Evinrude/Johnson Outboard Engines Models Repair Service Manuals
Evinrude/Johnson Outboard Engines Models Repair Service Manuals
Evinrude E-tec 15, 25, 30 HP 2011 Service Manual.pdf
Evinrude E-tec 40, 50, 60 HP 2007 Service Manual.pdf
Evinrude E-tec 75, 90 HP 2007 Service Manual.pdf
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2008 Service Manual.pdf
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2010 Service Manual.pdf
Evinrude E-tec 200, 225, 250, 300 HP (V6 90 degr.) 2010 Service Manual.pdf
Evinrude E-tec & Ficht 40-250 HP 2002-2006 (All Engines 40-250 HP, 2-Stroke Fuel Injected Models).pdf
Evinrude E-tech 200, 225, 250 HP (V6, 3.3L, 90 degr.) Service Manual.pdf
Evinrude_Johnson 1.5-70HP Outboard Engine_Motor Service Manual.pdf
Evinrude_Johnson 1.5HP thru 40HP Outboard Engine Tune-Up & Repair Manual.pdf
Evinrude_Johnson 2HP-40HP Outboard Engine Shop Manual (incld. Electric Motor) 1973-1990.pdf
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual.pdf
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual (incld. Sea Drives) 1973-1989.pdf
Evinrude_Johnson Outboards 1992-2001 Service Manual 65-300HP SM-05190.pdf
bookmarked, Searchable, Printable, high quality PDF
Complete official service manual for Evinrude/Johnson Outboard Engines, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Evinrude/Johnson Outboard Engines Models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
...
Evinrude E-tec & Ficht 40-250 HP 2002-2006 (All Engines 40-250 HP, 2-Stroke Fuel Injected Models)....2
Introduction....2
Covered models....2
Contents....3
Master Index....5
1 General Information, Safety and Tools....12
1 Table of Contents....12
1-2 How to use this Manual....13
1-4 Boating Safety....15
1-10 Boating Equipment (not required but recommended)....21
1-13 Safety in Service....24
1-13 Troubleshooting....24
1-17 Shop Equipment....28
1-19 Tools....30
1-27 Fasteners, Measurements and Conversions....38
1-28 Specifications....39
2 Maintenance & Tune-up....42
2 Table of Contents....42
2-2 General Information....43
2-5 Lubrication Service....46
2-9 Engine Maintenance....50
2-26 Boat Maintentance....67
2-30 Tune-Up....71
2-37 Timing and Synchronization....78
2-43 Storage (what to do before and after)....84
2-47 Clearing a Submerged motor....88
2-48 Specifications....89
3 Fuel & Ignition Systems....96
3 Table of Contents....96
3-2 Fuel System Basics....97
3-6 Fuel Tank and lines....101
3-11 FICHT Fuel Injection (DI/FFI) & Ignition System....106
3-54 E-TEC Fuel Injection & Ignition System....149
3-92 Specificatons....187
4 Electrical Systems....188
4 Table of Contents....188
4-2 Understanding and Troubleshooting Electrical Systems....189
4-8 Charging Circuit....195
4-18 Starting Circuit....205
4-35 Warning System....222
4-38 Wiring Diagrams Index....225
4-60 Specifications....247
5 Lubrication and Cooling....248
5 Table of Contents....248
5-2 Oil Injection System - DI/FICHT Motors....249
5-10 Oil Inection System - E-TEC Motors....257
5-18 Cooling System....265
5-38 Specifications....285
6 Powerhead....286
6 Table of Contents....286
6-2 Powerhead....287
6-29 Powerhead Break-in....314
6-30 Powerhead Exploded Views....315
6-38 Specifations....323
7 Lower Unit....326
7 Table of Contents....326
7-2 Gearcase....327
8 TRIM and TILT....364
8 Table of Content....364
8-2 TRIM/TILT Systems....365
9 Remote Controls....384
9 Table of Contents....384
9-2 Remote Controls....385
10 Hand Rewind Starter....400
10 Table of Contents....400
10-2 Hand Rewind Starter....401
10-4 Disassembly & Assembly....403
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2008 Service Manual....407
INTRODUCTION....411
ABBREVIATIONS USED IN THIS MANUAL....414
Units of Measurement....414
List of Abbreviations....414
ENGINE EMISSIONS INFORMATION....415
Manufacturer’s Responsibility....415
Dealer’s Responsibility....415
Owner’s Responsibility....415
EPA Emission Regulations....415
MODEL DESIGNATION....416
MODELS COVERED IN THIS MANUAL....417
Identifying Model and Serial Numbers....417
SERVICE SPECIFICATIONS....418
STANDARD TORQUE SPECIFICATIONS....420
PRODUCT REFERENCE AND ILLUSTRATIONS....420
SPECIAL TOOLS....421
DIAGNOSTIC TOOLS....422
UNIVERSAL TOOLS....422
ELECTRICAL / IGNITION TOOLS....424
FUEL /OIL SYSTEM TOOLS....425
POWERHEAD TOOLS....425
GEARCASE TOOLS....426
TRIM AND TILT TOOLS....430
SHOP AIDS....431
NOTES....434
Technician’s Notes....434
Related Documents....434
INSTALLATION AND PREDELIVERY....435
BOAT RIGGING....436
Remote Controls....436
Battery Installation....437
Battery Switches and Multiple Batteries....438
Auxiliary Battery Charging....440
Battery and Switch Wiring Diagrams....441
Fuel System Requirements....443
Oiling System Set-Up....445
Cable and Hose Installation....448
OUTBOARD INSTALLATION....452
Hull Preparation....452
Transom Measuring and Drilling....454
Drilling and Hardware Diagrams....456
Lifting the Outboard....457
Steering Systems....457
Outboard Mounting....459
OUTBOARD RIGGING....460
Cable, Hose, and Wire Routing....460
Control Cable Installation....461
Electrical Harness Connections....463
Water Pressure Gauge....464
CANbus Connections....464
FUEL AND OIL PRIMING....466
Fuel Requirements....466
Fuel System Priming....467
Oil Requirements....467
Oil Injection Rate....468
Break-In Oiling....469
Oil Supply Priming....469
BEFORE START-UP....471
Gearcase Lubricant....471
Oil Level....471
Trim and Tilt Fluid....471
RUNNING CHECKS....472
Engine Monitoring System....472
Fuel System....472
Emergency Stop / Key Switch....472
Remote Control Operation....472
Start-In-Gear Prevention....472
Tachometer Pulse Setting....473
Water Pump Overboard Indicator....473
Operating Temperature....473
Idle Speed....473
Break-In....473
PROPELLERS....474
Propeller Selection....474
Propeller Hardware Installation....475
FINAL ADJUSTMENTS....476
Tilt Limit Switch Adjustment....476
Trim Sending Unit Adjustment....477
Trim Tab Adjustment....478
Dual-Outboard Alignment....479
NOTES....480
Technician’s Notes....480
Related Documents....480
MAINTENANCE....481
INSPECTION AND MAINTENANCE SCHEDULE....482
ANTI-CORROSION PROTECTION....483
Sacrificial Anodes....483
Testing Procedure - Continuity....483
Metallic Component Protection....483
Exterior Finishes....483
COOLING SYSTEM....484
Flushing....484
Water Intake Screens....485
Additional Maintenance....485
LUBRICATION....485
Steering System....485
Swivel Bracket and Trailering Bracket....486
Tilt Tube....486
