure Sensor (Optional CANbus) 13. CANbus Connector 14. EMM 15. Starter Solenoid 16. Accessory Charge Connector 17. Trim/Tilt Relay Module 18. Key Switch Connector 19. Trim/Tilt Connector 20. SystemCheck Connector 21. Trim/Tilt Switch 22. Shift Interrupt Switch 23. Temperature Sensor (2) 24. Fuel Injector (4) 25. Ignition Coil (2) 26. Low Oil Switch 27. Water in Fuel Sender (Optional) 31 28. Trim Sending Unit 29. Tilt Limit Switch 30. Trim/Tilt Motor Connector 31. Exhaust Valve Actuator 32. Exhaust Valve Relay Module

1 2 3 4

29

25

4

24 23 3

60°V4 115/130HP E-TEC 4

3

004980

A

FUSE

B

10

4

7

18

5 2 6

5

BCA

A B C

3

3

4

1

CBA

1 2 3

1

B A

19

1 6

20

2 5 3 4 4 3 21

5 4 3 2 1

13

1 2 3

12

15

8 9 10 11 12 13

14 15 16 17 18 19

20 21 22 23 24 25 26

10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25

26 27 28 29 30 31 32 33 34

6

1 2 3 4 5 6 7

2

1 2 3 4 5 6 7 8 9

+

A B

2 1

3 2 1

J1-B

28

J1-A

14 1

3

2 4

5

6

16

J2

21 3 2 1

11 12 13

27

1 2

24 25 26 27 28 29

22

20 21 22 23

14 15

1 2

16 17

5 6 7 8 9 10

26

18 19

1 2

A B

30

1 2

12 3

123 2 1

A B

1 2

1

2

2

1 8

A B

23 24

4

12 3

12 3

11

25 4

3

6 6

5

9

17

23 3

12 3

12 3

1. Oil Injector 2. Electric Starter 3. Air Temperature Sensor 4. Throttle Position Sensor 5. Crankshaft Position Sensor 6. Stator 7. Diagnostic Connector 8. Main Harness Ground 9. Capacitor 10. Fuse (10 Amp) 11. High Pressure Fuel Pump 12. Water Pressure Sensor (Optional CANbus) 13. CANbus Connector 14. EMM 15. Starter Solenoid 16. Accessory Charge Connector 17. Trim/Tilt Relay Module 18. Key Switch Connector 19. Trim/Tilt Connector 20. SystemCheck Connector 21. Trim/Tilt Switch 22. Shift Interrupt Switch 23. Temperature Sensor (2) 24. Fuel Injector (6) 25. Ignition Coil (3) 26. Low Oil Switch 27. Water in Fuel Sender (Optional) 28. Trim Sending Unit 29. Tilt Limit Switch 30. Trim/Tilt Motor Connector

1 2 3 4

29

5

24

60°V6 150-200HP E-TEC 004981

11

Throttle Position Sensor (TPS) out of idle range

3

3

12

Throttle Position Sensor (TPS) circuit fault

3

3

3 3 3

3 3 3

3

3

3 3

3

13 TPS below range 14 TPS above range 15 ROM (EMM program) 16

Crankshaft Position Sensor (CPS) Intermittent loss of SYNC

17 18 19 21 22 23 24 25 26 27

55 V circuit BELOW range 55 V circuit ABOVE range Start-in-gear Winterization activated Engine temperature switch closed EMM Temperature Sensor EMM Temperature BELOW range EMM Temperature ABOVE range 12 V circuit BELOW range 12 V circuit ABOVE range

3

3 3

3 3 3 3 3 3

3 3 3 3 3

29 EMM temperature OVER range

3

3

31 Engine temperature OVER range

3

3

28 Shift switch malfunction

32 33 34 35 37

Oil pressure switch, CONSTANT Excessive no oil faults Oil injection pump circuit OPEN (E-TEC / DI) No oil pressure (1997-2000 DI) Water in fuel

38 Oil pressure feedback NOT detected 39 Oil pressure prime failure 41 Engine Temperature Sensor (port/inline) Engine Temperature BELOW range (port/ 42 inline) Engine Temperature ABOVE range (port/ 43 inline) Barometric (Atmospheric) Pressure Sensor circuit fault (BP Sensor) 45 BP Sensor BELOW range 46 BP Sensor ABOVE range 44

