Evinrude E-Tec 75 (2007) manual

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SAFETY INFORMATION Before working on any p art 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 ® S pecial T ools. This man- ual is not a substitute for work experie nce. It is an organized guide for re[...]

DANGER Cont act with a rot ating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and object s before st arting 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 af ter the engine is[...]

4 T ABLE OF C ONTENT S SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS . . 17 2 INSTALLATION AND PREDELIVERY . . . . . . . . . . . . . . 31 3 MAINTENANCE . . . . . . . . . . . . . . .[...]

INTRODUCTION 5 INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MODEL DESIGNATION . . . . . . . . . . . . . . . . . [...]

6 INTRODUCTION MODELS COVERED IN THIS MANUAL MODELS COVERED IN THIS MANUAL This manual covers service information on all 3- cylinder , 79 cubic inch, Evinrude E-TEC™ mod- els. Use this manual together with the proper Part s Catalog for p art numbers and for exploded views of the outboard, which are a valuable aid to d isas- sembly and reassembly [...]

7 INTRODUCTION MODEL DESIGNA TION MODEL DESIGNA TION B E 90 DPL SU M PREFIX STYLE: J = Johnson E = Evinrude HORSEPOWER LENG TH: = 15” S td. L = 20” Long Y = 22.5” S pecial X = 25” X-long Z = 30” XX-long MODEL YR: I= 1 N= 2 T= 3 R= 4 O= 5 D= 6 U= 7 C= 8 E= 9 S= 0 Ex: SU = 2007 MODEL RUN or SUFFIX DESIGN FEA TURES: AP = Advanced Propu lsion[...]

8 INTRODUCTION TYPICAL P AGE – A TYPICAL P AGE – A Page Number Bold letter indica tes liquid product to be applied to a surface Pay attention to torque specifications. Some units app ear as in. lbs. Use appropriate torque . Tightening torque for a fastener. Subsection title indicates beginning of the subsection. Italic subheading above Service [...]

INTRODUCTION TYPICAL P AGE – B 9 TYPICAL P AGE – B 47 INST ALLA TION AND PREDELIVER Y OUTBOARD RIGGING PROCEDURE 2 Cable, Hose, and Wire Routing Route all hoses, co ntrol cables, and wi ring through a prot ective sleeve or conduit i nto the boat and through the grommet. Refer to the follo wing diagram to ensure proper positioning of rigging com[...]

10 INTRODUCTION TYPICAL P AGE – C TYPICAL P AGE – C 272 POWERHEAD INST ALLA TION IMPORT ANT : The motor mount , washer , and screw are servic ed as an assembly . Do not disas- semble. Inst allation Place mount assemblie s in position, with flats fac- ing away from each other . Apply Extreme Pressure Grease to al l sides of retain er and install[...]

INTRODUCTION TYPICAL P AGE – D 11 TYPICAL P AGE – D 209 OILING SYSTEM COMPONENTS 8 T wo pulse hoses con nect the pump to pulse fit - tings o n the front of the cylinder/c rankcase. • V4 Models – cylinders 1 and 3 • V6 Models – cylinders 1 and 4 Oil Injector-Manifold The oil injector- manifold distributes the oi l sup- plied by the oil l[...]

12 INTRODUCTION ABBREVIA TIONS USED IN THIS MANUAL ABBREVIA TIONS USED IN THIS MANUAL Unit s of Measurement List of Abbreviations A Amperes amp-hr Ampere hour fl. oz. fluid ounce ft. lbs. foot pounds HP horsepower in. inch in. Hg inches of mercury in. lbs. inch pounds kPa kilopascals ml milliliter mm millimeter N·m Newton meter P/N part number psi[...]

13 INTRODUCTION ENGINE EMISSIONS INFOR MA TION ENGINE EMISSIONS INFORMA TION Maintenance, replacement, or rep air of the emission control de vices and systems may be performed by any marine SI (sp ark ignition) engine rep air est ablishment or individual. Manufacturer ’ s Responsibility Beginning with 1999 model year outboards, man- ufacturers of[...]

14 INTRODUCTION SYMBOLS is also reserved to change any specifica tions or part s, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. S pecifications used are based on the latest product information availab le at the time of publication. The continuing accuracy of this manual cannot be gu[...]

15 INTRODUCTION SYMBOLS When “ Ω ” follows a value on the meter face, the procedure is measuring resist ance. Ω is the sym- bol for ohm, the unit of measu rement for resis- tance. Va l u e s When “ ≤ ” precedes a value on the meter face, the reading must be less than , or equal to, the value shown. When “ ≥ ” precedes a value on t[...]

16 INTRODUCTION NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

SERVICE SPECIFICA TION S AND SPECIAL TOOLS 17 1 SER VICE SPECIFICA TIONS AND SPECIAL T OOLS T ABLE OF CONTENTS TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 STANDARD TORQUE SPECIFICAT IONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

18 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS TECHNICAL DA T A TECHNICAL DA T A 75 – 90 HP E-TEC Models ENGINE Full Throttle Operating Range RPM 4500 to 5500 RPM Power 75 HP (56 kw) @ 5000 RPM 90 HP (67.1 kw) @ 5000 RPM Idle RPM in Gear 700 ± 50 EMM Controlled Idle RPM in Neutral 600 ± 50 EMM Controlled T est Propeller (L) Models: P/N 386246 (X[...]

SERVICE SPECIFICA TION S AND SPECIAL TOOLS TECHNICAL DA T A 19 1 75 – 90 HP E-TEC Models ELECTRICAL Minimum Battery Requirements 640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C) Alternator 25-Amp fully regulate d T achometer Setting 6 pulse (12 pole) Engine Fuse P/N 967545 – 10 A COOLING Maximum T emperature 200°F (94°C) Thermosta[...]

20 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS ST ANDARD TORQUE SPECIFICA TIONS ST ANDARD T ORQUE SPECIFICA TIONS St andard T orque 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?[...]

21 SERVICE SPECIFICA TION S AND SPECIAL TOOLS SPECIAL TOOLS 1 SPECIAL T OOLS Electrical / Ignition Lo Digital multimeter Ohms resolution 0.01 Purchase through local supplier DRC7265 Diagnostic Software for Windows based PC P/N 763724 005444 Interface cable P/N 437955 45583 S tator T e st Adapter P/N 5005799 002273 Peak reading voltmeter P/N 507972 [...]

22 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS SPECIAL TOOLS Fuel System Gearcase Fuel pressure gauge (15 PSI) P/N 5006397 90° fitting P/N 353322 004560 Fuel pressure gauge (60 PSI) P/N 5007100 90° fitting P/N 353322 005135 Fuel pressure gauge (100 PSI) P/N 5000902 002275 Nipple Kit P/N 5005844 002465 Gearcase filler P/N 501882 49790 Gearcase pres[...]

23 SERVICE SPECIFICA TION S AND SPECIAL TOOLS SPECIAL TOOLS 1 1. Pinion nut holder P/N 334455 2. Wrench retainer P/N 341438 40371 Backing plate P/N 325867 23621 1. Collar P/N 341440 2. Gauge bar P/N 328367 41553 Driveshaft puller P/N 390706 3 2884 1 2 1 2 Seal installer P/N 330268 32924 Driveshaft seal protector P/N 318674 23692 Driveshaft socket P[...]

24 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS SPECIAL TOOLS Powerhead Prop shaft housing bearing installer P/N 326562 32962 Universal driveshaft shimming tool P/N 393185 33362 Gearcase Alignment Gauge Kit P/N 5006349 004315 Universal pinion bearing remover and installer kit P/N 391257 33974 Gauging Head, “S” T ype Gearcases, P/N 352879 005072 S[...]

25 SERVICE SPECIFICA TION S AND SPECIAL TOOLS SPECIAL TOOLS 1 Universal Rod cap alignment fixture P/N 396749 21596 Wrist pin bearing installer P/N 336660 41029 Wrist pin pressing pin P/N 326356 23668 1. Wrist pin retaining ring driver P/N 318599 2. Wrist pin cone P/N 318600 DR1641 1 2 Flywheel holder P/N 77131 1 42938 Fresh water flusher P/N 500542[...]

26 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS SPECIAL TOOLS Slide hammer P/N 391008 CO1577 Slide hammer P/N 432128 15345 Slide hammer adapter P/N 390898 15356 Slide hammer adapter P/N 340624 39435 Syringe P/N 346936 50243 T emperature Gun P/N 772018 45240 Tilt tube nut wrench P/N 342680 46879 Tilt tube service kit P/N 434523 33249 Universal Puller [...]

27 SERVICE SPECIFICA TION S AND SPECIAL TOOLS SHOP AIDS 1 SHOP AIDS Cleaning Solvent P/N 771087 “6 in 1” Multi-Purpose Lubricant P/N 777192 Oil - XD100™ P/N 7771 18 Ultra 4-Stroke Outboard Oil, P/N 775594 Engine T uner P/N 777185 D.P .L. Spray P/N 777183 Oil - XD50™ P/N 777225 4-Stroke Outboard Oil, P/N 775597 Anti-Corrosion Spray P/N 77719[...]

28 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS SHOP AIDS HI-VIS™ Gearcase Lube P/N 775605 Moly Lube P/N 175356 S torage Fogging Oil P/N 777186 Lubriplate† 777 P/N 317619 T riple-Guard® Grease P/N 508298 Needle Bearing Grease, P/N 378642 Power T rim/Tilt and Power S teering Fluid P/N 775612 Black Neoprene Dip P/N 909570 Extreme Pressure Grease?[...]

29 SERVICE SPECIFICA TION S AND SPECIAL TOOLS SHOP AIDS 1 2 + 4™ Fuel conditioner P/N 775613 Gel-Seal and Gasket Remover P/N 771050 Permatex † No. 2, P/N 910032 GE † RTV Silicone Sealant P/N 263753 Fuel System Cleaner P/N 777184 Gel·Seal II P/N 327361 ThreeBond † 1 104, P/N 351052 ThreeBond 1207B, P/N 351053 Gasoila † Thread Sealant P/N [...]

30 SERVICE SPECIFICA TIONS AND SPECIAL T OOLS SHOP AIDS Locquic Primer P/N 772032 GM † Gear Mark Compound P/N 772666 Adhesive 847 P/N 776964 Thermal Joint Compound P/N 322170 Instant Bonding Adhesive P/N 509955[...]

INST ALLA TION AND PREDELIVER Y 31 2 INST ALLA TION AND PREDELIVER Y T ABLE OF CONTENTS BOAT RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 REMOTE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

32 INST ALLA TION AND PREDELIVER Y BOA T RIGGING BOA T RIGGING Remote Controls Control Selection Remote control styles and applications are described in the Evinrude/Johnso n Genuine Parts and Accessories Cat alog. Plan the installation of all remote controls carefully . Read the outboard's Operator's Guide and the remote control's i[...]

33 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Inst allation Guidelines Install the approp riate remote control following all instructions provided with the remote contro l. Make sure the following items are checked: • Correct length control cables and wiring har- nesses • Proper type and quality of cables and wiring harnesses • Correct r[...]

34 INST ALLA TION AND PREDELIVER Y BOA T RIGGING Battery Inst allation Each outboard requires it s own starting ba ttery . Select a battery that meet s or exceeds the mini- mum requirement s. Minimum 12 V olt Battery Recommenda- tions Location and Prep aration Proper installa tion will prevent battery movement while underway . • Secure all batter[...]

35 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Battery Cable Requirements Evinrude/Johnson outboards are shipped with stranded copper battery cables fo r typical installa- tions in which the starting battery is positioned close to the transom. S pecialized outb oard installations with extended length battery cables require an increased wire siz[...]

36 INST ALLA TION AND PREDELIVER Y BOA T RIGGING Battery Switch Requirement s Battery switches must meet the fo llowing require- ments. • The switch must be approved for marine use. • The switch must be a “make befo re break” design to protect the charging system from a no-load condition. • Switch amperage rating should be ade quate for t[...]

37 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Battery and Switch Wiring Diagrams T wo outboards: T wo starting batteries for each outboard 1 2 OFF BOTH SECONDARY + PRIMARY #1 S + #2 O ne ou tb oar d : B a tt ery di sconnec t O ne ou tb oar d : O ne pr i mary s t ar ti ng battery; one secondary battery OFF ON + PRIMARY #1 S 000135rev1 SECONDARY[...]

38 INST ALLA TION AND PREDELIVER Y BOA T RIGGING T wo outboards: One primary st arting battery for each outboard PRIMARY #1 PRIMARY #2 S S 000086rev2 + + 1 2 OFF BOTH 1 2 OFF BOTH #1 #2 Positive (+) Battery cables Negative (–) Batte ry cables[...]

39 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Fuel System Requirement s Overview Fuel systems must meet minimum specifications to insure the proper delivery of fuel to the out- board. The guidelines established by the ABYC and U.S. Coast Guard should always be followed. • Permanent fuel tanks mu st be properly vented outside of the hull. •[...]

40 INST ALLA TION AND PREDELIVER Y BOA T RIGGING Fuel Filters Boat-mounted fuel filters and water-sep arating fuel filter assemblies must meet the required fu el flow and filter specification. The filter must be mounted to a rigid surface above the “full” level of the fuel tank an d accessible for servicing. Fuel Filter Assembly , P/N 174176, m[...]

41 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Cable and Hose Inst allation Before inst allation, identify all required wiring, cables, and hoses: • Throttle and shif t cables • Modular Wiring System (MWS) harness • Battery cables and switches • Fuel supply hose • Primer bulb or primer pump Determine whether any additional wirin g or [...]

42 INST ALLA TION AND PREDELIVER Y BOA T RIGGING Protective Sleeve/Conduit Make sure all cables, wiring, and hoses have been identified and fitted to t he appropriate lengths. Next, locate appropriate shielding to protect the components that route to the outboard . An expandable “flexweave” sl eeve or a flexible con- duit may be used to bundle [...]

43 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Oetiker † Clamp Servicing Use Oetiker clamp s for making hose connections. These clamps provide co rrosion resistance, mini- mize the potential for ab rasion of rigging compo- nents, and provide solid, per manent connections. The selection and inst allation of an Oetiker clamp is essential in the[...]