Throttle and Shift Linkage....486
Propeller Shaft....487
Gearcase Lubricant....487
Trim and Tilt....489
BATTERY AND BATTERY CONNECTIONS....490
FUEL AND OIL SYSTEMS....490
Fuel Filter....490
Oil Filters and Oil Reservoir....491
Air Silencer....491
Hoses and Connections....491
SPARK PLUGS....492
Indexing....492
EXHAUST PRESSURE FITTING....493
Operation Test....493
Cleaning....493
STORAGE....494
Fuel System Treatment....494
Internal Engine Treatment....494
Additional Recommendations....495
PRE-SEASON SERVICE....495
Outboard Mounting Bolts....495
Gearcase Lubricant....495
Battery(s)....495
Power Trim and Tilt....495
Operational Checks....495
SUBMERGED ENGINES....496
Engine Dropped Overboard (Not Running)....496
Engine Dropped Overboard (Running)....496
Engine Dropped Overboard (In Salt Water)....496
Prolonged Submersion (Fresh or Salt Water)....496
ENGINE COVER SERVICE....497
UPPER COVER SERVICE....498
Latch Hook Installation....498
Upper Cover Cap Replacement....498
LOWER COVER SERVICE....499
Lower Cover Removal....499
Lower Cover Installation....499
Latch Handle Installation....500
Trim Switch Installation....500
ENGINE MANAGEMENT MODULE (EMM)....501
DESCRIPTION....502
EMM Functions....502
EMM Connections....502
LED Indicators....502
EMM INPUTS AND OUTPUTS DIAGRAM....503
INTERNAL SENSORS....504
EMM Temperature Sensor....504
55 V Circuit Sensor....504
12 V Circuit Sensor....504
Barometric Pressure Sensor....505
Exhaust Pressure Sensor....505
EXTERNAL SENSORS....505
Air Temperature Sensor....505
Engine Temperature Sensor....505
Oil Pressure Sensor....506
Throttle Position Sensor....507
Crankshaft Position Sensor....507
Neutral Switch (V4 Models)....507
INTERNAL EMM FUNCTIONS....508
Start Assist Circuit (SAC)....508
ROM Verification....508
Idle Controller....508
RPM Limiter....508
Exhaust Valve (V4 Models)....508
Engine Monitor and Warning Systems....508
Fault Code Creation and Storage....508
ENGINE MONITORING SYSTEM....509
System Self-Test....509
Service Mode....509
Engine Running....509
S.A.F.E. WARNING SYSTEM....510
Activation....510
Recovery....510
SHUTDOWN MODE....510
Recovery....510
DIAGNOSTIC SOFTWARE FUNCTIONS....511
Communication....511
Static Information....511
Dynamic Information....512
Stored Service Codes (Faults)....512
Hard Faults....512
Persistent Faults....512
Static Tests....512
Dynamic Tests....513
Oil Control Settings....514
Tiller/Remote Programming....514
Ignition Timing....515
TPS Calibration....515
Fuel Injector Servicing....516
Reports....516
Software Replacement....517
EMM Transfer....517
EMM SERVICING....518
Removal....518
Installation....518
SYSTEM ANALYSIS....519
DIAGNOSTIC PROCEDURES....520
Visual Inspections....520
Operational Inspections....520
Troubleshooting....521
DYNAMIC TESTS....522
Cylinder Drop Tests....522
Fuel Control Adjustment....522
Inductive Amp Meter Test....522
EMM LED INDICATORS....523
Key ON....523
Starting....523
Running....524
IGNITION OUTPUT TESTS....525
Required Ignition Systems....525
Wiring Inspection....525
Crankshaft Position Sensor (CPS) Test....526
System Voltage Test....526
Ignition Voltage Test....527
Static Ignition Test....527
Running Ignition Tests....528
Ignition Primary Circuit Resistance Test....529
Ignition Coil Tests....529
Capacitor Test....530
FUEL DELIVERY TESTS....530
Fuel Pump Static Test....530
Fuel Injector Static Test....531
Running Fuel System Tests....531
EXHAUST VALVE (V4 MODELS)....533
Exhaust Valve Static Test....533
NOTES....534
Technician’s Notes....534
Related Documents....534
ELECTRICAL AND IGNITION....535
SERVICE CHART....536
DASH CONNECTIONS, INSTRUMENT HARNESS....538
ELECTRICAL HARNESS CONNECTIONS....539
Engine Harness to Stator Connector....539
EMM J1-A Connector....539
EMM J1-B Connector....540
EMM J2 Connector....540
GROUND CIRCUITS....541
EMM Ground Tests....541
Additional Ground Tests....541
FUSE....541
SENSOR TESTS....542
Crankshaft Position Sensor (CPS) Test....542
Throttle Position Sensor (TPS) Test....542
Engine Temperature Sensor Test....543
Air Temperature Sensor (AT) Test....543
STATOR TESTS....544
Stator Resistance Tests....544
Stator Voltage Output Test....544
CHARGING SYSTEM TESTS....545
12 V Charging Circuit....545
Auxiliary Battery - Charge Wire....546
55 V Alternator Circuit....546
ELECTRIC START CIRCUIT....547
Start Circuit Diagram....547
Start Circuit Operation....548
ELECTRIC START TESTS....549
Starter Solenoid Test....549
No Load Current Draw Test....550
REMOTE CONTROL SWITCH TESTS....551
Key Switch Test....551
Neutral Start Circuit Test....551
Neutral Start Switch Test....552
Emergency Stop Switch Test....552
TILT/TRIM RELAY TEST....553
Operation....553
Test Procedure....553
EXHAUST VALVE RELAY TESTS....554
Operation....554
Exhaust Valve Relay Module Test....555
EMM Outputs to Relay Module Test....555
SystemCheck CIRCUIT TESTS....556
Gauge Self-Test Check....556
CHECK ENGINE Circuit Test....557
WATER TEMP/ HOT Circuit Test....557
LOW OIL Circuit Test....558
NO OIL Circuit....558
TACHOMETER CIRCUIT TESTS....558
FLYWHEEL AND STATOR SERVICING....559
Flywheel Removal....559
Stator Service....560
Flywheel Installation....560
TIMING ADJUSTMENTS....562
Timing Pointer....562
Timing Verification....563
TPS CALIBRATION....564
ELECTRIC STARTER SERVICING....564
Starter Removal....564
Starter Disassembly....565
Starter Cleaning and Inspection....567
Starter Assembly....568
Starter Installation....571
CONNECTOR SERVICING....572
DEUTSCH Connectors....572
AMP Connectors....573
Packard † Connectors....575
FUEL SYSTEM....577
SERVICE CHART....578
FUEL SYSTEM HOSE ROUTING....581
FUEL SYSTEM CIRCUIT DIAGRAM....582
COMPONENTS....583
Fuel Lift Pump....583
Fuel Filter....583
Vapor Separator....584
Fuel Circulation Pump....585
Fuel Manifolds....585
Fuel Injectors....585
FUEL SYSTEM TESTS....586
Fuel System Pressure Test....586
Pressure Regulator Test....587
Vapor Separator Vent Check....587
Fuel Injector Pressure Test....588
Fuel Injector Resistance Test....588
Circulation Pump Resistance Test....589
Lift Pump Pressure Test....589
Lift Pump Vacuum Test....589
Lift Pump Diaphragm Test....590
Anti-Siphon Valve Test....590
FUEL COMPONENT SERVICING....591
Relieving Fuel System Pressure....591
In-Line Fuel Filter Service....592
Optional Fuel Filter Service....592
Fuel Lift Pump Service....593
Vapor Separator Service....593
Fuel Manifold Service....594
Fuel Injector Service....595
Intake Manifold Service....598
Installation....599
OILING SYSTEM....601
SERVICE CHART....602