47 Air Temperature (AT) circuit 48 AT circuit BELOW range 49 AT circuit ABOVE range

3 3

3 3

SYSTEM CHECK WARNING LIGHT ACTIVATION

EMM LED ACTIVATION

CHECK ENGINE (IDLE ONLY)

SENSOR FAULT (LED 3) (IDLE ONLY)

CHECK ENGINE

SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

CHECK ENGINE

3 SENSOR FAULT (LED 3)

3 3

3 3 3 3 3

CHECK ENGINE

CHARGING FAULT (LED 1) CHARGING FAULT (LED 1)

ALL LIGHTS ON

ALL LED’s ON

3 3

CHECK ENGINE

3

WATER TEMP/HOT

3

WATER TEMP/HOT

NO OIL/OVERHEAT (LED 4) NO OIL/OVERHEAT (LED 4) NO OIL/OVERHEAT (LED 4) CHARGING FAULT (LED 1) CHARGING FAULT (LED 1) SENSOR FAULT (LED 3)

3 3

3

3

3 3

S.A.F.E.

EMM CIRCUIT/SENSOR

Evinrude E-TEC V-EMM Evinrude E-TEC 40-90HP INTERNAL SENSOR SHUT DOWN

CODE

EVINRUDE EMM SERVICE CODE CHART

3 3 3

3

3

3 3 3 3 3 3

3 3 3 3 3 3

3

WATER TEMP/HOT (FLASHING)

Flash NO OIL/OVERHEAT (LED4)

3

WATER TEMP/HOT (FLASHING)

Flash NO OIL/OVERHEAT (LED 4)

3

NO OIL – FLASHING

SENSOR FAULT (LED 3) Flash NO OIL/OVERHEAT (LED4) NO OIL/OVERHEAT (LED 4)

3 3

NO OIL NO OIL CHECK ENGINE

3

NO OIL

3

NO OIL

NO OIL/OVERHEAT (LED 4)

SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

3 3 3 3

WATER TEMP/HOT

TIME TO ACTIVATE

SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION

TPS Voltage > 0.65 with key ON. Becomes stored fault when outboard starts. When both hard and stored faults present, check for improperly adjusted throttle cable. 3000 to 7000 Ω (between pins A and B) 5 V* circuit 0.8 seconds/ Voltage range: < 0.15 V , > 4.925 V* 4000 to 8000 Ω (between pins A and C) 1.6 seconds for 90°V6 Circuit failure range voltage: 0.15 to 4.925 V* 8 seconds Voltage below 0.2 V. Confirm linkage and IDLE stop. 8 seconds Voltage above 4.85 V. Confirm linkage and WOT stop. (ROM “CHECKSUM” verification) Verify software program number in EMM. Reload or replace with proper program. Generates current, separate Ground (NEG) 560 ± 10% @ 77°F (25°C) 10 instances Verify tachometer reading. Check CPS mounting and resistance. Inspect flywheel encoder ribs. Air gap range: 00.036 to 0.110 in. (1 to 2.8 mm), nominal 0.073 in. (1.85 mm) 1 minute 55 V alternator output less than 45 V at 500 to 1000 RPM, or less than 52 V above 1000 RPM. Perform stator/charging tests. 1 minute 55 V alternator output above 57 V. Perform stator/charging tests. Eliminate loose connections in 55 V circuit. Check capacitor. 0.5 seconds Tiller models only The outboard stops automatically after successful completion of winterization. Refer to Maintenance or Operator’s Guide. Test engine temperature and switch operation 8 seconds Refer to associated codes 24 or 25. 8 seconds EMM temperature less than -22°F (-30°C). 8 seconds EMM temperature greater than 176°F (80°C). Code 25 activates S.A.F.E. See Code 29. 5 minutes Battery voltage less than 12 V @ 500 to 2000 RPM or less than 12.5 V @ 2000 RPM or higher. Perform stator/charging tests. 5 minutes Battery voltage exceeded 15.5 V. Check battery connections and wiring. Check shift switch linkage and switch activation. Check continuity of switch: normally open / continuity depressed. Not utilized on 60°V4 (remote models) or 60°V6 models. Outboard will crank but will NOT RESTART until EMM temperature falls below 212°F (100°C). Verify EMM cooling and outboard 4 seconds cooling system operation. Check engine temperature and cooling system operation. Check temperature sensor resistance. Code 31 activates SHUTDOWN at 4 seconds 248°F (120°C) and Code 43 or 69 activates S.A.F.E. at 212°F (100°C) or 194°F (90°C) on 200-250 HP, (90°V), models. 255 oiler cycles Oil pressure switch not “switching” between oil pulses, EMM not detecting change in manifold pressure. 5 hours Outboard has run 5 hours with code 34 or 38. SHUTDOWN mode initiated. Outboard restarts and runs for 1 minute intervals. 4 seconds Check oil injection pump circuit resistance Test for oil movement in system 5 V* circuit and Ground (NEG) Resistance infinite, no continuity between probes 255 oiler cycles (150 for 60°V6 Loss of oil manifold pressure. Check oil supply. Perform injection pump tests. Monitor oil flow to distribution hoses. and 90°V6) Lack of pressure after rapid cycling injector. Check oil supply to injector. Perform injector static test. Monitor oil flow to distribution hoses. 8 seconds 5 V* circuit and Ground (NEG) 9000 to 11000 Ω @ 77°F (25°C) 8 seconds