44 INST ALLA TION AND PREDELIVER Y BOA T RIGGING Clamp Inst allation A constant stress sho uld be applied to close the ear clamps. This method ensures a positive stress on the hose and does not result in excessive co m- pression or exp ansion of the band material. IMPORT ANT : Use only Oetiker recommended tools to close Oetiker stepless clamp s. Oe[...]

45 INST ALLA TION AND PREDELIVER Y BOA T RIGGING 2 Control Cable Identification IMPORT ANT : Control cable function must be identified before rigging outboard. Identify each control cable: • Put the control handle into NEUTRAL position. The throttle cable casing guide will retract com- pletely and the shift ca ble casing guide will go to the midp[...]

46 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION OUTBOARD INST ALLA TION Hull Prep aration Maximum Cap acity Before installing ou tboard: • Refer to the boat manufacturer's certification label for maximum horsepower rating. • Refer to ABYC S t andards to determine the maximum horsepower capacity for boa ts with- out certification[...]

47 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION 2 T r ansom Bracket s and Jack Plates When mounting an outboard on b oats 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 surfac[...]

48 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION If the standard spacing does not allow full steering travel in a particular inst allation, it may be neces- sary to increase the spacing. IMPORT ANT : Some steering systems may require additional sp acing. Refer to steering sys- tem manufacturer for recommendations. The width of the top edg[...]

49 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION 2 T r ansom Drilling Locations All models use the st andard ABYC 4-Bolt mount- ing pattern. T ransom drill fixture, P/N 434367 or P/N 385368, may be used as a guide for correct hole place- ment. If drill fixture is unavailab le, refer to Drilling and Hardware Diagram on p. 50 for measure- m[...]

50 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION Drilling and Hardware Diagram IMPORT ANT : This is not a template. Quantity 1. Center of Transom 5. Bolt * 4 * Choose from the following bolt sizes: 2. T op of Transom 6. 318272 Plate 2 327053 3 in. (76 mm) 3. 1/2” Bolt Hole Loca tions 7. 318273 Retainer 2 318573 3 1/2 in. (89 mm) 4. Outs[...]

51 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION 2 Lif ting the Outboard Lif ting Fixtures Remove shipping carton. Remove any banding material used to secure out- board to shipping p alette. The mounting hardware used to attach the outboard to the shipping frame is reused to fasten outboard to boat transom. Use correct Lift ing Fixture to[...]

52 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION IMPORT ANT : Install ste ering cable through tilt tube before mounting outboard on transom. T ighten nut secure ly . Manual Hydraulic Steering Manual hydraulic steering systems use hydraulic fluid to transfer motion and load from the helm to the outboard. Hydraulic steerin g systems offer c[...]

53 INST ALLA TION AND PREDELIVER Y OUTBOARD INST ALLA TION 2 Outboard Mounting Mounting Height Boat performance depends on outbo ard mounting height. Generally , the anti-ventilation plate of the gear- case should be in alignment with the bottom of the hull. Conventional V -hulls often perform well with the anti-ventilation plate appro ximately 1 i[...]

54 INST ALLA TION AND PREDELIVER Y OUTBOARD RIGGING OUTBOARD RIGGING Cable, Hose, and Wire Routing Remove cable ret ainer from anchor block. Apply a liberal amount of T riple-Guard grease to bot h anchor block pockets. Move the remote control handle to NEUTRAL and confirm that throttle is in the IDLE position. Apply soapy water to the inside surfac[...]

55 INST ALLA TION AND PREDELIVER Y OUTBOARD RIGGING 2 If there are not e nough threads on the shif t cable to allow the adjustment, or if the gearcase does not shift fully into FOR W ARD or REVERSE, refer to SHIFT ROD ADJUSTMENT on p. 265 and Shif t Linkage Adjustment on p. 230. Pull firmly on throttle cable casing to remove backlash. With engine t[...]

56 INST ALLA TION AND PREDELIVER Y OUTBOARD RIGGING Electrical Harness Connections Provide sufficient slack at outboard end to permit steering and tilting of outboard without binding cables. Place the wiring harness through notch in lower motor cover and route to the recess in the fly- wheel cover . Secure the cable with a tie strap as shown: Befor[...]

57 INST ALLA TION AND PREDELIVER Y FUEL AND OIL PRIMING 2 FUEL AND OIL PRIMING Fuel Requirement s Minimum Octane Evinrude/Johnson outboards a re certified to oper- ate on unleaded automotive gasoline with an octane rating equal t o or higher than: • 87 (R+M)/2 AKI, or • 90 RON Use unleaded gasoline that co ntains methyl ter- tiary butyl ether ([...]

58 INST ALLA TION AND PREDELIVER Y FUEL AND OIL PRIMING Fuel System Priming V ent Line Clamp In compliance with Code of Fed eral Regulations, 49 CFR §173.220, all outbo ards utilizing a fuel vapor separator must be shipped with a vent line clamp installed. This clamp must be removed prior to attempting to prime the fuel syste m or start the outboa[...]

59 INST ALLA TION AND PREDELIVER Y FUEL AND OIL PRIMING 2 Oil Requirement s IMPORT ANT : Failure to follow these recom- mendations could void the outboard warranty if a lubrication-related failure occurs. Evinrude/Johnson XD100, XD50 , or XD30 out- board oil is recommended for use in Evinrude E- TEC outboards. Evinrude/Johnson XD100 ou tboard oil i[...]

60 INST ALLA TION AND PREDELIVER Y FUEL AND OIL PRIMING Oil Supply Priming Follow these step s for initial outboard set-up: • Fill the oil tank with XD100, XD50 , or XD30 oil. • Use the Evinrude Diagnostics Soft ware pro- gram to confirm that the EMM is prog rammed for the type of oil being use d. • S t art the outboard and use the oil primin[...]

61 INST ALLA TION AND PREDELIVER Y BEFORE ST ART -UP 2 BEFORE ST ART -UP Gearcase Lubricant With outboard in vertical po sition, check the gear- case lubricant level: • Remove the lubricant level plug. Lubrica nt 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[...]

62 INST ALLA TION AND PREDELIVER Y RUNNING CHECKS RUNNING CHECKS SystemCheck Operation Attach eme rgency stop lanyard. T urn key switch to ON. Observe the SystemCheck self-test function. W arning horn should soun d for 1/2 second and all warning indicator lights should turn on at the same time, then turn of f one at a time. Fuel System Perform runn[...]

63 INST ALLA TION AND PREDELIVER Y RUNNING CHECKS 2 T achometer Pulse Setting Confirm accuracy of t achometer reading. • Adjust dial on back of tacho meter to required setting (the outboard should n ot be running). W ater Pump Overboard Indicator A steady stream of water should flow from the overboard indicator . Operating T emperature An outboar[...]

64 INST ALLA TION AND PREDELIVER Y PROPELLERS PROPELLERS Propeller Selection W ater testing with various propeller designs and sizes is the best method of p ropeller selection. The correct propeller , under normal load condi- tions, will allow the engine to run near the mid- point of the RPM operating range at full throttle. Refer to TECHNICAL DA T[...]

65 INST ALLA TION AND PREDELIVER Y PROPELLERS 2 Propeller Hardware Inst allation Apply T riple -Guard grease to the entire propeller shaft before inst alling the propeller . Install thrust bush ing onto propeller shaft with shoulder of thrust bushing f acing aft. T aper of bushing must match taper of propshaft. Install propeller on prope ller shaft[...]

66 INST ALLA TION AND PREDELIVER Y FINAL ADJUSTMENTS FINAL ADJUSTMENTS T ilt Limit Switch Adjustment 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. T ilt out- board(s) to highest point of clearance and turn the steering system l ock to lock. If t[...]

67 INST ALLA TION AND PREDELIVER Y FINAL ADJUSTMENTS 2 T rim Sending Unit Adjustment T ilt the outboard and engage the tilt suppo rt. T emporarily install a thrust rod, P/N 4 36541, in the number 3 hole. Loosen the sending unit screws, to allow the sending unit to pivot. Disengage the tilt support. Lower the outbo ard against the thrust rod. Observ[...]

68 INST ALLA TION AND PREDELIVER Y FINAL ADJUSTMENTS T rim T ab Adjustment 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. IMPORT ANT : A single trim tab adjustment will relieve steering effort under only one set [...]

69 INST ALLA TION AND PREDELIVER Y FINAL ADJUSTMENTS 2 Dual-Outboard Alignment Dual outboards must be connected with a tie bar and adjusted to align the o utboards for correct water flow to the gearcases and pro pellers. Incorrect outboard alignment could cause one or more of the following: • Propeller ventilation • Reduction of top speed • I[...]

70 INST ALLA TION AND PREDELIVER Y NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

MAINTENANCE 71 3 MAINTENANCE T ABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 SACRIFICIAL ANODES . . . . . . . . . . .[...]

72 MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized prod ucts. Periodic maintenance contributes to the product’s life sp an. The following chart provides gui delines for outb oard inspection and maintenance to be performed by an authorized Dealer[...]

73 MAINTENANCE ANTI-CORROSION PROTECTION 3 ANTI-CORROSION PROTECTION Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water . Salt, brackish, and pollu ted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal component s of the out- board from galvanic corrosion. Outboards are equipped[...]

74 MAINTENANCE COOLING SYSTEM COOLING SYSTEM Check the condition of cooling system compo- nents regularly . The outboa rd cooling system con- sists of: • water intake screens; • water pump; • all internal water passages; • thermostat; • all external water hoses and fittings; • vapor separator cooling passages and fittings; • EMM cooli[...]

75 MAINTENANCE LUBRICA TION 3 W ater Int ake Screens Inspect condition of water int ake screens. Clean or replace as needed. Confirm function of overboard water pressure indi- cator . Additional Maintenance • Confirm function of SystemCheck engine moni- tor . • Check operation or visual ly inspect thermost at and pressure relief valve. Clean or[...]

76 MAINTENANCE LUBRICA TION Swivel Bracket and T railering Bracket Lubricate the swivel bracket with T riple-Guard grease. Apply grease until the grease begins to flow from the upper or lower swivel bra cket areas. Coat the pivot points of the trailering bracket with T riple-Guard grease. T ilt T ube Lubricate the tilt tube grease fittings with Tr [...]

77 MAINTENANCE LUBRICA TION 3 Propeller Shaf t Debris from the water can become lodged around propeller shaft. F requent inspection can minimize potential gearcase damage. Remove propeller . Refer to Propeller Hardware Inst allation on p. 65. Inspect bushing and blade surfaces. Replace damaged or worn propellers. Clean propeller shaf t. Inspect pro[...]

78 MAINTENANCE BA TTERY AND BA TTER Y CONNECTIONS T rim and Tilt Position outboard in FULL TIL T (UP) position. Engage the tilt support bracke t. Inspect for fluid leaks. Rep air all leaks. Remove the fill cap and che ck fluid level. The fluid level must be even with bottom of the reservoir fill cap hole. Add Biodegradable TNT F luid, as needed, to[...]

79 MAINTENANCE FUEL AND OIL SYSTEMS 3 FUEL AND OIL SYSTEMS Routine replacement of fi lters reduces the possi- bility of foreign material restricting the incoming fuel supplies. Replacement filter elements are availa ble through Evinrude/Johnson Genuine Parts . Fuel Filter Evinrude E-TEC outboards are equipped with an in line fuel filter . Oil Reser[...]

80 MAINTENANCE SP ARK PLUGS SP ARK PLUGS S p ark plugs should be removed and examined periodically . Replace worn, fouled or damaged spark plugs. Use only recommended sp ark plugs with the cor- rect gap setting. • Remove spark plugs and inspect condition. • Set spark plug gap on new , replacemen t spark plugs. • Mark spark plugs for gro und e[...]

81 MAINTENANCE ST ORAGE 3 ST ORAGE IMPORT ANT : DO NOT start outboard without a water supply to the outboard’ s cooling system. Cooling system and/or powerhead damag e could occur . Fuel System T reatment S t abilize the boat’s fuel supply with Evinrude/ Johnson 2+4 Fuel Conditioner following the instructions on the cont ainer . Internal Engine[...]

82 MAINTENANCE PRE-SEASON SER VICE Additional Recommendations • T op 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 sha ft. • Blow water from gearcase speedometer pickup system (gearca[...]

83 MAINTENANCE SUBMERGED ENGINES 3 SUBMERGED ENGINES Once an outboard has been submerged in fresh or salt water , it must be serviced within three (3) hours of recovery . Immediate se rvice can mini- mize the corrosive af fect that air has on the pol- ished surfaces of the crankshaft, connecting rods, and internal powerhead bearings. IMPORT ANT : I[...]

84 MAINTENANCE NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

ENGINE MANAGEMENT MODU LE (EMM) 85 4 ENGINE MANAGEMENT MODULE ( EMM ) T ABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 EMM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

86 ENGINE MANAGEMENT MODULE (EMM) DESCRIPTION DESCRIPTION The Engine Management Module ( EMM) is a water-cooled microprocessor . It controls numer- ous outboard systems including alternator output for the 12 V and 55 V circuits. The stator provides the EMM with voltage input s that are essential to alternator output. This section discusses the func[...]

87 ENGINE MANAGEMENT MODU LE (EMM) SENSORS AND FUNCTIONS 4 SENSORS AND FUNCTIONS Sensor inputs and inte rnal EMM controllers are used to control outboard operation. Use the Evinrude Diagnostics Software program to trou- bleshoot the sensors. Refer to Evinrude EMM Service Code Chart at ba ck of manual for com- plete list of all engine fault codes. I[...]

88 ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Barometric Pressure Sensor Supplies the EMM with barometric pressure read- ing to compensate for ch anges in altitude and air density . If the BP sensor is out of the expected range (below 13.3 KPa or above 1 19.0 KPa), or the sen- sor or circuit fails, the EMM: If the BP sensor is below expec[...]