OILING SYSTEM CIRCUIT DIAGRAM....603
OIL SUPPLY DIAGRAMS - V4....604
OIL SUPPLY DIAGRAMS - V6....606
OIL RECIRCULATION DIAGRAMS - V4....608
OIL RECIRCULATION DIAGRAMS - V6....610
COMPONENTS....612
Oil Tank Assembly....612
Oil Injection Pump....612
Oil Pressure Sensor....612
Electrical Circuit (55 V)....613
LOW OIL Warning....613
NO OIL Warning....613
Cylinder and Crankcase....613
Oil Recirculation System....614
OIL CONTROL SETTINGS....615
Oil Priming....615
Oiling Rates....615
Break-in Oiling....615
OILING SYSTEM TESTS....615
Oil Injection Pump Static Test....615
Oil Injection Pump Voltage Test....616
Oil Injection Pump Circuit Resistance Test....616
Oil Supply Vacuum Test....617
Oil Injection Pump Function Test....618
Oil Injection Fittings Flow Test....618
LOW OIL Sending Unit Test....618
OIL COMPONENT SERVICING....619
Oil Distribution Hoses....619
Oil Injection Pump....620
NOTES....622
Technician’s Notes....622
Related Documents....622
COOLING SYSTEM....623
HOSE ROUTING AND WATER FLOW DIAGRAMS....624
HOSE ROUTING AND WATER FLOW DIAGRAMS....625
COMPONENTS....626
Water Pump and Intakes....626
Water Supply Tube....626
Adapter/Inner Exhaust Housing....626
Pressure Relief Valve....627
Thermostats....627
Block Venting....627
Water Pressure Connection....627
OPERATION....628
Cylinder Block / Cylinder Head Cooling....628
EMM and Vapor Separator Cooling....628
ENGINE TEMPERATURE CHECK....629
Software Method....629
Pyrometer Method....629
Idle Operating Temperature Troubleshooting (Below Range)....630
THERMOSTAT SERVICING....631
Disassembly....631
Inspection....631
Assembly....631
PRESSURE RELIEF VALVE SERVICING....632
Disassembly....632
Inspection....632
Assembly....632
POWERHEAD....633
SERVICE CHART....634
POWERHEAD REMOVAL....636
POWERHEAD DISASSEMBLY....638
General....638
Throttle Linkage Removal....638
Shift Linkage Removal....638
Crankcase Disassembly....639
Cylinder Head Removal....639
Connecting Rods and Pistons....640
Crankshaft Removal....641
CYLINDER BLOCK CLEANING....643
POWERHEAD INSPECTION....644
Cylinder Head....644
Crankshaft....645
Cylinder Bore....645
Pistons....646
Piston Rings....646
Bearings....646
POWERHEAD ASSEMBLY....647
Crankshaft Assembly....647
Pistons and Connecting Rods....648
Cylinder Head Installation....650
Crankshaft and Connecting Rods....651
Crankcase Assembly....654
Shift Linkage Installation....656
Throttle Linkage Installation....656
Final Powerhead Assembly....657
UPPER MOUNT SERVICING....658
Removal....658
Installation....659
POWERHEAD INSTALLATION....659
POWERHEAD VIEWS....663
V4 Starboard - Hose Routings....663
V4 Port - Hose Routings....664
V4 Starboard....665
V4 Port....666
V4 Front....667
V4 Rear....668
V4 - V6 Top - Hose Routings....669
V4 - V6 Top....670
V6 Starboard - Hose Routings....671
V6 Port - Hose Routings....672
V6 Starboard....673
V6 Port....674
V6 Front....675
V6 Rear....676
MIDSECTION....677
SERVICE CHART....678
TILT TUBE....681
Removal....681
Installation....682
EXHAUST HOUSING....683
Exhaust Housing Removal....683
Exhaust Housing Disassembly....684
Cleaning and Inspection....685
Exhaust Housing Assembly....685
Exhaust Housing Installation....688
STERN BRACKET....689
Stern Bracket Removal....689
Stern Bracket Disassembly....689
Stern Bracket Assembly....691
EXHAUST RELIEF MUFFLER ASSEMBLY....694
GEARCASE....695
SERVICE CHARTS....697
GEARCASE TYPES....706
Housing Identification....706
Housing Profiles....707
PROPELLER SERVICE....708
Inspection....708
GEARCASE LEAK TEST....708
SHIFT INTERRUPT SWITCH....708
GEARCASE REMOVAL AND INSTALLATION....709
Gearcase Removal....709
Gearcase Installation....710
WATER PUMP SERVICE....712
Disassembly....712
Inspection....712
Assembly....712
SHIFT ROD ADJUSTMENT....714
GEARCASE - STANDARD ROTATION....715
GEARCASE DISASSEMBLY....715
Pre-Disassembly Inspection....715
Propeller Shaft Bearing Housing Removal - “S2”, “O”, “L” and “M” Type....716
Propeller Shaft Bearing Housing Removal - “L2” and “M2” Type....717
Pinion Gear and Driveshaft Removal - “S2” Type....718
Pinion Gear and Driveshaft Removal - “O”, “L”, “L2”, “M” and “M2” Type....721
Driveshaft Service....722
Shift Housing, Gear and Propeller Shaft Removal....723
Water Intake Screens....723
GEARCASE HOUSING INSPECTION....724
SHIFTER, BEARING AND SEAL SERVICE....724
Shift Housing Disassembly....724
Shift Housing Assembly....725
Pinion Bearing Removal....727
Pinion Bearing Installation....728
Driveshaft Bearing Housing Service....729
Propeller Shaft Bearing Housing Service....730
DRIVESHAFT SHIMMING....733
GEARCASE ASSEMBLY....735
Water Intake Screens....735
Shift Housing, Gear, and Propeller Shaft Installation....735
Shift Rod Cover....735
Pinion Gear and Driveshaft Installation - “S2” Type....737
Pinion Gear and Driveshaft Installation - “O”, “L”’ “L2”, “M” and “M2” Type....740
Propeller Shaft Bearing Housing and Gear Installation - “S2”, “O”, “L” and “M” Type....742
Propeller Shaft Bearing Housing and Gear Installation - “L2” Type....743
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....744
Final Assembly and Adjustment....745
GEARCASE - COUNTER ROTATION....746
GEARCASE DISASSEMBLY....746
Pre-Disassembly Inspection....746
Propeller Shaft Bearing Housing Removal - “O” and “M” Type....746
Propeller Shaft Bearing Housing Removal - “M2” Type....746
Pinion Gear Removal and Driveshaft Servicing....747
Shift Housing, Gear and Propeller Shaft Removal....748
Water Intake Screens....748
GEARCASE HOUSING INSPECTION....748
SHIFTER, BEARING AND SEAL SERVICING....749
Shift Housing Disassembly....749
Shift Housing Assembly....750
Pinion Bearing....752
Propeller Shaft Bearing Housing and Forward Gear - “O” Type....752
Propeller Shaft Bearing Housing and Forward Gear - “M” and “M2” Type....756
DRIVESHAFT SHIMMING....759
GEARCASE ASSEMBLY....761
Water Intake Screens....761
Shift Housing, Gear, and Propeller Shaft Installation....761
Shift Rod Cover....761
Pinion Gear and Driveshaft Installation....761
Propeller Shaft Bearing Housing and Gear Installation - “O” and “M” Type....761
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....762
Final Assembly and Adjustment....763
NOTES....764
Technician’s Notes....764
Related Documents....764
TRIM AND TILT....765
SERVICE CHART....766
SYSTEM DESCRIPTION....768
Manual Adjustment....768
Trailering Bracket And Tilt Support....768
MODES OF OPERATION (Three Piston System)....769
Trim-OUT / Tilt-UP Mode....769
2....769
Tilt-DOWN / Trim-IN Mode....770