NO OIL/OVERHEAT (LED 4)

8 seconds

SENSOR FAULT (LED 3)

8 seconds

SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

8 seconds 8 seconds

SENSOR FAULT (LED 3)

8 seconds

SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

8 seconds 8 seconds

Engine temperature below -4°F (-20°C). Check engine temperature and sensor resistance. Engine temperature: 40 - 90 HP models ≥ 212°F (100°C); 115-250 HP 60°V & 90°V models ≥ 212°F (100°C) below 3000 RPM or ≥ 194°F (90°C) above 3000 RPM. Check engine temperature and cooling system operation. Check tempera;ture sensor resistance. Code 31 activates SHUTDOWN at 248°F (120°C) and Code 43 or 69 activates S.A.F.E. at 212°F (100°C) on 40 - 90 HP models or 194°F (90°C) on 115-250 HP 60°V & 90°V models. Make sure EMM’s BP sensor tube is NOT plugged (possible “rich” running condition). Check atmospheric condition for comparison. Clear code and retest. Circuit failure range: less than 3.9 in. Hg (13.3 kPa) or greater than 35.1 in. Hg (119.0 kPa) Below 20.7 in. Hg (70 kPa) Above 31 in. Hg (105 kPa) 5 V* circuit and Ground (NEG) 9000 to 11000 Ω @ 77°F (25°C) Circuit failure range: less than -14.98°F (-26.1°C) or greater than 331.7°F (166.5°C) Air temperature below 14°F (-10°C) Air temperature above 149°F (65°C)

Rev 08/06

page 1

Fuel injector circuit #1 OPEN Fuel injector circuit #2 OPEN Fuel injector circuit #3 OPEN Fuel injector circuit #4 OPEN Fuel injector circuit #5 OPEN Fuel injector circuit #6 OPEN

3 3 3 3 3 3 3

3 3 3

Operating temperature not reached (port/ inline)

3

3

59 Operating temperature not reached (stbd)

3

61 62 63 64 65 66 67 68

Fuel injector circuit #1 SHORTED Fuel injector circuit #2 SHORTED Fuel injector circuit #3 SHORTED Fuel injector circuit #4 SHORTED Fuel injector circuit #5 SHORTED Fuel injector circuit #6 SHORTED Engine Temperature Sensor (starboard) Engine Temperature BELOW range (stbd)

3 3 3 3 3 3 3 3

69 Engine Temperature ABOVE range (stbd)

3

71 Oil pressure circuit sensor fault detected 72 Oil pressure BELOW expected range 73 Oil pressure ABOVE expected range

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

57 High RPM with low TPS setting 58

74 Water pressure sensor circuit fault detected 75 76 77 78 79 81 82 83 84 85 86 87 88 89

Water pressure BELOW expected range Water pressure ABOVE expected range S.A.C. overcurrent fault Analog 5V circuit overload detected Starter solenoid circuit OPEN Ignition primary circuit #1 OPEN Ignition primary circuit #2 OPEN Ignition primary circuit #3 OPEN Ignition primary circuit #4 OPEN Ignition primary circuit #5 OPEN Ignition primary circuit #6 OPEN Exhaust pressure circuit fault Exhaust pressure BELOW expected range Exhaust pressure ABOVE expected range

91 Fuel pump circuit OPEN 92 Exhaust valve solenoid OPEN (115HP)

3

3

3

S.A.F.E.