89 ENGINE MANAGEMENT MODU LE (EMM) SENSORS AND FUNCTIONS 4 Oil Pressure Switch The oil pressure switch monitors oil pressure in the oil distribution manifold. The switch require s approximately 7 p si (48 kPa) (nominal) to close. If the switch fails to indica te pressure in the oil dis- tribution manifold, the EMM : If the switch indicates constant[...]

90 ENGINE MANAGEMENT MODULE (EMM) SENSORS AND FUNCTIONS Neutral Switch The powerhead mounted neutral swit ch provides a ground signal for the EMM to indicate shift link- age position. This allows the EMM to control idle speed variations for NEUTRAL or IN GEAR. Addi- tionally , tiller m odels use the switch for st art in gear protection. Fuel and ig[...]

91 ENGINE MANAGEMENT MODU LE (EMM) EMM INPUTS AND OU TPUTS DIAGRAM 4 EMM INPUTS AND OUTPUTS DIAGRAM + 2 C B A INPUTS OUTPUTS 11 6 4 8 9 10 2 7 A B 5 3 12 1 21 J1-B J1-A J2 1 3 12 2 1 13 14 15 1 2 3 4 16 002043 1. Engine Management Module ( EMM ) 2. Battery (12 volt) 3. Stator 4. Crankshaft Position Sensor (CPS) 5. Throttle Position Sensor (TPS) 6. [...]

92 ENGINE MANAGEMENT MODULE (EMM) S.A.F .E. W ARNING SYSTEM S.A.F .E. WA R N I N G SYSTEM The EMM activates S.A.F .E. ( Speed Adjusting Failsafe Electronics ) and the dash-mounted Sys- temCheck gauge and horn to alert the operator of abnormal operating conditions and to prevent engine damage that cou ld result from: • Loss of oil flow • Engine [...]

93 ENGINE MANAGEMENT MODU LE (EMM) EMM DIAGNOSTICS 4 EMM DIAGNOSTICS LED Indicators The EMM has LED indicators lo cated next to the electrical connectors that provide information related to various electrical circuit s. St arting Mode “S t arting mode” occurs from EMM power ON until outboard is running for 2 seconds. LED 1 – S t ator signal 3[...]

94 ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS LED 4 – Engine overheat, EMM te mperature or sensor , oil injection pump or sensor , “NO OIL / OVERHEA T .” For LIGHT ON, investigate possible fault codes: • Code 23 – EMM tempera ture sensor circuit fault • Code 24 – EMM temp. below expected range • Code 25 – EMM temp. above exp e[...]

95 ENGINE MANAGEMENT MODU LE (EMM) EMM DIAGNOSTICS 4 Program Information St atic Information Refers to information viewed when the outboard is NOT running. This includ es manufacturing infor- mation. The outboard model and serial numbers displayed on the Identity screen must ma tch the identifica- tion label on the outboard swivel bracket. The seri[...]

96 ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS times the event occurred, operating hours of first and last occurrence. Hard Fault s A hard fault is a code tha t currently e xists. Hard faults become stored faults only if the o utboard is running. Persistent Fault s The Persistent Faults screen provides a history of all previously stored c odes, [...]

97 ENGINE MANAGEMENT MODU LE (EMM) EMM DIAGNOSTICS 4 Oil Injector Use the diagnostic sof tware to test the oil injection pump electrical circuit. Monitor the voltag e at pin 2 (blue wire) of oil tank con nector . V oltage should drop while the static test is active. IMPORT ANT : Oil injection pump will not activate on 12 V . Use voltmete r to check[...]

98 ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Oil Control Oil Injection Ratio (Used with XD100 oil only) Evinrude E-TEC outboards can be programmed to run a reduced oiling ra te. This feature should only be used with Evinrude/Johnson XD100 oil. Powerhead Break-In Use the diagnostic software to initiate bre ak-in oil- ing. Break-in is a predeter[...]

99 ENGINE MANAGEMENT MODU LE (EMM) EMM DIAGNOSTICS 4 Perform timing verification af ter any of the follow- ing procedures: • Powerhead replacement • Crankshaft replacement • Flywheel removal or replacement • CPS replacement • EMM replacement • EMM software replacement IMPORT ANT : Make sure the timing pointer is set and the outboard rea[...]

100 ENGINE MANAGEMENT MODULE (EMM) EMM DIAGNOSTICS Fuel Control Adjustment 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 n ot be used by itself to identify a faulty injector . Adjus[...]

101 ENGINE MANAGEMENT MODU LE (EMM) SYSTEMCHECK ENGINE MONITOR 4 Sof tware Replacement Software programs or “maps” are down loaded 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 pro- gram. IMPORT AN[...]

102 ENGINE MANAGEMENT MODULE (EMM) SYSTEMCHECK ENGINE MONITOR The system logic is provided by a microprocessor in the gauge. The microprocessor connects to the EMM and the oil level sending unit of the oil tank. Refer to the EMM Service Code Ch art located at the back of this manual for a detailed list of service codes related to SystemCheck activa[...]

SYSTEM ANAL YSIS 103 5 SYSTEM ANAL YSIS T ABLE OF CONTENTS ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 FUSE[...]

104 SYSTEM ANAL YSIS ELECTRICAL CONNECTI ONS ELECTRICAL CONNECTIONS Inspect wiring and electric al connections. Disas- semble and clean all corroded co nnections. Replace damaged wiring, connect ors, or termi- nals. Repair any shorted electrical circuits. Refer to wiring diagrams and reference chart s to identify specific wiring details. IMPORT ANT[...]

105 SYSTEM ANAL YSIS ELECTRICAL CONNECTIONS 5 J1-B Connector J2 Connector Refer to CONNECTOR SERVICING on p. 149 for AMP connector servicing procedures. 001876 Pin No. Descriptio n of Circuit Wire Colo r 1. Injector , cyli nder 2 Purple 2. Injector , cyli nder 3 Green 3. +55 V , in (ignition) White/Red 4. +55 V , in (ignition) White/Red 5. vacant 6[...]

106 SYSTEM ANAL YSIS GROUND CIRCUITS GROUND CIRCUITS All ground circuits are essential to optimum out- board performance. Make ce rtain all ground con- nections are clean and tight. Refer to wiring diagrams to identify specific wiring det ails. T est Procedure Disconnect the battery cables a t the battery . Use an ohmmeter to check g rounds at the [...]

107 SYSTEM ANAL YSIS EMM DIAGNOSTICS 5 EMM DIAGNOSTICS Access EMM information using the EMM ’s L ED indicators and the Evinrude Diagnostics Sof tware program. EMM turned ON is verified through LED d isplay or communication with diagnostic sof tware. To a c c e s s EMM information using the d iagnostic software, connect interface cable to diagnost[...]

108 SYSTEM ANAL YSIS DIAGNOSTIC PROCEDURES DIAGNOSTIC PROCEDURES The key to ef fective troubleshooting is confirming the proper operation of ea ch engine system. Causes of electrical failu res may be d ifficult to iso- late. Check the integrity of all connections, grounds, and wiring prior to replacin g a suspect component. Refer to GROUND CIRCUITS[...]

109 SYSTEM ANAL YSIS DIAGNOSTIC PROCEDURES 5 Symptoms Outboard will not crank, st arter does not operate (electric st art models): • 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 (yel- low/red wire) of starter solenoid with key [...]

110 SYSTEM ANAL YSIS SPECIALIZED TE ST PROCEDURES SPECIALIZED TEST PROCEDURES The following test s are performed with the out- board running. Observe the operation of each electrical circuit. Look fo r inconsistencies betwe en similar circuits and variation s in cylinder perfor- mance. Dynamic T est s Use the diagnostic program to perform Dynamic F[...]

111 SYSTEM ANAL YSIS SPECIALIZED TE ST PROCEDURES 5 Ignition System Output Use the timing light to monitor each sp ark plug lead for a consistent flash. The strobe should indi- cate one flash per revolution. Intermitten t output or multiple flashes per revolution indicate improper ignition control. T est ignition system grounds, primary circuit res[...]

112 SYSTEM ANAL YSIS ST ART CIRCUIT V olt age T esting Use a digital multimeter to check voltages. Identify all wiring and circuit s prior to performing any volt- age tests. Refer to Wiring Diagrams and descrip- tions of the various systems for specific information on each circuit. 55 V Circuit s All 55 V circuit s are supplied 12 V when the key sw[...]

113 SYSTEM ANAL YSIS ST ART CIRCUIT 5 St arter Motor and Drive Gear • S t arter motor operation, refer to ELECTR IC ST ARTER SERVICING on p. 145. • S t arter bendix operation. S tarter Solenoid Activation Solenoid Wiring The positive (B+) battery cable connects to the large front terminal of the starter solenoid. This terminal also provides the[...]

114 SYSTEM ANAL YSIS IGNITION AND ELEC TRICAL CIRCUITS IGNITION AND ELECTRICAL CIRCUITS Following is a complete list of circuit s required for ignition output: St o p C i r c u i t • Outboard running: black/yellow wire NOT grounded (emergency stop switch lanyard in place). Neutral Switch • Powerhead mounted neutral switch provides a switched gr[...]

115 SYSTEM ANAL YSIS IGNITION OUTPUT 5 IGNITION OUTPUT Wiring Inspection Visua lly inspect all wiring, connections, and grounds. Use an ohmmeter to perf orm resistance test s on all ground circuits and connections. Oh mmeter readings should be approximat ely 0.0 Ω . Check that main engine wire harness ground stud has continuity to the cylinder/cra[...]

116 SYSTEM ANAL YSIS IGNITION OUTPUT System V olt age The ignition module of the EMM is po wered by input voltage on pins 3 and 4 of EMM J1-B con- nector . Use the engine Monitor screen of th e Evinrude Diagnostics Software program to check syste m voltage. Result s: • “KEY ON” - Approximately 1 V less than battery voltage, system volt age is[...]

117 SYSTEM ANAL YSIS IGNITION OUTPUT 5 Result s: • GOOD spark control on all cylinders and out- board runs, refer to Running Ignition T est s on p. 1 17 and Dynamic T est s on p. 1 10. • NO spark control on one or more cylinders, note cylinders. Refer to Ignition Primary Circuit Resist ance T est on p. 1 18 and Ignition Coil T ests on p. 128. R[...]

118 SYSTEM ANAL YSIS IGNITION OUTPUT Ignition Primary Circuit Resist ance T est Disconnect the battery cables a t the battery . Calibrate ohmmeter to low ohms scale. With key switch OFF , remove the EMM J1-B con- nector and measure resist ance of each primary circuit. Note resistance readin g between each pri- mary wire and ground. Refer to engine [...]

119 SYSTEM ANAL YSIS FUEL DELIVERY 5 FUEL DELIVER Y Refer to Relieving Fuel System Pressure on p. 168. 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 Press[...]

120 SYSTEM ANAL YSIS FUEL INJECTOR OPERA TION V apor Sep arator Checks Fuel Supply The vapor separator must provide “so lid” fuel to the fuel circulation pump. Make sure the va por separator receives th e proper fuel supply from the fuel lift pump. Perform Lif t Pump Pressure T est on p. 166. • Use primer to check fuel movement through fuel l[...]

121 SYSTEM ANAL YSIS FUEL INJECTOR OPERA TION 5 Dynamic T est s Use the engine Mon itor screen of the diagnostic software pro gram to monitor outboard system voltage. Perform these te sts while monitoring volt- age. If voltage drops as RPM increases, check stator and charg ing system operation. Run or crank outboard. Monit or the injector control w[...]

122 SYSTEM ANAL YSIS NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

ELECTRICAL AND IGNITION 123 6 ELECTRICAL AND IGNITION T ABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 DASH CONNECTIONS, INSTRUMENT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 IGNI[...]

124 ELECTRICAL AND IGNITION SERVICE CHAR T SER VICE CHART 75 – 90 HP M ODELS A F F F F 100 to 1 15 ft. lbs. (136 to 156 N·m) 5 to 8 in lbs. (.6 to .9 N·m) 84 to 108 in lbs. (9.5 to 12.2 N·m) 120 to 140 in lbs. (13.6 to 15.8 N·m) 60 to 84 in lbs. (6.8 to 9.5 N·m) 60 to 84 in lbs. (6.8 to 9.5 N·m) 168 to 192 in lbs. (19 to 21 N·m) 24 to 36 i[...]

ELECTRICAL AND IGNITION SERVICE CHAR T 125 6 60 to 84 in. lbs. (6.8 to 9.5 N·m) 7 to 10 in. lbs. (0.8 to 1.1 N·m) 24 to 36 in lbs. (2.7 to 4 N·m) 60 to 84 in lbs. (7 to 9.5 N·m) F 30 to 42 in lbs. (3.4 to 4.8 N·m) 24 to 36 in lbs. (2.7 to 4 N·m) B 15 to 30 ft. lbs. (20.3 to 40.7 N·m) X J F, T A T riple-Guard Grease B Gasket Sealing Compound [...]

126 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/t an [...]

127 ELECTRICAL AND IGNITION IGNITION SYSTEM TESTS 6 IGNITION SYSTEM TESTS Sensor Resist ance T est s All sensor circuit s 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 . IMPORT ANT : U[...]

128 ELECTRICAL AND IGNITION IGNITION SYSTEM TESTS Engine T emperature Sensor T est Use an ohmmeter to measure resista nce. Air T emperature Sensor (A T) T est Use an ohmmeter to measure resista nce. Ignition Coil T est s Primary Winding Resist ance T est Connect ohmmeter between coil primary terminal and clean engine ground . IMPORT ANT : A reading[...]

129 ELECTRICAL AND IGNITION IGNITION SYSTEM TESTS 6 S tator T est s The stator consists of 3 windings (4 poles each) on a 5 inch diameter core and generates an out- put voltage of 55 V AC (1 100 watts maximum). This voltage is converted by the EMM and used to provide 12 VDC for battery charging (3 to 5 A at 500 RPM and 25 A at WOT) and 55 VDC for f[...]

130 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS Cap acitor T est The capacito r should charge when you use an ohmmeter on the high oh ms scale with the proper polarity . The resistance will increase until it goe s to (nearly) infinity . If the capacitor is shorted, then it will never charge. If it is open, the resista nce will be infinite immedia[...]