Impact Relief....771
1....771
Shallow Water Drive Tilt Relief....772
Thermal Expansion Relief....772
Manual Release - UP....773
Manual Release - DOWN....774
ROUTINE INSPECTIONS....775
General....775
Reservoir Fluid....775
Manual Release Valve....775
Stern Brackets....775
TROUBLESHOOTING....775
Three Piston System....775
Single Piston System....779
ELECTRICAL CIRCUIT TESTS....779
Relay Testing....779
Trim and Tilt Motor Current Draw Tests....779
Trim and Tilt Motor No Load Test....780
Trim Gauge Test....781
Trim Sender Test....782
TRIM AND TILT SERVICE....782
Removal....782
Installation....784
SERVICING - THREE PISTON SYSTEM....785
Disassembly....785
Tilt Piston Removal....788
Tilt Piston Identification....789
Tilt Piston Assembly....789
Tilt Rod Assembly....790
Trim Rod Removal....791
Trim Rod Assembly....792
Manifold and Reservoir Installation....793
Trim Rod Installation....794
Tilt Rod Installation....795
Motor Installation....795
SERVICING-SINGLE PISTON SYSTEM....797
Disassembly....797
Assembly....798
ADJUSTMENTS....800
SAFETY....801
TABLE OF CONTENTS....801
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....803
Outboard Shift Systems and Safety....804
Outboard Speed Control System and Safety....805
Outboard Steering Control System and Safety....806
Outboard Fuel, Electrical System, and Safety....808
Outboard Mounting System and Safety....811
If weakened, parts could fail later on the water, when not expected....812
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....813
Outboard Emergency Stop System and Safety....814
Summing up....816
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....817
Handling Outboards....817
Handling Lead/Acid Batteries....821
Gasoline - Handle With Care!....822
Hazardous Products....823
Safety Awareness Test....824
INDEX....825
TROUBLE CHECK CHART....835
OUTBOARD WILL NOT START....835
OUTBOARD WILL NOT START....836
OUTBOARD HARD TO START....837
OUTBOARD WILL NOT SHUT OFF....838
OUTBOARD STARTS AND STALLS....838
OUTBOARD STARTS, LOW MAXIMUM RPM....839
EXCESSIVE SMOKING....839
OUTBOARD SURGES, RUNS ROUGH....840
DIAGRAMS....841
Evinrude E-tec 115, 130, 150, 175, 200 HP (V4_V6 60 degr.) 2010 Service Manual....852
INTRODUCTION....856
ABBREVIATIONS USED IN THIS MANUAL....859
Units of Measurement....859
List of Abbreviations....859
EMISSION-RELATED INSTALLATION INSTRUCTIONS....860
Manufacturer’s Responsibility....860
Dealer’s Responsibility....860
Owner’s Responsibility....860
EPA Emission Regulations....860
MODEL DESIGNATION....861
MODELS COVERED IN THIS MANUAL....862
SERVICE SPECIFICATIONS....863
STANDARD TORQUE SPECIFICATIONS....865
PRODUCT REFERENCE AND ILLUSTRATIONS....865
SPECIAL TOOLS....866
DIAGNOSTIC TOOLS....867
UNIVERSAL TOOLS....867
ELECTRICAL / IGNITION TOOLS....869
FUEL /OIL SYSTEM TOOLS....870
POWERHEAD TOOLS....870
GEARCASE TOOLS....871
TRIM AND TILT TOOLS....874
SHOP AIDS....876
NOTES....879
Technician’s Notes....879
Related Documents....879
INSTALLATION AND PREDELIVERY....880
BOAT RIGGING....881
Remote Controls....881
Information Display Systems....883
Battery Installation....888
Auxiliary Battery Charging....890
Battery and Switch Wiring Diagrams....891
Fuel System Requirements....893
Remote Oil Tank Installation....896
Cable and Hose Installation....899
Oetiker Clamp Servicing....901
OUTBOARD INSTALLATION....903
Hull Preparation....903
Transom Measuring and Drilling....905
Drilling and Hardware Diagrams....907
Lifting the Outboard....909
Steering Systems....909
Outboard Mounting....911
OUTBOARD RIGGING....912
Common Practices - All Models....912
Cable, Hose, and Wire Routing....913
Control Cable Installation....914
Battery Cable Connections....915
SystemCheck Harness Connections....915
I-Command Network Connections....916
ICON Network Connections....918
Water Pressure Gauge....919
FUEL AND OIL PRIMING....920
Fuel Requirements....920
Fuel System Priming....921
Oil Requirements....921
Oil Injection Rate....922
Break-In Oiling....923
Oil Supply Priming....923
BEFORE START-UP....925
Gearcase Lubricant....925
Oil Level....925
Trim and Tilt Fluid....925
RUNNING CHECKS....926
Engine Monitoring System....926
Fuel System....926
Emergency Stop / Key Switch....926
Remote Control Operation....926
Start-In-Gear Prevention....926
Tachometer Pulse Setting....927
I-Command Set up....927
Water Pump Overboard Indicator....927
Operating Temperature....927
Idle Speed....927
Break-In....927
PROPELLERS....928
Propeller Selection....928
Propeller Hardware Installation....929
WATER TEST AND FINAL ADJUSTMENTS....930
Engine Mounting Height and Jack Plate Adjustment....930
Fuel System Vacuum....930
Engine Water Pressure....930
Water Pressure Chart....931
Tilt Limit Switch Adjustment....932
Trim Sending Unit Adjustment....933
Trim Tab Adjustment....934
Dual-Outboard Alignment....935
MAINTENANCE....936
INSPECTION AND MAINTENANCE SCHEDULE....937
ANTI-CORROSION PROTECTION....938
Sacrificial Anodes....938
Testing Procedure - Continuity....938
Metallic Component Protection....938
Exterior Finishes....938
COOLING SYSTEM....939
Flushing....939
Water Intake Screens....940
Additional Maintenance....940
LUBRICATION....940
Steering System....940
Swivel Bracket and Trailering Bracket....941
Tilt Tube....941
Throttle and Shift Linkage....941
Propeller Shaft....942
Gearcase Lubricant....942
Trim and Tilt....944
BATTERY AND BATTERY CONNECTIONS....945
FUEL AND OIL SYSTEMS....945
Fuel Filter....945
Oil Filters and Oil Reservoir....946
Air Silencer....946
Hoses and Connections....946
SPARK PLUGS....947
Indexing....947
EXHAUST PRESSURE FITTING....948
Operation Test....948
Cleaning....948
STORAGE....949
Fuel System Treatment....949
Internal Engine Treatment....949
Additional Recommendations....950
PRE-SEASON SERVICE....951
Outboard Mounting Bolts....951
Gearcase Lubricant....951
Battery(s)....951
Power Trim and Tilt....951
Operational Checks....951
SUBMERGED ENGINES....952
Engine Dropped Overboard (Not Running)....952
Engine Dropped Overboard (Running)....952
Engine Dropped Overboard (In Salt Water)....952
Prolonged Submersion (Fresh or Salt Water)....952
NOTES....953
Technician’s Notes....953
Related Documents....953
ENGINE COVER SERVICE....954
UPPER COVER SERVICE....955
Latch Hook Installation....955
Upper Cover Cap Replacement....955
LOWER COVER SERVICE....956
Lower Cover Removal....956
Lower Cover Installation....956
Latch Handle Installation....957
Trim Switch Installation....957
ENGINE MANAGEMENT MODULE (EMM)....958