Evinrude E-TEC V-EMM Evinrude E-TEC 40-90HP INTERNAL SENSOR SHUT DOWN

CODE 51 52 53 54 55 56

EMM CIRCUIT/SENSOR

SYSTEM CHECK WARNING LIGHT ACTIVATION

CHECK ENGINE (FLASHING)

3

EMM LED ACTIVATION

TIME TO ACTIVATE

SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION

INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2)

8 seconds 8 seconds 8 seconds 8 seconds 8 seconds 8 seconds

Check circuit resistance

Flash SENSOR FAULT (LED 3)

5 seconds

EMM has detected abnormally high RPM relative to TPS position. This could be caused by uncontrolled fuel entering the combustion cycle. DO NOT attempt to clear code and START the outboard until the problem has been evaluated and repaired.

SENSOR FAULT (LED 3)

SENSOR FAULT (LED 3) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

3 3 3

3

WATER TEMP/HOT

NO OIL/OVERHEAT (LED 4) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3)

CANBus Option

3 3 3 3 3

3 3 3 3

CHECK ENGINE CHECK ENGINE

SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) CHARGING FAULT (LED 1) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) INJECTOR/IGNITION FAULT (LED 2) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) SENSOR FAULT (LED 3) INJECTOR/IGNITION FAULT (LED 2)

9 minutes/ Engine operating temperature less than 104° F (40° C) with engine speed less than 2300 RPM or 122°F (50°C) on 115-250 HP 60°V 10 minutes for & 90°V models. 90°V 9 minutes/ Engine operating temperature less than 104° F (40° C) with engine speed less than 2300 RPM or 122°F (50°C) on 115-250 HP 60°V 10 minutes for & 90°V models. 90°V6 8 seconds 8 seconds 8 seconds Test for shorts to ground. Check wiring and perform resistance test on injector circuits. Check for pinched or chafed wiring. 8 seconds 8 seconds 8 seconds 8 seconds 5 V* circuit and Ground (NEG) 9000 to 11000 Ω @ 77°F (25°C) 8 seconds Engine temperature below -4°F (-20°C). Check engine temperature and sensor resistance. Engine temperature: 40 - 90 HP models ≥ 212°F (100°C); 115-250 HP 60°V & 90°V models ≥ 212°F (100°C) below 3000 RPM or ≥ 194°F (90°C) above 3000 RPM. Check engine temperature and cooling system operation. Check tempera;ture sensor resistance. 8 seconds Code 31 activates SHUTDOWN at 248°F (120°C) and Code 43 or 69 activates S.A.F.E. at 212°F (100°C) on 40 - 90 HP models or 194°F (90°C) on 115-250 HP 60°V & 90°V models. 4 seconds < 0.12 V , > 4.88 V 8 seconds < 0.5 V 8 seconds > 4.5 V Use Evinrude Diagnostic Software to activate option 8 seconds < 0.12 V , > 4.88 V 8 seconds < 0.5 V 8 seconds > 4.5 V 8 seconds Check for shorted 55 V wiring (injector circuits). Check for pinched or chaffed wiring. 8 seconds Sensor voltage reference fault. Check sensors and related wiring. Check for pinched or chaffed wiring. 8 seconds Check starter solenoid circuit for continuity (key switch OFF) and for 12 V with key switch ON. 100 instances 100 instances 100 instances Check circuit resistance 100 instances 100 instances 100 instances 8 seconds < 0.12 V , > 4.88 V Check for plugged or pinched hose or exhaust fitting. 8 seconds < 40 in. water 8 seconds > 80 in. water 55 V engine running (40-90HP Inline) 2 seconds approximately 1Ω @ 77°F (25°C) 12 V key ON / engine running (200-250HP “90°V”) Check exhaust valve control module circuit for continuity. (EMM J1-B connector between pins 5 &12, electric fuel pump wiring connector disconnected.) Refer exhaust valve relay test. Use Evinrude Diagnostic Software for “static” test of actuator motor.

93 Water injection solenoid OPEN (60HP) 3 94 Fuel pump circuit SHORTED INJECTOR/IGNITION FAULT (LED 2) 8 seconds Test for shorts to ground. Check wiring and perform resistance test on pump circuit. 3 3 97 Intermittent switched B+ detected Check connections and wiring 3 * Sensor voltages are listed for description purposes only. Sensor voltage readings should be viewed using Diagnostic Program. NOTE: Always note service codes before clearing codes. Clear stored codes using diagnostic software. Some hard codes, such as code 57, are cleared by turning EMM “OFF” and then “ON” again. page 2

Rev 08/06

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