131 ELECTRICAL AND IGNITION CHARGING SYSTEM TESTS 6 Following the manufacturer ’s directio ns, connect the variable load tester (carbon pile) across the battery terminals. S tevens model LB-85 and Snap-on model MT540D are examples of testers available. S t art the outboard and run it at approximately 5000 RPM. Use the variable load tester to draw[...]

132 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS SystemCheck CIRCUIT TESTS Make sure the SystemCheck engine monitor can alert the operator during a “NO OIL,” “W A TER TEMP” or “HOT ,” “CHECK ENGINE,” or “LOW OIL” condition. Check the condition of t he warning system and associated wiring and connections. T est the engine mo[...]

133 ELECTRICAL AND IGNITION SystemCheck CIRCUIT TESTS 6 the two connectors, r eplace SystemCheck gauge. T urn the key switch OFF and reconnect all discon- nected circuit s. CHECK ENGINE Circuit T est Separate th e 6-pin SystemCheck connector of MWS instrument harness from engine harness. Black wire (pin 3) must be grounded. Using a jumper wire, con[...]

134 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS LOW OIL Circuit T est T urn the key switch ON. Using a jumper wire, con- nect tan/black wire (pin 4) of the engine harness connector to a clean engine ground. The LOW OIL light should turn on after 4 0 seconds. If the LOW OIL light does not turn on after con- necting the terminal to ground, te[...]

135 ELECTRICAL AND IGNITION REMOTE CONTROL SWITCH TESTS 6 Neutral S t art Circuit T est Use an ohmmeter or continuity light to test the continuity of the circuit while positioning the remote control in NEUTRAL, FOR W ARD, and REVERSE. IMPORT ANT : T urn propeller shaf t or disconnect shift cable t o allow proper remote control shif t action while o[...]

136 ELECTRICAL AND IGNITION ELECTRIC ST ARTER TESTS Emergency Stop Switch T est This switch can be incorporated into the key switch or inst alled as a separate switch. Either style effectively conne cts the “M” terminals of the key switch. The emergency stop switch function grounds the stop circuit wire (black/yellow) when the lanyard clip is r[...]

137 ELECTRICAL AND IGNITION ELECTRIC ST AR TER TESTS 6 STEP 2 Apply B+ to terminal “A ” of solenoid and ground (NEG) to terminal “B” of solenoid. Measure resis- tance between the st arter positive (+) cable termi- nal and the positive battery (+) cable terminal. • The solenoid must close with an audible click. • Ohmmeter must show conti[...]

138 ELECTRICAL AND IGNITION TIL T/TRIM RELA Y TEST TIL T/TRIM RELA Y TEST The tilt and trim (TNT) module contains the cir- cuitry and relays required for power trim and tilt operation. The tilt and trim switch provides B+ input to green/white or blue/white wire of the TNT module. Operation The relay activates when B+ inp ut from the switch is suppl[...]

139 ELECTRICAL AND IGNITION T ACHOMETER CIRCUIT TESTS 6 T ACHOMETER CIRCUIT TESTS IMPORT ANT : Make sure all outboard and boat wiring and connectors are in good condition . Check voltage a t the battery . Use this reading as a reference for battery volta ge. STEP 1 Connect the red meter lead to the tachometer pur- ple wire and the black meter lead [...]

140 ELECTRICAL AND IGNITION FL YWHEEL SER VICING FL YWHEEL SERVICING IMPORT ANT : Weak flywheel mag nets can cause low alternator output and af fect outboard performance. W eak flywheel magnets can also cause low readings on ignition test equipment such as the peak-reading voltmeter , which might cause unnecessary replac ement of ignition com- pone[...]

141 ELECTRICAL AND IGNITION FL YWHEEL SERVICING 6 Remove flywheel nut using Flywheel Holder , P/N 77131 1, or equivalent, and a 1 5/16 in. socket. Discard flywheel nut. Apply Moly Lube grease to the threads of the puller pressing screw , P/N 307637, and the center hole of the crankshaf t. Assemble the following component s from Univer- sal Puller S[...]

142 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS TIMING ADJUSTMENTS T iming 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 pis- ton is used to synchronize the electronic timing controlled by the EMM with the mechanical posi- tion of the number [...]

143 ELECTRICAL AND IGNITION TIMING ADJUSTMENTS 6 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 ret aining screw and adjust the pointer location to align with the cast-in TDC boss on the flywheel. T ighten retaining screw . In[...]

144 ELECTRICAL AND IGNITION SP ARK PLUGS SP ARK PLUGS Inspection S p ark plugs should be removed and examined periodically . Replace worn, fouled or damaged spark plugs. Use only recommended sp ark plugs with the cor- rect gap setting. • Remove spark plugs and inspect condition. • Set spark plug gap on new , replacemen t spark plugs. • Mark s[...]

145 ELECTRICAL AND IGNITION ELECTRIC ST ARTER SER VICING 6 ELECTRIC ST ARTER SER VICING Removal IMPORT ANT : Do not clean the st arter drive while the starter motor and drive are inst alled on the powerhead. The cleaning agent could drain into the starter motor , washing dirt from the drive into the starter b earings and commut ator . Disconnect th[...]

146 ELECTRICAL AND IGNITION ELECTRIC ST ARTER SER VICING Remove brus h holder c ap from a rmature an d frame assembly . Do not lose the brush springs. Slowly , remove the armature from frame. Cleaning and Inspection Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. Clean the commutator with 300[...]

147 ELECTRICAL AND IGNITION ELECTRIC ST ARTER SER VICING 6 If the pinion does not properly engage the fly- wheel, the pinion an d screw shaft assembly cou ld be worn, distorted, or dirt y . Locate the cause of binding and correct it b efore completing the assembly . Inspect and replace end cap thrust washer if dis- torted or worn excessively . Asse[...]

148 ELECTRICAL AND IGNITION ELECTRIC ST ARTER SER VICING Apply Locquic Primer and Screw Lock to the threaded portion, and inst all the two thru-bolts. T orque bolts 100 to1 10 in. lbs. (1 1 to 12.5 N· m). Lubricate the splines (helix) of st arter pinion shaft with St arter Bendix Lube . DO NOT use liquid or aerosol spray lubricant s. Install pinio[...]

149 ELECTRICAL AND IGNITION CONNECTOR SER VICING 6 CONNECT OR SER VICING DEUTSCH Connectors IMPORT ANT : Electrical Grease is recom- mended. Incorrect grease application can cause electrical or warning system problems. T o disconnect the connector , press the latch and pull the connectors ap art. T o connect the connector , confirm that the seal is[...]

150 ELECTRICAL AND IGNITION CONNECTOR SER VICING AMP Connectors IMPORT ANT : Always use the a ppropriate meter test probes and adapters when testin g compo- nents fitted with these terminals. Electrical grease is NOT used on AMP connectors. S UPERSEAL † 1.5 Disconnect Lift latch. Pull connectors a part. Connect Confirm the seal is in place. Push [...]

151 ELECTRICAL AND IGNITION CONNECTOR SER VICING 6 S UPER S EAL † The J1-A and J1-B connectors of the EMM are AMP Super Seal connectors. Disconnect Depress BOTH latches and pull connector from plug. Connect Push connector into plug until latches en gage. T erminal Removal Open lock mechanism and remove te rminal from connector housing. T erminal [...]

152 ELECTRICAL AND IGNITION CONNECTOR SER VICING T erminal Installation Align terminal with connector housing and push terminal with seal into connecto r housing until seated. Packard † Connectors IMPORT ANT : Always use the appropriate meter test probes and adapters when testing compo- nents fitte d with these terminals. Disconnect Lift latch(s)[...]

153 ELECTRICAL AND IGNITION CONNECTOR SER VICING 6 T erminal Removal A tab on the back side of the terminal engages a shoulder in the connector housing to hold the ter- minal in place. The term inal is removed by push- ing wire and terminal through connector housing. Insert a thin wire, such as a paper clip, into the connector above the terminal to[...]

154 ELECTRICAL AND IGNITION NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

FUEL SYSTEM 155 7 FUEL SYSTEM T ABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15[...]

156 FUEL SYSTEM SERVICE CHAR T SER VICE CHART I NJECTORS , V AP OR S EPARATOR , F UEL P UMP 24-36 in. lbs. (2.8-4.0 N·m) 24-36 in. lbs. (2.7-4 N·m) 60-84 in. lbs (7-9.5 N·m) 60-84 in. lbs (7-9.5 N·m) H S H 60-84 in. lbs (7-9.5 N·m) F A A 60-84 in. lbs. (6.8-9.5 N·m) 24-26 Ft. lbs. (33-35 N·m) 120 in. lbs. (14 N·m) 1 2 3 F A T riple-Guard Gr[...]

FUEL SYSTEM SERVICE CHAR T 157 7 R EED P LATE A SSEMBLY AND T HROTTLE B ODY 25-35 in. lbs (2.8-3.5 n·m) 60-120 in. lbs (7-14 n·m) 10-14 in. lbs (1.1-1.6 n·m) 10-14 in. lbs (1.1-1.6 n·m) 60-120 in. lbs (7-14 n·m) 10-18 in. lbs (1.1-2.0 n·m) F F IMPORT ANT : DO NOT lubricate TPS to throttle shaft surface A T riple-Guard Grease B Gasket Sealing [...]

158 FUEL SYSTEM COMPONENTS COMPONENTS The Evinrude E-TEC direct injection syste m con- sists of the following comp onents: • Fuel Lift Pump • Fuel Filter • V apor Separator • Fuel Circulation Pump • Fuel Supply Manifolds • Fuel Return Manifolds • Fuel Injectors Fuel Lif t Pump The fuel lift pump is a mechanical, pressure-pulse pump. T[...]

159 FUEL SYSTEM COMPONENTS 7 The vapor sep arator is serviced as an assembly and includes the fuel circulation pump. Fuel Reservoir The vapor sep arator accumulates fuel in an inter- nal fuel reservoir and supplies fuel to the electric circulation pump. It is wa ter-cooled to enhance vapor separating cap abilities. Cooling W ater is used to cool th[...]

160 FUEL SYSTEM COMPONENTS Pressure Regulator The fuel pressure regulator help s maintain consis- tent fuel pressure in the fuel system. Fuel returning from the injectors enters the fu el chamber of the vapor separat or through a pres- sure regulator . The pressure regulator maintains approximately 20 to 30 p si (138 to 207 kPa) of fuel pressure in[...]

161 FUEL SYSTEM COMPONENTS 7 Fuel Injectors Fuel injectors are fuel metering (55 V), electric injector pumps bolted directly to the cylinder head. The EMM supplies 55 V and controls the activa- tion of each injector . Fuel Flow Compensation Flow tests included in the injector manufa cturing process measure the flow rates of each injector . Each inj[...]

162 FUEL SYSTEM FUEL SYSTEM HOSE ROUTING FUEL SYSTEM HOSE ROUTING 002148 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12. 13. Fuel supply from boat fuel system Oil into fuel sup ply Fuel lift pump (2 to 8 p si) Pulse h ose from cylinde r/crank case Fuel filter Fuel supply to vapor sep arator V apor separator Electric fuel circulation pump (20 to 30 psi) Fue[...]

163 FUEL SYSTEM DIRECT INJECTION ELECTRICAL CIRCUITS 7 DIRECT INJECTION ELECTRICAL CIRCUITS The outboard’ s 55 V alternato r circuit supplies the injectors and fuel circulation pump with the cu rrent required to activate the fuel injectors and pump. Unique circuits from the EMM distribute this cur- rent to the specific injector or pump . The EMM [...]

164 FUEL SYSTEM FUEL COMPONENT TESTS FUEL COMPONENT TESTS Injectors Pressure T est This test requires fitting and O-ring kit, P/N 5005844. Disconnect the battery cables a t the battery . Relieve fuel system pressure. See Relieving Fuel System Pressure on p. 168. IMPORT ANT : Perform test with injector mounted to cylinder head and fittings inst alle[...]

165 FUEL SYSTEM FUEL COMPONENT TESTS 7 Fuel Supply Fuel System Pressure T est Relieve fuel system pressure. See Relieving Fuel System Pressure on p. 168. After relie ving fuel system pressu re, install a 0 to 100 psi (0 to 690 kPa) Fue l Pressure Gauge, P/N 5000902 or equivalent, to the upper fuel pres- sure test fitting. ST ART outboard and che ck[...]

166 FUEL SYSTEM FUEL COMPONENT TESTS open check valve at approximately 1 5 psi (103 kPa). Circulation Pump Resist ance T est Disconnect the battery cables a t the battery . Use a digital multimeter to measure the fuel pump circuit and coil re sistance. Lif t Pump Pressure T est Install a 0 to 15 p si (0 to 103 kPa) Fuel Pressure Gauge, P/N 5006397 [...]

167 FUEL SYSTEM FUEL COMPONENT TESTS 7 Lif t Pump V acuum T est Confirm fuel supply to the fuel lif t pump. T emporarily 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 (in let). Secure con- nections with tie strap s to prevent fuel or air leaks. IMPORT ANT : Do not use fue[...]

168 FUEL SYSTEM FUEL COMPONENT SER VICING FUEL COMPONENT SER VICING Relieving Fuel System Pressure IMPORT ANT : Minimize fuel system pressure prior to disassembly . T emporarily restrict the fuel supply hose from fuel tank with hose pincer . Remove propeller and disconnect circulation fuel pump electrical connecto r . If outboard runs, st art and r[...]

169 FUEL SYSTEM FUEL COMPONENT SE RVICING 7 Fuel Filter Removal Disconnect the battery cables a t the battery . Remove filter carefully to prevent spilling content s. Inspect contents for any pre sence of water . If water is present, identify the source and correct the problem. T ake additional fuel samples and drain fuel t ank(s) if necessary . In[...]

170 FUEL SYSTEM FUEL COMPONENT SER VICING Inst allation Fasten fuel pump to the cylinder/crankcase with pump to crankcase s crews. Apply Nut Lock to screws and install screws into crankcase. T orque screws to 24 to 36 in. lbs. (2.8 to 4.0 N·m). Connect the fuel outlet hose to the fuel filter . Secure with tie strap. Connect the fuel supply hose to[...]