DESCRIPTION....959
EMM Functions....959
EMM Connections....959
LED Indicators....959
EMM INPUTS AND OUTPUTS DIAGRAM....960
INTERNAL SENSORS....961
EMM Temperature Sensor....961
55 V Circuit Sensor....961
12 V Circuit Sensor....961
5 V Circuit Sensor....962
Barometric Pressure Sensor....962
Exhaust Pressure Sensor....962
EXTERNAL SENSORS....963
Air Temperature Sensor....963
Engine Temperature Sensor....963
Oil Pressure Sensor....964
Throttle Position Sensor....964
Crankshaft Position Sensor....965
Neutral Switch (V4 Models)....965
INTERNAL EMM FUNCTIONS....966
Start Assist Circuit (SAC)....966
ROM Verification....966
Idle Controller....966
RPM Limiter....966
Exhaust Valve (V4 Models)....966
Engine Monitor and Warning Systems....966
Fault Code Creation and Storage....966
ENGINE MONITOR SYSTEM....967
System Self-Test....967
Service Mode....967
Engine Running....967
S.A.F.E. WARNING SYSTEM....968
Activation....968
Recovery....968
SHUTDOWN MODE....968
Recovery....968
DIAGNOSTIC SOFTWARE FUNCTIONS....969
Communication....969
Static Information....969
Dynamic Information....970
Stored Service Codes (Faults)....970
Hard Faults....970
Persistent Faults....970
Static Tests....970
Dynamic Tests....971
Oil Control Settings....972
Tiller/Remote Programming....972
Ignition Timing....973
TPS Calibration....973
Fuel Injector Servicing....973
Reports....974
Software Replacement....974
EMM Transfer....974
EMM SERVICING....975
Removal....975
Installation....975
SYSTEM ANALYSIS....976
DIAGNOSTIC PROCEDURES....977
Visual Inspections....977
Operational Inspections....977
Troubleshooting....978
DYNAMIC TESTS....979
Cylinder Drop Tests....979
Fuel Control Adjustment....979
Inductive Amp Meter Test....979
EMM LED INDICATORS....980
Key ON....980
Starting....980
Running....981
IGNITION OUTPUT TESTS....982
Required Ignition Systems....982
Wiring Inspection....982
Crankshaft Position Sensor (CPS) Test....983
System Voltage Test....983
Static Ignition Test....984
Running Ignition Tests....985
Ignition Control Circuit Tests....986
Ignition Coil Tests....986
Capacitor Test....986
FUEL DELIVERY TESTS....987
Fuel Pump Static Test....987
Fuel Injector Static Test....987
Running Fuel System Tests....988
EXHAUST VALVE (V4 MODELS)....989
Exhaust Valve Static Test....989
ELECTRICAL AND IGNITION....990
SERVICE CHART....991
IGNITION SYSTEM CIRCUIT DIAGRAM - V4....993
IGNITION SYSTEM CIRCUIT DIAGRAM - V6....994
ELECTRICAL HARNESS CONNECTIONS....995
Engine Harness to Stator Connector....995
EMM J1-A Connector....995
EMM J1-B Connector....996
EMM J2 Connector....996
GROUND CIRCUITS....997
EMM Ground Tests....997
Additional Ground Tests....997
FUSE....997
SENSOR TESTS....998
Crankshaft Position Sensor (CPS) Test....998
Throttle Position Sensor (TPS) Test....998
Engine Temperature Sensor Test....999
Air Temperature Sensor (AT) Test....999
STATOR TESTS....1000
Stator Resistance Tests....1000
Stator Voltage Output Test....1000
CHARGING SYSTEM TESTS....1001
12 V Charging Circuit....1001
Auxiliary Battery Charge Wire....1002
55 V Alternator Circuit....1002
ELECTRIC START CIRCUIT....1003
Start Circuit Diagram....1003
Start Circuit Operation....1004
ELECTRIC START TESTS....1005
Starter Solenoid Test....1005
No Load Current Draw Test....1006
REMOTE CONTROL SWITCH TESTS....1007
Key Switch Test....1007
Neutral Start Circuit Test....1007
Neutral Start Switch Test....1008
Emergency Stop Switch Test....1008
TILT/TRIM RELAY TEST....1009
Operation....1009
Test Procedure....1009
EXHAUST VALVE RELAY TESTS....1010
Operation....1010
Exhaust Valve Relay Module Test....1011
EMM Outputs to Relay Module Test....1011
SystemCheck CIRCUIT TESTS....1012
Gauge Self-Test Check....1012
CHECK ENGINE Circuit Test....1013
WATER TEMP/ HOT Circuit Test....1013
LOW OIL Circuit Test....1014
NO OIL Circuit....1014
TACHOMETER CIRCUIT TESTS....1014
FLYWHEEL AND STATOR SERVICING....1015
Flywheel Removal....1015
Stator Service....1016
Flywheel Installation....1016
IGNITION COIL SERVICING....1018
Ignition Coil Removal....1018
Ignition Coil Bracket Removal....1018
Ignition Coil Bracket Installation....1018
Ignition Coil Installation....1018
TIMING ADJUSTMENTS....1019
Timing Pointer....1019
Timing Verification....1020
TPS Calibration....1021
ELECTRIC STARTER SERVICING....1021
Starter Removal....1021
Starter Disassembly....1022
Starter Cleaning and Inspection....1024
Starter Assembly....1025
Starter Installation....1028
CONNECTOR SERVICING....1028
DEUTSCH Connectors....1028
AMP Connectors....1029
Packard Connectors....1031
NOTES....1033
Technician’s Notes....1033
Related Documents....1033
FUEL SYSTEM....1034
SERVICE CHART....1035
FUEL SYSTEM HOSE ROUTING....1038
FUEL SYSTEM CIRCUIT DIAGRAM - V4....1039
FUEL SYSTEM CIRCUIT DIAGRAM - V6....1040
COMPONENTS....1041
Fuel Lift Pump....1041
Fuel Filter....1041
Vapor Separator....1041
Fuel Circulation Pump....1042
Fuel Manifolds....1043
Fuel Injectors....1043
FUEL SYSTEM TESTS....1044
Fuel System Pressure Test....1044
Pressure Regulator Test....1045
Vapor Separator Vent Check....1045
Fuel Injector Pressure Test....1045
Fuel Injector Resistance Test....1046
Circulation Pump Resistance Test....1046
Lift Pump Pressure Test....1046
Lift Pump Vacuum Test....1047
Lift Pump Diaphragm Test....1047
Anti-Siphon Valve Test....1048
FUEL COMPONENT SERVICING....1048
Relieving Fuel System Pressure....1048
Fuel Filter Service....1049
Fuel Lift Pump Service....1050
Vapor Separator Service....1050
Fuel Manifold Service....1051
Fuel Injector Service....1052
Intake Manifold Service....1054
OILING SYSTEM....1058
SERVICE CHART....1059
OILING SYSTEM CIRCUIT DIAGRAM....1060
OIL SUPPLY DIAGRAMS - V4....1061
OIL SUPPLY DIAGRAMS - V6....1063
OIL RECIRCULATION DIAGRAMS - V4....1065
OIL RECIRCULATION DIAGRAMS - V6....1067
COMPONENTS....1069
Oil Tank Assembly....1069
Oil Injection Pump....1069
Oil Pressure Sensor....1069
Electrical Circuit (55 V)....1070
LOW OIL Warning....1070
NO OIL Warning....1070
Cylinder and Crankcase....1070
Oil Recirculation System....1071
OIL CONTROL SETTINGS....1072
Oil Priming....1072
Oiling Rates....1072
Break-in Oiling....1072
OILING SYSTEM TESTS....1072
Oil Injection Pump Static Test....1072
Oil Injection Pump Voltage Test....1073
Oil Injection Pump Circuit Resistance Test....1073
Oil Supply Vacuum Test....1074
Oil Injection Pump Function Test....1075
Oil Injection Fittings Flow Test....1075
LOW OIL Sending Unit Test....1075
OIL COMPONENT SERVICING....1076