171 FUEL SYSTEM FUEL COMPONENT SE RVICING 7 IMPORT ANT : Fuel injector(s) must be installed in the correct cylinder location(s). Use the Evinrude Diagnostics Software program to con- firm that the EMM programming matches injector positioning by cylinder location. The in jector infor- mation screen of the diagnostic program d isplays injector serial[...]

172 FUEL SYSTEM FUEL COMPONENT SER VICING Thread adaptor and stud into face of injector . Hold mounting cup securely . Work slide hammer to separate injector from mount housing. Remove adaptor from injector . Remove crush ring and O-rings from injector . Inspect and clean injec- tor filter . Inst all new crush ring and O-rings. Lubri- cate O-rings [...]

173 FUEL SYSTEM FUEL COMPONENT SE RVICING 7 The following items and their mating surfaces must be cleaned prior to reassembly: • Injector • Cylinder head • Adapter • Screws • Threaded areas Position injector and insulator in the proper cylin- der location. IMPORT ANT : Be careful not to pinch an y wiring or hoses during assembly . Lubrica[...]

174 FUEL SYSTEM INT AKE MANIFOLD Fuel Manifolds Removal Disconnect the battery cables a t the battery . Relieve fuel system pressure. Re fer to Relieving Fuel System Pressure on p. 168. Remove fuel manifold reta iner screws and remove retainer from fuel injector . Disconnect fuel manifold fittings from fuel injector ports. Remove clamps and disconn[...]

175 FUEL SYSTEM INT AKE MANIFOLD 7 Remove the reed valve ret ainer screws and remove the assembly . Use caution to prevent dama ging reed valve assemblies. Inspection IMPORT ANT : DO NOT disassemble reed valve assemblies unless reed plate seat s, reed valves, or reed stops are da maged, corroded, or cont ami- nated with debris. Damaged reed plates [...]

176 FUEL SYSTEM INT AKE MANIFOLD 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 25 to 35 in. lbs. (2.8 to 4.0 N·m). Inst allation Position reed plate assembly on cylinde r/crank- case. Apply Nut Lock to screws. Install all screws. T ighten the cen[...]

OILING SYSTEM 177 8 OILING SYSTEM T ABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

178 OILING SYSTEM SERVICE CHAR T SER VICE CHART 60 - 84 in lbs. (6.8 - 9.5 N·m) F 30 - 42 in lbs. (3.4 - 4.8 N·m) 30 - 42 in lbs. (3.4 - 4.8 N·m) 30 - 42 in lbs. (3.4 - 4.8 N·m) F F 002213 A T riple-Guard Grease B Gasket Sealing Compound C Adhesive 847 E Red Ultra Lock F Blue Nut Loc k H Outboard Engine Lubricant S STP Oil T reatment[...]

179 OILING SYSTEM COMPONENTS 8 COMPONENTS The oiling system consist s of the following compo- nents: • Oil tank and injection pump and manifold assembly (includes distribution manifold and pressure switch) • Oil pressure switch • SystemCheck LOW and NO OIL warning sig- nals • Cylinder and crankcase • Oil recirculation system Oil T ank Ass[...]

180 OILING SYSTEM COMPONENTS Code 32 A constantly close d oil pressure switch ( EMM does not detect oil pressure changes for 255 cycles) activates service code 32 and the EMM : Electrical Circuit (55 V) The oil injector is powered by the 55 V electrical circuit. The EMM controls injection pump opera- tion by opening and closing the circuit’ s gro[...]

OILING SYSTEM COMPONENTS 181 8 Oiling System Electrical Diagram 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 . 12. 13. 14. St a t o r S t ator output (55 V) Alternator grounds (BLACK) Injector circuit grounds (BLACK) Alternator output, WHITE / RED wires (55 V) Capacitor (55 V) Main harness ground (BLACK) 55 V to injection pump (WHITE / RED) EMM oil injector p[...]

182 OILING SYSTEM COMPONENTS Cylinder and Crankcase Each cylinder has a pressed-in fitting at the front of the cylinder/crankcase which is connected to an oil distribution hose. Lubrication for each cylinder is injected through these fittings. Additionally , one oil distribution hose is rout ed to a check valve that is connected to the incoming fue[...]

183 OILING SYSTEM COMPONENTS 8 Oil Recirculation System External hoses and fittings, in ternal cylin- der/crankcase p assages, and intake manifold p as- sages are used to “recirculate” any accumulation of oil from various locations in the powerhead. The movement of oil in these “oil circuit s” is con- trolled by check valves. Cylinder Recir[...]

184 OILING SYSTEM PRIMING PRIMING The oiling system of the outbo ard must be primed if the oil tank assembly is replaced, the oiling sys- tem is ru n out of oil, o r the sy stem i s disa ssem- bled for servicing. ST ART outboard and run it at IDLE. Use the diag- nostic software program to activate “Prime Oil.” IMPORT ANT : All clear “blue” [...]

185 OILING SYSTEM OILING SYSTEM TESTS 8 OILING SYSTEM TESTS IMPORT ANT : Always perform visual inspections to identify oiling system leaks. Ma ke sure the oil tank is filled and oil su pply is not contaminated. Oil Injection Pump St atic T est IMPORT ANT : S t atic tests are performed with the outboard not running. Use the Evinrude Diagnostics Soft[...]

186 OILING SYSTEM OILING SYSTEM TESTS Oil Injection Pump Circuit Resist ance T est Disconnect the battery cables a t the battery . Disconnect oil t ank electrical connector from engine wire harness connect or . Calibrate ohmmeter to the LOW OHMS scale and measure the resistance between pin 1 and 2 of the oil tank conne ctor . Result s: • If injec[...]

187 OILING SYSTEM OILING SYSTEM TESTS 8 Result s: • Oil movement is confirmed, co mpare to oil flow of other distribution hoses. • No oil flow , co mpare to o il flow at other distribu- tion hoses. One or more hoses fail to flow oil, check for kinked or restricted hose or fittings before replacing oil t ank assembly . Injector Fittings to Cylin[...]

188 OILING SYSTEM OILING SYSTEM TESTS Oil-to-Fuel Check V alve T est The oil-to-fuel check valve controls oil that flows into the outboard fuel system. Oil is injected into the incoming fuel supply before the fuel lift pump. IMPORT ANT : T emporarily disconnect fuel sup- ply hose to relieve pressure in the hose . Using a marker or pen, mark the pos[...]

189 OILING SYSTEM OIL COMPONENT SE RVICING 8 OIL COMPONENT SER VICING IMPORT ANT : Access to certain oil distribution hoses requires removal of various engine compo- nents. 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 disassemb l[...]

190 OILING SYSTEM OIL COMPONENT SERVICING Oil T ank Assembly Removal Disconnect the battery cables a t the battery . Remove engine covers and air silencer . Disconnect the electrical connector to the oil injec- tion pump and manifold assembly . IMPORT ANT : Note oil distribution hose rout- ings before proceeding with disassembly . Clamps and protec[...]

COOLING SYSTEM 191 9 COOLING SYSTEM T ABLE OF CONTENTS HOSE ROUTING AND WATER FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 SOFTWARE METHOD . . . . . . . . . . . [...]

192 COOLING SYSTEM HOSE ROUTING AND W A TER FLOW DIAGRAM HOSE ROUTING AND W A TER FLOW DIAGRAM Outgoing water (warm/hot) Incoming water (cool) 6 4 8 9 10 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. W ater intake screens W ater pump W ater tube Adapter housing Cylinder block Pressure relief valve Thermostat W ater supply to EMM W ater supply , EMM to vapor sep[...]

193 COOLING SYSTEM ENGINE TEMPERA TURE CHECK 9 ENGINE TEMPERA TURE CHECK IMPORT ANT : The engine temperatures listed below are based on an int ake water temperature of 70° ± 10°F (21° ± 3°C). Install correct test propeller and pla ce outboard in a test tank or in the water . S tart outboard and run at 3000 RPM in FOR W ARD gear for at least f[...]

194 COOLING SYSTEM ENGINE TEMPERA TURE CHECK IMPORT ANT : If you get low or inaccurate read- ings with a digit al pyrometer , coat the pro be loca- tion with Thermal Joint Compound , P/N 322170. IMPORT ANT : Digital pyrometer or tempera ture gun measurement s may be slightly lower than software temperatu re readings. Idle Operating T emperature T r[...]

195 COOLING SYSTEM COMPONENTS 9 COMPONENTS General Description All models use a two-st age cooling system design. The cooling system is dependent on water pump pressure and controlled by thermost at and pressure relief valve operation. IMPORT ANT : Restricted or inadequate water flow through the outboard reduces cooling system performance and may l[...]

196 COOLING SYSTEM COMPONENTS Adapter Housing • Adapts the cylin der/crankcase assembly (pow- erhead) to the megaphon e and exhaust hous- ings and the water tube. • Provides water passages which route incoming and outgoing cooling water . • Provides exhaust passages which connect to the inner exhaust of the outboard’s midsection. Pressure R[...]

197 COOLING SYSTEM COMPONENTS 9 Thermost at The thermost at is used to control water flow a nd operating temperature at slower speed s (below 2000 RPM). Overheating: A restricted or faulty thermostat typ- ically results in LOW SPEED overheating. Overcooling: Debris may prevent the thermo stat from closing completely . Refer to THERMOST A T SERVICIN[...]

198 COOLING SYSTEM OPERA TION OPERA TION Cylinder Block / Cylinder Head Cooling The thermostat is located in the top o f the cylinder head. A sepa rate pressure valve is positioned in the top of the cylinder block adjacent to the exhaust cover . The thermost at and pressure valve control the flow of water entering the vertical water passages of the[...]

199 COOLING SYSTEM THERMOST A T SE RVICING 9 THERMOST A T SER VICING Disassembly Remove the therm ostat cover and O-ring fro m cyl- inder head. Remove spring, thermosta t, and gasket. Remove the cylinder head if cylinder head seal requires replacement. Plac e new seal in the cylin- der head with side marked “TO CYL HEAD” facing thermostat. Insp[...]

200 COOLING SYSTEM PRESSURE RELIEF V AL VE SERVICING PRESSURE RELIEF V AL VE SERVICING The pressure relief valve assembly should be ser- viced at the same time as the thermostat. Disassembly Remove pressure relief valve cover retaining screws. Remove the pressure relief valve assembly . Inspection Inspect all components for cracks, heat d amage, or[...]

POWERHEAD 201 10 POWERHEAD T ABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

202 POWERHEAD SERVICE CHAR T SER VICE CHART 002281 F 60-84 In. lbs. (7-9.5 N·m) B 120-144 In. lbs. (13.5-16 N·m) A H 168-192 In. lbs. (19-21.5 N·m) 15-30 Ft. lbs. (20-41 N·m) IMPORT ANT See Spark Plug Indexing Procedure Q Apply to crankcase mating flange M Apply to water passages F 60-84 In. lbs. (7-9.5 N·m) H 26-30 Ft. lbs. (35-41 N·m) B 60-[...]

POWERHEAD SERVICE CHAR T 203 10 H 30-32 Ft. lbs. (41-43 N·m) Must have alignment tool H G Y H H H H B A D Y Y 15-20 Ft. lbs. (20-27 N·m) 1 10-130 Ft. lbs. (149-176 N·m) A T riple-Guard Grease B Gasket Sealing Compound D Mo ly Lube E Red Ultra Lock F Blue Nut Lock G Needle Bearing Grease H O utboard Lubricant P Permatex No. 2 Q Gel Seal II Y Extr[...]

204 POWERHEAD GENERAL GENERAL Cylinder Compression T esting S t art and run outboard until it achieves operating temperature, then shut OFF . Disconnect crankshaf t position sensor (CPS) con- nector . Remove all spark plugs. Advance throttle linkage to WOT . Inst all compression tester’s hose att achment into spark plug hole (14 mm threads). Whil[...]

205 POWERHEAD REMOV AL 10 REMOV AL IMPORT ANT : Reinstall faste ners, nuts, and bolts in their holes as engine components are removed. This will simp lify identification and assembly . Loosen screw and remove the air silen cer . Remove lower engine cover screws, including one at inside, top rear . Loosen port side cover slightly , and disconnect tr[...]

206 POWERHEAD REMOV AL Remove six retaining screws and exhaust relief muffler . Install Lif ting Fixture, P/N 396748, on flywheel and seat the three screws completely . IMPORT ANT : Be sure to use only the 1 1/8 in. (short) screws, P/N 398 067, included with the tool to avoid damage to electronic components under the flywheel. Fasten appropriate ch[...]

207 POWERHEAD DISASSEMBL Y 10 DISASSEMBL Y General Remove the electric starter an d solenoid. Refer to St a r t e r Removal on p. 145. Remove the oil tank a nd oil injection hoses. Refer to Oil T ank Assembly on p. 190. Remove the EMM , wiring harness assembly , fly- wheel, and st ator . Refer to ELECTRICAL AND IGNITION and ENGINE MANAGEMENT MOD- U[...]

208 POWERHEAD DISASSEMBL Y Crankcase Remove the throttle body and ree d plate assem- blies. Refer to INT AKE MANIFOLD on p. 174. Remove pressure valve assembly . Refer to PRESSURE RELIEF V AL VE SER VICING on p. 200. Disconnect crankcase and block-to-block oil recir- culating hoses. Remove screws and one double-ended stud and remove exhaust side wa[...]

209 POWERHEAD DISASSEMBL Y 10 Separate crankcase an d cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to loosen. Cylinder Head Remove thermost at cover and thermostat asse m- bly . Refer to THERMOST A T SERVICING on p. 199. Loosen in st ages and remove cylinder he ad retaining screws. Remove the cylin der he[...]

210 POWERHEAD DISASSEMBL Y IMPORT ANT : Reatta ch 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 cont act inside surface of cylin- der or crankshaf t. IMPORT ANT : Identify all internal component s so that if reused, they can be reinst alled in their origi[...]

211 POWERHEAD DISASSEMBL Y 10 Remove the upper main bearing . Remove the lower bearing seal housing. Remove the housing O-ring. Discard O-ring. T o remove the housing seal, use a punch as shown. Discard seal. Inspect housing and replace if necessary . Remove O-ring from crankshaft sleeve and inspect it. Replace the O-ring if it is not in good condi[...]

212 POWERHEAD CLEANING Remove the lower main be aring only if it needs to be replaced. Use external ret aining ring pliers to remove the lower bearing ret aining ring. Using an appropriate bearing sep arator , support the bearing, place sep arator flats a gainst the bearing, and press of f the crankshaft. Remove center main bearin gs and split slee[...]

213 POWERHEAD INSPECTION 10 Use Gel Seal and Gasket Remover t o r e m o v e a l l traces of gasket s, adhesives, and Gel-Seal II™ sealant from the cylinder block and crankcase . Carefully rem ove any ca rbon accum ulation f rom the tops and ring grooves of the piston using Engine T uner . A ring groove cleanin g tool can be made by breaking an ol[...]

214 POWERHEAD INSPECTION Crankshaf t Measure the diameter of each crankpin and main bearing journal. The lo wer main bearing journal would only be measured if the bea ring was removed for another reason. 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 [...]

215 POWERHEAD INSPECTION 10 the cylinder . Use a feeler gauge to measure the ring end gap. IMPORT ANT : Ring end gap increases approxi- mately 0.003 in. (0.076 mm) for each 0.001 in. (0.025 mm) increase in cylin der bore diameter . DO NOT exceed cylinder oversize dimension. Use a machinist’ s straightedge to check for proper ring clearance. Posit[...]

216 POWERHEAD ASSEMBL Y ASSEMBL Y IMPORT ANT : Proceed slowly . Make no forced assemblies unless a pressing operation is called for . All interna l components must be perf ectly clean and lightly coated with outboard lubricant. IMPORT ANT : Use new wrist pin ret aining rings, gaskets , seals, and O-rings during assembly . Crankshaf t Oil the end of[...]

217 POWERHEAD ASSEMBL Y 10 Lubricate upper main bearing with outbo ard lubri- cant and install on crankshaft. Pack lip of upper oil seal with Extreme Pressure Grease . Place seal on crankshaf t with lip toward driveshaft and enclosed face toward flywheel. Lightly apply Gasket Sealing Compound on the outer rim of a new lowe r housing seal. Press sea[...]

218 POWERHEAD ASSEMBL Y Pistons and Connecting Rods IMPORT ANT : It is very import ant that the pis- tons in this engine are oriented correctly . New pistons are st amped “EXH.” This marking should be oriented to the exha ust side of the block. As another reference, the splash bowl on the dome of the piston will be located toward the flywheel a[...]

219 POWERHEAD ASSEMBL Y 10 Oil the wrist pin bore and wrist pin. Push the wrist pin part way through the t op wrist pin hole. Place connecting rod, with bearings, washer s, and tool, into the piston with the alignment dot s facing the top of the piston. Install wrist pin through piston and connecting rod, pushing bearing tool out throu gh the pisto[...]

220 POWERHEAD ASSEMBL Y IMPORT ANT : Before continuing, make sure that all Gel-Seal II has been removed from the cyl- inder block and crankcase mating flanges. If traces of hardened Gel-Seal II are lef t, main bear- ings could be misaligned. Refer to CLEANING on p. 212 . Coat pistons, rings, cylinder walls, and Ring Com- pressor , P/N 336314 (P/N 3[...]

221 POWERHEAD ASSEMBL Y 10 Apply a 1/16 in. (2 mm) bead o f RTV Adhesive around each water p assage on the block and cyl- inder head as shown. Install cylin der head. Apply outboard lubricant to threads and install the cylinder head screws. Fol- lowing sequence on cylinder head , torque all screws in stage s to 168 to 192 in. lbs. (19 to 21.5 N·m)[...]

222 POWERHEAD ASSEMBL Y Lubricate each crankpin and bearing assembly with outboard lubricant. Slowly pull connectin g rod up to crankshaft and install bearing halves. Lubricate rod cap screw threads and und er screw head mating surface with a light coat of T riple- Guard grease. Apply outboard lubricant to screw hole threads in rod, and to screw he[...]

223 POWERHEAD ASSEMBL Y 10 Secure restraining jaw “C” and forcin g jaw “D” to frame. Apply a light coat of outboard lubricant to the cor- ners of the connecting rod and rod cap. Place frame on connecting rod using the following pro- cedure. • Position frame onto th e connecting rod so the contact area of the jaw is ce ntered on the side o[...]

224 POWERHEAD ASSEMBL Y T est at least three corners of the rod and cap joint with a pick. Joint must be smooth with no step. Repeat steps for re maining connecting rods. Crankcase Thoroughly clean and deg rease the mating flanges of the crankcase and cylinder block with a non-petroleum based solvent, such as isopropyl alcohol or acetone, and let a[...]

[...]

226 POWERHEAD ASSEMBL Y Shif t Linkage Place the spring, guide, and ball of the shift detent assembly into the crankcase. Lubricate with Tr i - ple-Guard grease. Lubricate shift lin kage bosses at the base of the crankcase with T riple-Guard grease. Insert bush- ings into bosses. Apply T riple-Guard grease to the shaft and detent of the shift lever[...]

227 POWERHEAD ASSEMBL Y 10 Throttle Linkage Apply Nut Lock to threads of throttle return lever screw . Insert spring into cavity of throttle return lever . Install lever , screw , and washer on cra nkcase and hook spring on rib as shown. T orque screw to 120 to 144 in. lbs. (13.5 to 16 N·m). Apply Nut Lock to threads of throttle lever screw . Inst[...]

228 POWERHEAD UPPER MOUNT SERVICING UPPER MOUNT SER VICING Removal Remove mount ret ainer screw . Insert suitable pun ch in taper of mount ret ainer . T ap side of punch to loosen mount retainer . Dislodge mount assemblies and remove. Inspect mounts and replace if necessary . IMPORT ANT : The motor mount, washer , and screw are serviced as an assem[...]

229 POWERHEAD INST ALLA TION 10 INST ALLA TION Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only . Install gasket on adapter . T o ensure proper sealing, ma ting sur- faces must be clean. Coat the driveshaft splines with Moly Lube . Do not apply lubricant to end of driveshaf t. Slowly lower powerhead onto exhaust [...]

230 POWERHEAD INST ALLA TION Apply Gasket Sealing Compound to exhaust relief muffler gasket and ret aining screws. Install muffler and torque screws 60 to 84 in. lbs. (7 to 9.5 N·m). Shif t Linkage Adjustment Adjust shift linkage as follows: • Loosen adjustment screws on shif t lever . • Be sure that ball is centered in detent assembly . • A[...]

231 POWERHEAD INST ALLA TION 10 Connect the power trim connectors. Installation of lower motor covers will be greatly simplified if the following step s are performed in sequence: • Place starboard cover on outboard and route fuel hose and battery cable through grommet notch. • Insert trim cable grommet into port side cover . • Connect trim/t[...]

232 POWERHEAD INST ALLA TION Install air silencer and tighten screw . IMPORT ANT : Perform the following procedures before returning outboard to service: • Index all sp ark plugs. Refer to S park Plu g Indexing on p. 144. • Use the Evinrude D iagnostics So ftware pro- gram to initiate powerhead break-in. Refer to Powerhead Break-In on p. 98. ?[...]

233 POWERHEAD POWERHEAD VIEWS 10 POWERHEAD VIEWS Port Short Block S t arboard Short Block[...]

234 POWERHEAD POWERHEAD VIEWS Port Dressed Powerhead S tarboard Dressed Powerhead[...]

235 POWERHEAD POWERHEAD VIEWS 10 Front[...]

236 POWERHEAD POWERHEAD VIEWS Rear[...]

237 POWERHEAD POWERHEAD VIEWS 10 To p[...]

238 POWERHEAD NOTES NOTES T echnician’ s Notes Related Document s Bulletins Instruction Sheet s Other[...]

MIDSECTION 239 11 MIDSECTION T ABLE OF CONTENTS SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

240 MIDSECTION SERVICE CHAR T SER VICE CHART S TERN B RACKET 40-50 In. lbs. (4.5-5.7 N·m) 40 Ft. lbs. (54 N·m) 38-45 Ft. lbs. (52-61 N·m) 130-150 Ft. lbs. (176-204 N·m) Marine Sealant See "Installation & Predelivery" in manual 170-190 In. lbs. (19-22 N·m) 40-50 In. lbs. (4.5-5.7 N·m) 50-54 Ft. lbs. (68-73 N·m) See Text 216-240 [...]

MIDSECTION SERVICE CHAR T 241 11 E XHAUST H OUSING B 60-84 In. lbs. (7-9.5 N·m) B 60-84 In. lbs. (7-9.5 N·m) E 60-84 In. lbs. (7-9.5 N·m) C C A B B 60-84 In. lbs. (7-9.5 N·m) F 150-180 In. lbs. (17-20 N·m) A A C B 18-20 Ft. lbs. (24.5-27 N·m) A T riple-Guard Grease B Gasket Sealing Compound C Adhesive 847 D Mo ly Lube E Red Ultra Lock F Blue [...]

242 MIDSECTION TIL T TUBE TIL T TUBE The tilt tube may be serviced withou t major disas- sembly of the outboard using T i lt T ube Service Kit, P/N 434523. Removal Pull locking tabs on tilt limit ca m loose from collar . Remove the cam and collar from the tilt tube. Remove the nut from the st arboard side. Thread the sp acer from T ilt T ube Servic[...]

243 MIDSECTION TIL T TUBE 11 Thread Slide Hammer , P/N 432128, into the adapter until at least 2 in. (51 mm) of thread are engaged. Pull tilt tube from stern bracket with the slide ham- mer . Whe n tilt tube clears the port stern bracket, remove tilt tube from the sp acer . Inst allation Thread starboard e nd of tilt tube into the space r . Thread [...]

244 MIDSECTION EXHAUST HOUSING EXHAUST HOUSING Removal Before removing the midsection: • The gearcase must be remove d. Refer to Gear- case REMOV AL AND INST ALLA TION on p. 260. • The powerhead must be removed. Refer to Powerhead REMOV AL on p. 205. Remove and discard four lower mount screws. Remove the exhaust housing. Remove lower mount cove[...]

245 MIDSECTION EXHAUST HOUSING 11 Lift the adapter/inner exhaust housing out of the exhaust housing. Remove the three upper screws and three lower screws securing the inner exhaust housing to the adapter housing. Remove the water tube from the inner exhaust housing. Discard water tube grommet. Remove the seal from the bottom flan ge of the inner ex[...]

246 MIDSECTION EXHAUST HOUSING Cleaning and Inspection Clean all part s with part s cleaning solvent and dry with compressed air . All nut and screw threads coated with thread locking material must be thor- oughly cleaned before assembly . When using a thread locking product, be sure to prime the threads with Locquic Primer . Examine the upper and [...]

247 MIDSECTION EXHAUST HOUSING 11 Install the water tube through the top of the inner exhaust housing and align as shown: Place a new gasket between the inner exhaust housing and the adapter housing. Apply Ultra Lock to the screws. Inst all the three lower screws and three upper screws and torque to 60 to 84 in. lbs. (7 to 9.5 N·m). Apply Adhesive[...]

248 MIDSECTION EXHAUST HOUSING the hole in the outer housing and t he alignment pin into the adapter housing. Apply Gasket Sea ling Compound to threads of the four retain ing screws and torque to 60 to 84 in. lbs. (7 to 9.5 N·m). If removed, coat the lower mount s with soapy water and press into the exhaust housing with the “OUTSIDE” mark faci[...]

249 MIDSECTION STERN BRACKET 11 Inst allation Bring the exhaust housing into position with the stern bracket. Install four new lower mount screws. These screws have lock-patch pre-app lied, assisting in a secure mount. T orque screws to 38 to 45 f t. lbs. (51 to 61 N·m). Install gearcase . Refer to Gearcase REMOV AL AND INST ALLA TION on p. 260. I[...]

250 MIDSECTION STERN BRACKET Remove the steering shaft and thrust washer . It may be necessary to tap the steering shaf t out using a wood dowel and mallet . Pry out upper and lower steering shaft seals and discard. Remove the upper and lower steering shaft bushings. Remove the tilt tube. Refer to TIL T TUBE on p. 242. Remove the two tilt tube wash[...]

251 MIDSECTION STERN BRACKET 11 Remove the tilt limit switch and ret ainer from the swivel bracket. Disconnect the trail lock sp ring and remove it from the swivel bracket. Remove trail arm ret ainer . Remove the trail lock arm and bushings from the swivel bracket. Remove the two trim rod rollers from the swivel bracket. Remove the tilt support and[...]

252 MIDSECTION STERN BRACKET Assembly IMPORT ANT : Before proceeding, make sure all components h ave been thoroughly cleaned. Replace any seals that have bee n removed. Inspect all thrust washers and bushings for evi- dence of deterioration. Install the detent roller and spring and the tilt sup- port with bushing in the swivel bracket. T orque bush[...]

253 MIDSECTION STERN BRACKET 11 Install the tilt limit switch and retainer on the swivel bracket. T orque screws to 40 to 50 in. lbs. (4.5 to 5.7 N·m). Route the trim sender wires through the braided tube, and install the sender unit in the port stern bracket. Install the upper an d lower steering shaft bushings and new seals in the swivel bracket[...]

254 MIDSECTION STERN BRACKET Install the steering shaft keeper . Apply Locquic Primer and Nut Lock to the splines of the steering shaft and lower mount b racket. Install the lower mount bracket and a new locking nut with its u nstaked side facing the mount bracket. Align the bracket with the steering arm and torque the nut to 130 to 15 0 ft. lbs. ([...]

[...]