Oil Distribution Hoses....1076
Oil Injection Pump....1077
NOTES....1079
Technician’s Notes....1079
Related Documents....1079
COOLING SYSTEM....1080
HOSE ROUTING AND WATER FLOW DIAGRAMS....1081
HOSE ROUTING AND WATER FLOW DIAGRAMS....1082
COMPONENTS....1083
Water Pump and Intakes....1083
Water Supply Tube....1083
Adapter/Inner Exhaust Housing....1083
Pressure Relief Valve....1084
Thermostats....1084
Block Venting....1084
OPERATION....1085
Cylinder Block / Cylinder Head Cooling....1085
EMM and Vapor Separator Cooling....1085
ENGINE TEMPERATURE CHECK....1086
Software Method....1086
Pyrometer Method....1086
Idle Operating Temperature Troubleshooting (Below Range)....1087
TEMPERATURE SENDER SERVICING....1088
Removal....1088
Installation....1088
THERMOSTAT SERVICING....1088
Disassembly....1088
Inspection....1089
Assembly....1089
PRESSURE RELIEF VALVE SERVICING....1089
Disassembly....1089
Inspection....1089
Assembly....1089
POWERHEAD....1090
SERVICE CHART....1091
COMPRESSION TESTING....1093
POWERHEAD REMOVAL....1093
POWERHEAD DISASSEMBLY....1095
Systems Removal....1095
Throttle Linkage Removal....1096
Shift Linkage Removal....1096
Crankcase Disassembly....1096
Cylinder Head Removal....1097
Connecting Rods and Pistons....1097
Crankshaft Removal....1098
CYLINDER BLOCK CLEANING....1101
POWERHEAD INSPECTION....1102
Cylinder Head....1102
Crankshaft....1102
Cylinder Bore....1103
Pistons....1103
Piston Rings....1103
Bearings....1104
POWERHEAD ASSEMBLY....1104
Crankshaft Assembly....1104
Pistons and Connecting Rods....1106
Cylinder Head Installation....1108
Crankshaft and Connecting Rods....1109
Crankcase Assembly....1112
Shift Linkage Installation....1113
Throttle Linkage Installation....1114
Final Powerhead Assembly....1114
UPPER MOUNT SERVICING....1115
Removal....1115
Installation....1116
POWERHEAD INSTALLATION....1116
Pre-Service Adjustments....1119
POWERHEAD VIEWS....1120
V4 Starboard - Hose Routings....1120
V4 Port - Hose Routings....1120
V4 Starboard....1121
V4 Port....1121
V4 Front....1122
V4 Rear....1123
V4 - V6 Top - Hose Routings....1124
V4 - V6 Top....1125
V6 Starboard - Hose Routings....1126
V6 Port - Hose Routings....1127
V6 Starboard....1128
V6 Port....1129
V6 Front....1130
V6 Rear....1131
MIDSECTION....1132
SERVICE CHART....1133
TILT TUBE....1137
Removal....1137
Installation....1138
EXHAUST HOUSING SERVICE....1139
Exhaust Housing Removal....1139
Lower Mount Service....1139
Exhaust Housing Installation....1140
Exhaust Housing Disassembly - V6 Models....1141
Exhaust Housing Disassembly - V4 Models....1141
Cleaning and Inspection....1142
Exhaust Housing Assembly - V6 Models....1142
Exhaust Housing Assembly - V4 Models....1143
EXTENSION SERVICE - V4 Models....1145
Removal....1145
Installation....1145
STERN BRACKET....1145
Stern Bracket Removal....1145
Stern Bracket Disassembly....1145
Stern Bracket Assembly....1148
EXHAUST RELIEF MUFFLER ASSEMBLY....1151
GEARCASE....1152
SERVICE CHARTS....1154
GEARCASE TYPES....1160
Housing Identification....1160
Housing Profiles....1161
PROPELLER SERVICE....1162
Inspection....1162
GEARCASE LEAK TEST....1162
SHIFT INTERRUPT SWITCH....1162
GEARCASE REMOVAL AND INSTALLATION....1163
Gearcase Removal....1163
Gearcase Installation....1164
WATER PUMP SERVICE....1166
Disassembly....1166
Inspection....1166
Assembly....1166
SHIFT ROD ADJUSTMENT....1169
GEARCASE - STANDARD ROTATION....1170
GEARCASE DISASSEMBLY....1170
Pre-Disassembly Inspection....1170
Propeller Shaft Bearing Housing Removal - “S2” and “O” Type....1171
Propeller Shaft Bearing Housing Removal - “L2” and “M2” Type....1172
Pinion Gear and Driveshaft Removal - “S2” Type....1173
Pinion Gear and Driveshaft Removal - “O”, “L2”, and “M2” Type....1176
Driveshaft Service....1177
Shift Housing, Gear and Propeller Shaft Removal....1178
Water Intake Screens....1178
GEARCASE HOUSING INSPECTION....1179
SHIFTER, BEARING AND SEAL SERVICE....1180
Pinion Bearing Removal....1180
Pinion Bearing Installation....1180
Shift Housing Disassembly....1181
Shift Housing Assembly....1183
Driveshaft Bearing Housing Service....1185
Propeller Shaft Bearing Housing Service....1186
DRIVESHAFT SHIMMING....1188
GEARCASE ASSEMBLY....1190
Water Intake Screens....1190
Shift Housing, Gear, and Propeller Shaft Installation....1190
Shift Rod Housing Installation....1191
Pinion Gear and Driveshaft Installation - “S2” Type....1192
Pinion Gear and Driveshaft Installation - “O”, “L2”, and “M2” Type....1196
Propeller Shaft Bearing Housing and Gear Installation - “S2” and “O” Type....1197
Propeller Shaft Bearing Housing and Gear Installation - “L2” Type....1198
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....1200
Final Assembly and Adjustment....1201
GEARCASE - COUNTER ROTATION....1202
GEARCASE DISASSEMBLY....1202
Pre-Disassembly Inspection....1202
Propeller Shaft Bearing Housing Removal - “O” Type....1202
Propeller Shaft Bearing Housing Removal - “M2” Type....1202
Pinion Gear Removal and Driveshaft Servicing....1203
Shift Housing, Gear and Propeller Shaft Removal....1204
Water Intake Screens....1204
GEARCASE HOUSING INSPECTION....1204
SHIFTER, BEARING AND SEAL SERVICING....1205
Shift Housing Disassembly....1205
Shift Housing Assembly....1206
Pinion Bearing....1208
Propeller Shaft Bearing Housing and Forward Gear - “O” Type....1208
Propeller Shaft Bearing Housing and Forward Gear - “M2” Type....1212
DRIVESHAFT SHIMMING....1215
GEARCASE ASSEMBLY....1216
Water Intake Screens....1216
Shift Housing, Gear, and Propeller Shaft Installation....1216
Shift Rod Cover....1217
Pinion Gear and Driveshaft Installation....1217
Propeller Shaft Bearing Housing and Gear Installation - “O” Type....1217
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....1218
Final Assembly and Adjustment....1219
TRIM AND TILT....1220
SERVICE CHART....1221
SYSTEM DESCRIPTION....1223
Manual Adjustment....1223
Trailering Bracket And Tilt Support....1223
MODES OF OPERATION (Three Piston System)....1224
Trim-OUT / Tilt-UP Mode....1224
2....1224
Tilt-DOWN / Trim-IN Mode....1225
Impact Relief....1226
1....1226
Shallow Water Drive Tilt Relief....1227
Thermal Expansion Relief....1227
Manual Release - UP....1228
Manual Release - DOWN....1229
ROUTINE INSPECTIONS....1230
General....1230
Reservoir Fluid....1230
Manual Release Valve....1230
Stern Brackets....1230
TROUBLESHOOTING....1230
Single Piston System....1230
Three Piston System....1231
ELECTRICAL CIRCUIT TESTS....1234
Relay Testing....1234
Trim and Tilt Motor Current Draw Tests....1234