256 GEARCASE SERVICE CHAR T SER VICE CHART “S” T YPE G EAR CASE 120-144 In. lbs. (13.6-16.3 N·m) 108-132 In. lbs. (12.2-14.9 N·m) 18-20 Ft. lbs. (24-27 N·m) 100-1 10 Ft. lbs. (136-149 N·m) Use Outboard Lubricant on threads only, taper must be clean and dry. A A B E B B 60-84 In. lbs. (7-9.5 N·m) 35-40 Ft. lbs. (47-54 N·m) C B G B 60-84 In[...]

GEARCASE SERVICE CHAR T 257 12 “O” T YPE G EARC ASE A B E B B 108-132 In. lbs. (12.2-14.9 N·m) 18-20 Ft. lbs. (24-27 N·m) 70-80 Ft. lbs. (95-109 N·m) E A 15-20 In. lbs. (1.7-2.3 N·m) 100-1 10 Ft. lbs. (136-149 N·m) Use Outboard Lubricant on threads only, taper must be clean and dry. 35-40 Ft. lbs. (47-54 N·m) 60-84 In. lbs. (7-9.5 N·m) G[...]

258 GEARCASE GEARCASE TYPES GEARCASE TYPES PROPELLER Inspection Carefully examine propeller and outboard for the following: • Damaged blades and signs of propeller cavit a- tion (burned paint, etc.) • S pun or ove rheated inner hub • Worn or twisted splines and inadequate lubr i- cant • Damaged or missing conv erging ring (if applica- ble) [...]

259 GEARCASE LEAK TEST 12 Inspection Inspect the lubricant for water cont amination. W ater can make the lubricant milky in appear- ance. Howeve r , normal aerati on can al so cause the same appearance. T o check for water contamination, drain lubricant into a suitable glass cont ainer . Allow the drain ed oil to settle for a minimum of one hour to[...]

260 GEARCASE REMOV AL AND INST ALLA TION REMOV AL AND INST ALLA TION Removal Remove screw from shift lever to release the lower shift rod. Note where the index mark on the gearcase aligns with the index number of the adjust able trim tab so the trim tab can be reinstalled in the same posi- tion. Remove the trim t ab retaining screw and trim tab fro[...]

261 GEARCASE REMOV AL AND INST ALLA TION 12 Inst allation IMPORT ANT : Before installat ion of gearcase on motor , shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 265. Coat the driveshaft splines with Moly Lub e . DO NOT coat top surface of th e driveshaft because lubricant may prevent seat ing of the driveshaft in the cra[...]

262 GEARCASE WA T E R P U M P 54 N·m). For adjustment, refe r to Tr i m Ta b Adjustment on p. 68. 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). IMPORT ANT : During break-in period of a reas- sembled gearcase, chan ge the gearcase lubricant between 10 to 20 hours of ope ration. WA[...]

263 GEARCASE WA T E R P U M P 12 Assembly Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs. IMPORT ANT : Do not allow any adhesive to get into the air bleed groove in the imp eller housing. If this groove is blocked by adhesive, the pump will lose its prime and will not pump water . Install the O-ring in groove in the i[...]

264 GEARCASE WA T E R P U M P Run a thin bead of Adhesive 847 in the seal groove, and inst all the special shaped O-ring seal. Apply Gasket Sealing Compound to both sides of a new impeller plate gasket. Inst all the gasket and impeller plate. Apply T riple-Guard grease to a new impeller O- ring. Slide the O-ring down the driveshaf t and slide half [...]

265 GEARCASE SHIFT ROD ADJUSTMENT 12 SHIFT ROD ADJUSTMENT Check the shift rod height from the shif t rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997. With the shift ro d and detent lever in NEUTRAL, rotate the shif t rod up or down as necessary for correct adjustment. Onc e correct height is achieved, rota[...]

266 GEARCASE DISASSEMBL Y DISASSEMBL Y IMPORT ANT : Clean and inspect all components during disassembly . Replace any da maged com- ponents, seals, O-rings, and gasket s upon assem- bly . Remove the propeller and mounting hardware. Drain and inspect oil as described in LUBRIC ANT on p. 258. Remove gearcase as described in REMOV AL AND INST ALLA TIO[...]

267 GEARCASE DISASSEMBL Y 12 Propeller Shaf t Bearing Housing Removal Remove the two screws, washers, and ret ainers holding the propeller shaf t bearing housing. Remove wedge, screw , and washer (“O” T ype). Remove the propeller shaf t bearing housing from the gearcase using the following: • Puller body , screw , and handle from Universal Pu[...]

268 GEARCASE DISASSEMBL Y Remove the four driveshaf t bearing housing screws with washers. Remove pinion nut and d riveshaft from the gear- case. If driveshaft cannot be removed , refer to (Spe cial) Driveshaft Remov al Procedures on p. 268. The bearing housing, sh ims, thrust bearing, and thrust washer will come out with the driveshaf t. Reach ins[...]

269 GEARCASE DISASSEMBL Y 12 Driveshaf t Service T o separate the upper driveshaf t (if needed) from the lower driveshaf t, remove the roll pin. Replace the damaged component. T o assemble the driveshaft, inst all new driveshaft retainer into the groove of the upper driveshaft. Install the upp er driveshaft into the lower drive- shaft, aligning the[...]

270 GEARCASE GEARCASE HOUS ING INSPECTION Shif t Housing, Gear and Propeller Shaf t Removal Push down on the shift rod. This will move the detent lever downward to clear the inside of the gearcase when the shaf t assembly is pulled out. Unthread the shif t rod from the detent lever . Remove the six screws, shift rod, and cover from the gearcase. Di[...]

271 GEARCASE BEARING AND SEAL REMOV AL 12 BEARING AND SEAL REMOV AL Shif t Housing IMPORT ANT : The shift h ousing and forward gear bearing are serviced as an assembly . If either are worn or damaged, replace th e complete assembly . Disassembly Insert a suitable to ol under one end of the clutch dog spring and remove it from its groove by unwrappi[...]

272 GEARCASE BEARING AND SEAL REMOV AL Wrap the housing with a sho p cloth to catch ball and spring. Rotate the shif ter detent 90° in either direction, then pull the dete nt out of the housing. Remove the detent ball and sp ring. Remove needle bearings from bearing housing for cleaning and inspection (“O” T ype). Pinion Gear Bearing Remove pi[...]

273 GEARCASE BEARING AND SEAL REMOV AL 12 Driveshaf t Bearing Housing The driveshaft b earing is not serviceable. Replace the bearing housing assembly if the bearing is worn or damaged. Also, inspect the driveshaf t bearing surface if the bearin g is damaged. Seal Removal Remove the driveshaft bearing housing seals using Puller Bridge, P/N 432127, [...]

274 GEARCASE BEARING AND SEA L INST ALLA TION Inspect the bearing housing anode. Replace anode if it is reduced to two-thirds of original size. Discard the bearing housing O-ring. Clean the housing and bearings in solvent a nd dry thor- oughly . If bearings were not replaced, rot ate the needles to check for freedom of movemen t. Inspect O-ring gro[...]

275 GEARCASE BEARING AND SEAL INST ALLA TION 12 Thoroughly grease 25 needle bearings with Nee- dle Bearing grease and place in the be aring case (“O” T ype gea rcases). With shifter dete nt in NEUTRAL, install arms of shift lever int o detent slots. Alig n the pivot holes and insert the retaining pin. Push shif ter detent down. Rest the cradle [...]

276 GEARCASE BEARING AND SEA L INST ALLA TION Align holes in the clutch dog with slot in the pro- peller shaf t. Install the clutch dog on the shaft with “PROP END” facing rear of the shaf t. IMPORT ANT : The clutch dog is not symmetri- cal. If installed backward, it will not fully engage and will immediately damage it self and the gears. Slide[...]

277 GEARCASE BEARING AND SEAL INST ALLA TION 12 IMPORT ANT : S p acers are different sizes and cannot be interchanged. Apply Needle Bearing grease to the needle bear- ings and insert them into the bearing case (“O” T ype g earcases). Place the bearing on the installer tool with the let- tered side of the bearing facing the top of the gearcase. [...]

278 GEARCASE BEARING AND SEA L INST ALLA TION Propeller Shaf t Bearing Housing Bearing Inst allation Oil, then install new be arings in bearing housing. Place the lettered end of the bearing case on the bearing insta ller , then press th e bearing into the housing until the tool seat s. When inst alled, the lettered end of the bearing shou ld be vi[...]

279 GEARCASE DRIVESHAFT SHIMMING 12 DRIVESHAFT SHIMMING IMPORT ANT : If new pinion gear is needed, replace gear set before shimming. Pinion gear backlash is achieved by using shims between the driveshaf t bearing housing and the thrust washer . When installing a new thrust bear- ing or washer , bearing hous ing, pinion, or drive- shaft, it is neces[...]

280 GEARCASE ASSEMBL Y gauges. Measure between e ach pair of screw holes. Replace the bearing housing and rep eat check if variance exceeds 0.004 in. (0.010 mm). Check the squareness of the pinion to the drive- shaft by holding t he shim gauge bar against the bearing housing (between the screw holes) while rotating just the driveshaf t and pinion a[...]

281 GEARCASE ASSEMBL Y 12 Shif t Rod Housing Inst allation Lubricate a new shift rod cover O-ring with Tr i p l e - Guard grease. Inst all the O-ring into the shif t rod cover . IMPORT ANT : Make sure O-ring is fully seated in groove around shift rod cover’s full circumfer- ence. Place the shif t rod grommet on the shif t rod. Install shif t rod [...]

282 GEARCASE ASSEMBL Y Pinion Gear and Driveshaf t Inst allation Refer to DRIVESHAFT SHIMMING on p. 279 before proceeding. Position the driveshaft thrust bearing, thrust washer , and shim(s) (selected earlier) on the driveshaft, exactly in orde r shown. Using Driveshaft Seal Protector , P/N 318674, slide the driveshaf t bearing housing onto the dri[...]

283 GEARCASE ASSEMBL Y 12 Retainer , P/N 341438, to torque the pinion nut to 100 to 1 10 ft. lbs. (136 to 149 N·m). Propeller Shaf t Bearing Housing and Gear Inst allation Oil and install thrust bearing and thrust washer on hub of reverse gear . Slide the gear assembly onto the propeller shaf t until it engages the pinion gear . Lightly apply Gask[...]

284 GEARCASE ASSEMBL Y “O” T ype Gearcases Loosen ret ainer screws 1/4 turn. Install wed ge, screw , and washer . Apply Ultra Lock to threads and torq ue screw 15 to 20 in. lbs. (1.7 to 2.3 N·m). Re-torque two ret ainer screws to 18 to 20 f t. 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). [...]

TRIM AND TIL T 285 13 TRIM AND TIL T T ABLE OF CONTENTS SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 MANUAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 TRAILER[...]

286 TRIM AND TIL T SYSTEM DESCRIP TION SYSTEM DESCRIPTION The power trim/tilt hydrau lic system is completely contained betwee n the outboard's stern brackets. The system consist s of: • Electric motor • Oil reservoir • Pump manifold assembly • Cylinder body assembly Optimal boat and outboard performance can be achieved by adjusting (t[...]

287 TRIM AND TIL T ROUTINE INSPECTIONS 13 ROUTINE INSPECTIONS General Check for external signs of fluid leakage. Correct causes as necessary . Check the battery and make sure it is in go od operating condition. Reservoir Fluid Check reservoir fluid level every three years or every 300 operating hours. System cap acity is approximately 20 fl. oz. (6[...]

288 TRIM AND TIL T TROUBLESHOOTING TROUBLESHOOTING Use the following guidelines to check a single pis- ton 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 coupl[...]

289 TRIM AND TIL T ELECTRICAL CIRCUIT TESTS 13 Connect a 0 to 100 A DC ammeter in series between the battery side of the st arter solenoid and the red lead to the trim/tilt rela y module. Observe ammeter and a stop watch while running hydraulic unit through several complete cycles. Compare test result s to the values listed: Performance Chart T est[...]

290 TRIM AND TIL T ELECTRICAL CIRCUIT TESTS Monitor motor RPM and current draw . The motor shaf t must rotate clockwise, as viewed from the pump end, when positive (+) is applied to the blue lead, and negative (–) is conne cted to green lead. The motor shaf t must rotate counterclockwise, a s viewed from the pump end, when positive (+) is applied[...]

291 TRIM AND TIL T REMOV AL AND INST ALLA TION 13 T rim Sender T est IMPORT ANT : T o avoid immediate meter dam- age, never apply a mu ltimeter to an electrical cir- cuit where voltage is present. Disconnect the 3-pin Deut sch connector between the instrument harness and engine trim harn ess. Connect an ohmmeter between the white/t an wire, termina[...]

292 TRIM AND TIL T REMOV AL AND INST ALLA TION Separate the trim/tilt unit wires in the braided tube to permit removal through the hole in the stern bracket. Unscrew the manual release valve, raise the unit, and lock it in place with the tilt support. Remove the external snap rings from the upper pin. Use a punch to remove the upper pin. Retract th[...]

293 TRIM AND TIL T REMOV AL AND INST ALLA TION 13 Remove the unit from the ste rn brackets far enough to remove the ground lead from the pump motor mounting screw . Inst allation Install the gro und lead. Position the hydraulic unit between the stern bracket s. Apply T riple-Guard grease to the lower pin and install the pin. If loosened, torque the[...]

294 TRIM AND TIL T SERVICING SER VICING Disassembly Thoroughly clean the unit be fore disassembling. Scrub all out side surfaces with a stiff brush a nd hot, soapy water to prevent surface dirt from con- taminating internal p arts. Always use a lint free shop cloth when handling power trim/tilt component s. If painting the unit is required, paint i[...]

295 TRIM AND TIL T SERVICING 13 Remove drive coupler from either the motor or the pump assembl y . Assembly IMPORT ANT : Use only Evinrude/Johnson Bio- degradable TNT Fluid to fill the hyd raulic system. Install drive cou pler in pump assembly . Install a new motor O-ring. Position the motor on the manifold and inst all four new screws and lock was[...]

296 TRIM AND TIL T ADJUSTMENTS Fill the oil reservoir up to the fill plug with Evinrude/Johnson Biodegradable TNT Fluid. Install an d tighten the fill plug. Do not torque the plug at this time. 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 b[...]

S–1 SAFETY SAFETY T ABLE 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–2[...]

S–3 SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM Enjoyable boating is the goal o f people who design an d build marine product s. T o rea ch this goal, manu- facturers are careful to make sure: • Product user is informed; and • Products ar e safe and reliable. It is up to you, the people who... • Rig boats; • Fix machinery[...]

S–4 SAFETY Outboard Shif t Systems and Safety What could happen? What is most import ant? The outboard Shif t System start s here at the remote control lever ... The outboard Shif t System start s here at the remote control lever ... ...and ends here at the propeller . When control lever is in FORW ARD, NEUTRAL or REVERSE... ...shift linkage must[...]

S–5 SAFETY Outboard Sp eed Control System and Safety What is most import ant? The outboard speed control system start s here at the remote control lever ... (single le ver remote control) ...and ends here on the powerhead. When control lever is moved from FORW ARD (or REVERSE) to NEUTRAL... Powerhead speed must slow down to allow operator to shif[...]

S–6 SAFETY Outboard St eering Control System and Safety What is most impor tant? The steering system: • Must not come apart; • Must not jam; and • Must not be sloppy or loose. The outboard steering system st arts here at the steering wheel... ...and ends here at the trim tab on the ou tboard. What could happen? • If steering system comes [...]

S–7 SAFETY T ransom Mounted Steering Systems – Check to Uncover Possible T rouble! How can loss of steeri ng control be minimized? When rigging or af ter servicing • Use a steering system recommended by th e outboard manufacturer which meets Marine Industry Safety S t andards (ABYC). • Read , understan d , and follow manufacturer ’s in st[...]

S–8 SAFETY Outboard Fuel, Electrical System, and Safety How Can Fire and Explosion Be Minimized? • Read , underst and , and follow manufact urer ’s in structions • Follow warnings marked “ ” closely . • Do not substitute fuel or electrical systems p arts with other parts which may look the same. Some electrical part s, like starter mo[...]

S–9 SAFETY If electrical p art s are replaced or even removed from the outboard, check the following: Wire and high volt age lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insula tion • Away from en gine cover latches which can ca tch and cut insulation from high volt age spark plug leads Sl[...]

S–10 SAFETY Af ter rep air on any part of the fuel system, pressure test engine portion of fue l system as shown: • Make sure silencer and it s gasket s are on engine and drain h ose is in place. • Air silencer mounting screws are special lock sc rews. Use only the special screws. GASOLINE GASOLINE When S toring: When Running: Squeeze until b[...]

S–11 SAFETY Outboard Mounting System and Safety What could happen? How Can Loss of Mounting Be Minimized? • Read , understa nd , and follow manufacturer ’s in structions. • Follow warnings marked “ ” closely . What is most import ant? • Outboard must st ay in position on boat’ s transom. Outboard may S...L...I...D...E on transom Boa[...]

S–12 SAFETY If weakened, p art s could fail later on the water , when not expected If owner tells you “I hit some thing really hard...” 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 mak[...]

S–13 SAFETY Outboard Hydraulic T ilt/T rim Shoc k Absorption System and Safety What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupant s from the outboard or its p arts entering th e boat. T ransom could break away and outboard may be lost overboard. How can possible condi[...]

S–14 SAFETY Outboard Emergency S top System and Safety What could happen? The emergency system begins here at the clip and lanyard... ...and ends here in the ignitio n system on the powerhead. What is most import ant? • The emergency stop system must STOP the eng ine when the clip is removed or the lanyard pulled from the emergency stop / key s[...]

S–15 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 b oat 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 [...]

S–16 SAFETY Summing up Now you know some things that can t ake the joy out of boa ting. No doubt about it—prop er safety takes time! • Reading and underst anding instructions • Re-reading warnings marked “ ” • Putting part s together correctly • Making correct adjustment s • T esting your work And making sure • Worn or d amaged [...]

S–17 SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first p art of this Safety section talked about sa fe boating and how you, the technician, can help keep it safe for the boater . But what about you? T echnicians can be hurt while: • Rigging boats • T roubleshooting problems • Fixing component s • T esting their work S[...]

S–18 SAFETY Running outboard with engine cover removed • T wo people working together on a live outboard must look out for each other . Never , ever , use the key to start the outboard befo re signaling your partner . He may be leaning over the outboard with hands on the flywheel, handling a “hot” e lectrical part, or near the prop eller . [...]

S–19 SAFETY Running outboard too fast (Overspeeding) • “T oo fast” means running faster than outboard normally runs on boat. Running outboards: Exhaust fumes • Whenever running the engine, assure there is proper vent ilation to avoid the accumulation of carbon monoxide (CO), which is odorless, colorless, and tast eless, and can lead to un[...]

S–20 SAFETY Running outboards: Propellers Eye protection DANGER Cont act with a rot ating propeller is likely to result in s erious injury or death. Assure the engine and prop area is clear of people and object s before st arting engine or operating boat. Do not allow anyone near a propeller , even when the engine is off. Blades can be s harp and[...]

S–21 SAFETY Handling Lead/Acid Batteries Charging lead acid batteries Battery gas is explosive! S trong acid solution (sulfuric acid) If so l u ti on ge t s i n t o eyes, was h and conta ct a doctor immediately . If spilled or splashed on an y part of body ... W ash with lots of water . 1) Attach and remove these cables with charger UNPLUGGED fro[...]

S–22 SAFETY Gasoline – Handle With Care! What can you do? • Always store gasoline out side in a safe can (flame arrester and pressu re relief valve in pour spout). • Fill portable tanks out side of boat. S pillage will collect in bottom of boat. • Use fuel as fuel ONL Y , not for a cleaner or degreaser . • If fumes are smelled in shop, [...]

S–23 SAFETY Hazardous Product s Know how it ems in the shop can hurt people... READ • “How and where to use” • “How to give First Aid.” Have recommend ed 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 curiou[...]

S–24 SAFETY Safety A wareness T est The T ec hnician’s Safety A wareness T est.... 1) Did you read this Safe ty section from page S–1 to page S–24? 2) Are you ready to t ake resp onsibility for the safe mainte nance practices and proce- dures of your repair shop, co-workers, and technicians? 3) Do you understand all the safety precautions a[...]

1 INDEX INDEX A n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n [...]

2 INDEX Corrosion Anodes 73, 250, 253, 266, 274 Battery Terminals 78 Cylinder walls 213 Exterior Finishes 73 Metallic Components 73 Steering Cable 75 Winter Storage 81 Crankcase Assembly 224 Disassembly 208 Crankshaft Assembly 216, 221 Disassembly 210 Inspection 214 Crankshaft Position Sensor Description 89 Operation Test 118 Resistance Test 127 Cy[...]

3 INDEX LED Indicators 107 Map Replacement 101 Reports 100 Sensors 87, 88 Service Codes 95 Timing Verification 98, 143 TPS Calibration 99 Transfer 101 Engine Temperature Sensor 128 Exhaust Housing Assembly 246 Cleaning and Inspection 246 Disassembly 244 Installation 249 Removal 244 Exterior Finish Protection 73 F n n n n n n n n n n n n n n n n n n[...]

4 INDEX K n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n [...]

5 INDEX Pressure Relief Valve Assembly 200 Disassembly 199 Inspection 200 Prime Oil 97 Priming Fuel System 58 Oiling System 184 Propeller Inspection 258 Installation 65 Selection 64 Propeller Shaft Installation 280 Lubrication 77 Removal 270 Propeller Shaft Bearing Housing Assembly 278 Disassembly 273 Installation 283 Removal 267 R n n n n n n n n [...]

6 INDEX Stern Bracket Assembly 252 Disassembly 249 Lubrication 76 Removal 249 Stop Circuit 136 Storage 81 Submerged Engines 83 Switches Key Switch 134 Swivel Bracket Installation 253 SystemCheck CHECK ENGINE Warni ng Signal 87, 89, 90 Circuits 132 Dash Connections 126 Description 101 Gauges 33, 101 Lights 102 LOW OIL Warning Signal 180, 188 NO OIL [...]

7 INDEX Lifting Eye, P/N 321537 S–17 Lifting Fixture, P/N 396748 206 Lower Driveshaft Pu ller, P/N 342681 268 Pinion Bearing Remove r/Installer, P/ N 391257 272, 276 Pinion Nut Holder, P/N 334455 267, 282 Pinion Nut Starting Tool, P/N 342216 282 Piston Stop Tool , P/N 342679 142 Primary Lock Tool, P/N 777077 150 Puller Bridge, P/N 432127 273 Ring[...]

8 INDEX W n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n [...]

TROUBLE CHECK CHART OUTBOARD WILL NOT ST ART T–1 TROUBLE CHECK CHART OUTBOARD WILL NOT ST ART OBSER V A TION POSSIBLE CAUSE PROCEDURE Outboard does not turn over Battery switch not ON Check battery sw itch operation Discharged battery Check battery , recharge or replace Battery cables and connections Clean and tighten connections. Check for volt [...]

T–2 TROUBLE CHECK CHART OUTBOARD WILL NOT ST AR T OUTBOARD WILL NOT ST ART OBSER V A TION POSSIBLE CAUSE PROCEDURE Outboard turns over S top circuit grounded Check wiring and emergency stop switch. Check the safety lanyard is installed and stop circuit is not grounded. In gear–T iller models Make sure outboard is in neutral No Fuel Check for fu[...]

TROUBLE CHECK CHART OUTBOARD HARD TO ST ART T–3 OUTBOARD HARD T O ST ART OBSER V A TION POSSIBLE CAUSE PROCEDURE Outboard eventually start s, may or may not run properly once started Weak battery Check battery , recharge or replace Battery cables and connections Clean and tighten connections, check volt age drop on high amperage circuit S tarter [...]

T–4 TROUBLE CHECK CHART OUTBOARD WILL NOT SHUT OFF OUTBOARD WILL NOT SHUT OFF OUTBOARD ST ARTS AND ST ALLS OBSER V A TION POSSIBLE CAUSE PROCEDURE Outboard start s and runs, normal performance while running Key switch or wire harness ground Check key switch and ground to key switch, refer to SYSTEM ANAL YSIS on p. 103 and ELECTRICAL AND IGNITION [...]

TROUBLE CHECK CHART OUTBOARD ST ARTS, LOW MAXIMUM RPM T–5 OUTBOARD ST ARTS, LOW MAXIMUM RPM EXCESSIVE SMOKING OBSER V A TION POSSIBLE CAUSE PROCEDURE SystemCheck light Outboard is in S.A.F .E. Access EMM service codes and check System- Check warning Setup or rigging change Incorrect propeller Refer to specifications, check recommended WOT RPM; wa[...]

T–6 TROUBLE CHECK CHART OUTBOARD SURGES, RUNS ROUGH OUTBOARD SURGES, RUNS ROUGH OBSER V A TION POSSIBLE CAUSE PROCEDURE 1200 RPM and above S.A.F .E. Acces s EMM fault codes May be erratic or inconsistent Incorrect, fouled, or worn spark plugs Replace spark plugs W ater in fuel system Check water separator/fuel filter , sample fuel from fuel retur[...]

Hose Routing and W ater Flow Diagram 75 – 90 HP EVINRUDE E - TEC Outgoing water (warm/hot) Incoming water (cool) 6 4 8 9 10 1. Intake water screens 2. W ater pump 3. W ater tube 4. Adaptor housing 5. Cylinder block 6. Pressure valve 7. Thermostat 8. W ater supply to EMM 9. W ater supply , EMM to vapor sep a rator 10. Overboard indicator , outgoin[...]

A B C 5 1 2 3 6 4 5 1 2 3 6 4 5 1 2 3 6 4 DRC6165R MWS Instrument Wiring Harness 1 2 5 1 2 3 6 7 4 8 A B C[...]

Dual Outboards B M M C A S 3 4 2 5 1 6 5 2 3 4 6 1 Lanyard Switch / Emergency Stop Circuits B M M C A S 5 2 3 4 6 1 Single Outboard 000705 B M M C A S[...]

B M M C A S OFF M B S A C M ON M B S A C M START M B S A C M 4 5 6 1 2 3 MWS Key Switch and Neutral Safety Switch 000691[...]

PUL GND +12V PUL / REV 5 6 4 3 2 S I G S I G S I G S I G + + 5 1 2 3 7 4 8 6 TO OUTBOARD WARNING HORN SYSTEM CHECK SPEEDOMETER TACHOMETER TRIM/TILT FUEL WATER PRES. LIGHT SWITCH VOLTMETER DRC6278R FUEL TANK SENDER TM MWS DASHBOARD[...]

1 2 3 4 Evinrude E-TEC EMM LED Diagnostic Indicators 1 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 Starting Mode : LED’s illuminate to indicate circuit function Running Mode : LED’ s illuminate to indicate circuit fault 1 2 3 4 1 2 3 4 1 [...]

A 3 2 1 1 2 3 5 6 7 8 12 13 14 15 16 9 10 1 1 7 6 5 4 3 2 1 13 12 1 1 10 9 8 7 6 5 4 3 2 1 8 9 18 17 16 15 14 13 12 1 1 10 13 12 1 1 10 17 16 15 14 34 33 32 31 30 29 28 27 26 24 25 23 22 21 20 19 18 26 24 25 23 22 21 20 19 17 16 15 14 18 FUSE B A C A B A B 1 2 3 1 2 3 1 2 3 1 2 3 2 1 2 1 J1-B J1-A J2 A B C 4 A B C 1 2 1 2 3 1 2 3 1 2 A B – + P[...]

EVINRUDE EMM SERV ICE CODE CHART CODE EMM CIRCUIT/SENSOR Evinrude E-TEC V -EMM Evinrude E-TEC 40-90HP INTERNAL SENSOR SHUT DOWN S.A.F .E. SYSTEM CHECK W ARNING LIGHT ACTIV A TION EMM LED ACTIV A TION TIME TO ACTIV A TE SENSOR: CIRCUIT VOL T AGE / RESIST ANCE ( Ω ) / INFORMA TION 11 Throttle Position Sensor (TPS) out of idle range 3 3 TPS V oltage [...]