Trim and Tilt Motor No Load Test....1235
Trim Gauge Test....1236
Trim Sender Test....1237
TRIM AND TILT SERVICE....1237
Removal....1237
Installation....1239
SERVICING - THREE PISTON SYSTEM....1240
Disassembly....1240
Tilt Piston Removal....1242
Tilt Piston Identification....1243
Tilt Piston Assembly....1244
Tilt Rod Assembly....1244
Trim Rod Removal....1246
Trim Rod Assembly....1247
Manifold and Reservoir Installation....1248
Trim Rod Installation....1249
Tilt Rod Installation....1249
Motor Installation....1250
SERVICING-SINGLE PISTON SYSTEM....1252
Disassembly....1252
Assembly....1253
ADJUSTMENTS....1254
NOTES....1255
Technician’s Notes....1255
Related Documents....1255
SAFETY....1256
TABLE OF CONTENTS....1256
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....1258
Outboard Shift Systems and Safety....1259
Outboard Speed Control System and Safety....1260
Outboard Steering Control System and Safety....1261
Outboard Fuel, Electrical System, and Safety....1263
Outboard Mounting System and Safety....1266
If weakened, parts could fail later on the water, when not expected....1267
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....1268
Outboard Emergency Stop System and Safety....1269
Summing up....1271
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....1272
Handling Outboards....1272
Handling Lead/Acid Batteries....1276
Gasoline - Handle With Care!....1277
Hazardous Products....1278
Safety Awareness Test....1279
INDEX....1280
NOTES....1289
Technician’s Notes....1289
Related Documents....1289
TROUBLE CHECK CHART....1290
OUTBOARD WILL NOT START....1290
OUTBOARD WILL NOT START....1291
OUTBOARD HARD TO START....1292
OUTBOARD WILL NOT SHUT OFF....1293
OUTBOARD STARTS AND STALLS....1293
OUTBOARD STARTS, LOW MAXIMUM RPM....1294
EXCESSIVE SMOKING....1294
OUTBOARD SURGES, RUNS ROUGH....1295
DIAGRAMS....1296
Evinrude E-tec 15, 25, 30 HP 2011 Service Manual....1308
REFERENCE INFORMATION....1312
SAFETY NOTICE....1313
ABBREVIATIONS USED IN THIS MANUAL....1315
Units of Measurement....1315
List of Abbreviations....1315
EMISSION-RELATED INSTALLATION INSTRUCTIONS....1316
Manufacturer’s Responsibility....1316
Dealer’s Responsibility....1316
Owner’s Responsibility....1316
EPA Emission Regulations....1316
MODEL DESIGNATION....1317
MODELS COVERED IN THIS MANUAL....1318
SERVICE SPECIFICATIONS....1319
STANDARD TORQUE SPECIFICATIONS....1321
PRODUCT REFERENCE AND ILLUSTRATIONS....1321
ROUTINE SERVICE....1322
INSPECTION AND MAINTENANCE SCHEDULE....1323
LIFTING THE OUTBOARD....1324
OUTBOARD RIGGING CONNECTIONS....1326
Common Practices - All Models....1326
Cable, Hose, and Wire Routing....1327
Control Cable Installation....1327
SystemCheck Harness Connections....1329
BATTERY AND BATTERY CONNECTIONS....1330
OETIKER CLAMP SERVICING....1331
Clamp Identification....1331
Clamp Selection....1331
Clamp Installation....1332
Clamp Removal....1332
ADJUSTMENTS....1333
Steering Friction Adjustment....1333
Throttle Friction Adjustment....1333
Tiller Height Adjustment....1334
Tiller Handle Ratchet....1334
Tiller Handle Friction....1334
Neutral Switch Adjustment....1334
Trim Sending Unit Adjustment....1335
Trim Tab Adjustment....1336
OPERATIONAL CHECKS....1337
Engine Monitoring System....1337
Fuel System....1337
Emergency Stop / Key Switch....1337
Remote Control Operation....1337
Start-In-Gear Prevention....1337
Tachometer Pulse Setting (SystemCheck)....1337
Water Pump Overboard Indicator....1338
Operating Temperature....1338
Idle Speed....1338
COOLING SYSTEM....1338
Water Intake Screens....1338
Engine Flushing....1339
Running the Outboard Using a Hose and Flushing Adapter....1340
LUBRICATION....1341
Steering System....1341
Tiller Handle....1341
Swivel Bracket and Trailering Bracket....1341
Tilt Tube....1341
Throttle and Shift Linkage....1342
Propeller Shaft....1342
Gearcase Lubricant....1343
Trim and Tilt....1344
SPARK PLUGS....1345
Indexing....1345
FUEL AND OIL SYSTEMS....1346
Fuel Filter....1346
Oil Filters and Oil Reservoir....1346
Air Silencer....1346
Hoses and Connections....1346
ANTI-CORROSION PROTECTION....1347
Sacrificial Anodes....1347
Testing Procedure - Continuity....1347
Metallic Component Protection....1347
Exterior Finishes....1347
STORAGE....1348
Fuel System Treatment....1348
Internal Engine Treatment....1348
Additional Recommendations....1349
PRE-SEASON SERVICE....1349
Outboard Mounting Bolts....1349
Gearcase Lubricant....1349
Battery(s)....1349
Power Trim and Tilt....1349
Operational Checks....1349
SUBMERGED ENGINES....1350
Engine Dropped Overboard (Not Running)....1350
Engine Dropped Overboard (Running)....1350
Engine Dropped Overboard (In Salt Water)....1350
Prolonged Submersion (Fresh or Salt Water)....1350
NOTES....1351
Technician’s Notes....1351
Related Documents....1351
ENGINE COVER SERVICE....1352
UPPER COVER SERVICE....1353
Latch Hook Installation....1353
LOWER COVER SERVICE....1354
Lower Cover Removal....1354
Lower Cover Installation....1354
Latch Handle Installation....1356
NOTES....1357
Technician’s Notes....1357
Related Documents....1357
ENGINE MANAGEMENT MODULE (EMM)....1358
DESCRIPTION....1359
EMM Functions....1359
EMM Connections....1359
LED Indicators....1359
EMM INPUTS AND OUTPUTS DIAGRAM....1360
INTERNAL SENSORS....1361
EMM Temperature Sensor....1361
55 V Circuit Sensor....1361
12 V Circuit Sensor....1361
5 V Circuit Sensor....1362
Barometric Pressure Sensor....1362
EXTERNAL SENSORS....1362
Air Temperature Sensor....1362
Engine Temperature Sensor....1363
Low Oil Switch....1363
Throttle Position Sensor....1364
Crankshaft Position Sensor....1364
Neutral Switch....1364
INTERNAL EMM FUNCTIONS....1365
ROM Verification....1365
Idle Controller....1365
RPM Limiter....1365
Neutral RPM Limiter....1365
Engine Monitor and Warning Systems....1365
Fault Code Creation and Storage....1365
ENGINE MONITOR SYSTEM....1365
System Self-Test....1366
Service Mode....1366
Engine Running....1366
S.A.F.E. WARNING SYSTEM....1366
Activation....1366
Recovery....1366
SHUTDOWN MODE....1367
Recovery....1367
DIAGNOSTIC SOFTWARE FUNCTIONS....1367
Communication....1367
Static Information....1368
Dynamic Information....1369
Stored Service Codes (Faults)....1369
Hard Faults....1369
Persistent Faults....1369
Static Tests....1369
Dynamic Tests....1370
Oil Control Settings....1371
Tiller/Remote Programming....1371
Ignition Timing....1372
TPS Calibration....1372
Fuel Injector Servicing....1373
Reports....1373
Software Replacement....1374
EMM Transfer....1374
EMM SERVICING....1375
Removal....1375
Installation....1375
SYSTEM ANALYSIS....1376
DIAGNOSTIC PROCEDURES....1377
Visual Inspections....1377
Operational Inspections....1377
Troubleshooting....1378
DYNAMIC TESTS....1379
Cylinder Drop Tests....1379
Fuel Control Adjustment....1379
Inductive Amp Meter Test....1379
EMM LED INDICATORS....1380
Key ON....1380
Starting....1380
Running....1381
IGNITION OUTPUT TESTS....1382
Required Ignition Systems....1382
Wiring Inspection....1382
Crankshaft Position Sensor (CPS) Test....1383
System Voltage Test....1383
Static Ignition Test....1384
Running Ignition Tests....1385
Ignition Control Circuit Tests....1386
Ignition Coil Tests....1386
FUEL DELIVERY TESTS....1387
Fuel Pump Static Test....1387
Fuel Injector Static Test....1387
Running Fuel System Tests....1388
NOTES....1389
Technician’s Notes....1389
Related Documents....1389
ELECTRICAL AND IGNITION....1390
SERVICE CHART....1391
IGNITION SYSTEM CIRCUIT DIAGRAM....1393
ELECTRICAL HARNESS CONNECTIONS....1394
Engine Harness to Stator Connector....1394
EMM J1-A Connector....1394
GROUND CIRCUITS....1395
EMM Ground Tests....1395
Additional Ground Tests....1395
FUSE....1395
SENSOR TESTS....1396
Crankshaft Position Sensor (CPS) Test....1396
Throttle Position Sensor (TPS) Test....1396
Engine Temperature Sensor Test....1397
Air Temperature Sensor (AT) Test....1397
STATOR TESTS....1398
Stator Resistance Tests....1398
Stator Voltage Output Test....1398
CHARGING SYSTEM TESTS....1400
Charging System Circuit Diagram....1400
12 V Charging Circuit....1401
55 V Alternator Circuit....1402
ELECTRIC START CIRCUIT....1403
Start Circuit Diagram....1403
Start Circuit Operation....1404
ELECTRIC START TESTS....1405
Starter Solenoid Test....1405
Starter Voltage Drop Test....1406
No Load Current Draw Test....1406
REMOTE CONTROL SWITCH TESTS....1407
Key Switch Test....1407
Neutral Start Circuit Test....1407
Neutral Start Switch Test....1408
Emergency Stop Switch Test....1408
TILT/TRIM RELAY TEST....1409
Operation....1409
Test Procedure....1409
SystemCheck CIRCUIT TESTS....1410
Gauge Self-Test Check....1410
LOW OIL Circuit Test....1411
TACHOMETER CIRCUIT TESTS....1412
FLYWHEEL AND STATOR SERVICING....1412
Flywheel Removal....1412
Stator Service....1413
Flywheel Installation....1413
IGNITION COIL SERVICING....1414
Ignition Coil Removal....1414
Ignition Coil Installation....1414
TIMING ADJUSTMENTS....1415
Timing Pointer....1415
Timing Verification....1415
TPS Calibration....1415
ELECTRIC STARTER SERVICING....1416
Starter Removal....1416
Starter Disassembly....1416
Starter Cleaning and Inspection....1417
Starter Assembly....1418
Starter Installation....1420
CONNECTOR SERVICING....1420
DEUTSCH Connectors....1420
AMP Connectors....1421
Packard Connectors....1423
FUEL SYSTEM....1424
SERVICE CHART....1425
FUEL SYSTEM HOSE ROUTING....1427
FUEL SYSTEM CIRCUIT DIAGRAM....1428
FUEL SYSTEM REQUIREMENTS....1429
Regulations and Guidelines....1429
Portable Fuel Tanks....1429
Fuel Flow Requirements....1429
Fuel Requirements....1430
COMPONENTS....1431
Fuel Lift Pump....1431
Fuel Filter....1431
Vapor Separator....1431
Fuel Circulation Pump....1432
Fuel Manifold....1433
Fuel Injectors....1433
FUEL SYSTEM PRIMING....1434
Vent Line Clamp....1434
Priming the Fuel System....1434
FUEL SYSTEM TESTS....1435
Fuel System Pressure Test....1435
Vapor Separator Vent Check....1436
Fuel Injector Pressure Test....1436
Fuel Injector Resistance Test....1436
Circulation Pump Resistance Test....1437
Lift Pump Pressure Test....1437
Lift Pump Vacuum Test....1438
Lift Pump Diaphragm Test....1438
Anti-Siphon Valve Test....1439
FUEL COMPONENT SERVICING....1439
Relieving Fuel System Pressure....1439
Fuel Filter Service....1440
Fuel Lift Pump Service....1441
Vapor Separator and Fuel Injector Service....1441
Intake Manifold Service....1447
OILING SYSTEM....1450
SERVICE CHART....1451
OIL SUPPLY DIAGRAMS....1452
OIL RECIRCULATION DIAGRAM....1453
OILING SYSTEM CIRCUIT DIAGRAM....1454
OIL SYSTEM REQUIREMENTS....1455
Recommended Lubricants....1455
COMPONENTS....1455
Oil Tank Assembly....1455
Oil Injection Pump....1455
Electrical Circuit (55 V)....1456
LOW OIL Warning....1456
NO OIL Warning....1456
Cylinder and Crankcase....1457
Oil Recirculation System....1457
OIL CONTROL SETTINGS....1458
Oil Injection Rate....1458
Break-In Oiling....1459
Oil Supply Priming....1459
OILING SYSTEM TESTS....1460
Oil Injection Pump Voltage Test....1460
Oil Injection Pump Resistance Test....1461
Oil Injection Pump Function Test....1462
Oil Injection Fittings Flow Test....1462
LOW OIL Sending Unit Test....1462
OIL COMPONENT SERVICING....1463
Oil Distribution Hoses....1463
Oil Tank Assembly....1464
Oil Injection Pump....1465
COOLING SYSTEM....1466
HOSE ROUTING AND WATER FLOW DIAGRAMS....1467
COMPONENTS....1468
Water Pump and Intakes....1468
Exhaust Housing....1468
Pressure Relief Valve....1469
Thermostat....1469
OPERATION....1470
Cylinder Block / Cylinder Head Cooling....1470
Vapor Separator, EMM and Battery Charge Module Cooling....1470
ENGINE TEMPERATURE CHECK....1471
Software Method....1471
Pyrometer Method....1471
Idle Operating Temperature Troubleshooting (Below Range)....1472
TEMPERATURE SENDER SERVICING....1473
Removal....1473
Installation....1473
THERMOSTAT AND PRESSURE RELIEF VALVE SERVICING....1473
Disassembly....1473
Inspection....1474
Assembly....1474
NOTES....1475
Technician’s Notes....1475
Related Documents....1475
POWERHEAD....1476
SERVICE CHART....1477
COMPRESSION TESTING....1479
POWERHEAD REMOVAL....1479
POWERHEAD DISASSEMBLY....1481
Systems Removal....1481
Throttle Linkage Removal....1482
Shift Linkage Removal....1482
Cylinder Head Removal....1482
Crankcase Disassembly....1482
Crankshaft Assembly Removal....1483
Connecting Rods and Pistons....1483
Crankshaft Service....1484
CYLINDER BLOCK CLEANING....1486
POWERHEAD INSPECTION....1487
Cylinder Head....1487
Bearings....1487
Cylinder Bore....1487
Pistons....1488
Piston Rings....1488
POWERHEAD ASSEMBLY....1488
Crankshaft Assembly....1488
Pistons and Connecting Rods....1490
Crankshaft Assembly Installation....1491
Crankcase Assembly....1492
Cylinder Head Installation....1493
Megaphone and Inner Exhaust Housing Installation....1494
Shift Linkage Installation....1495
Throttle Linkage Installation....1496
Final Powerhead Assembly....1496
POWERHEAD INSTALLATION....1497
Powerhead Mounting....1497
Shift Linkage Adjustment....1498
Final Adjustments....1499
POWERHEAD VIEWS....1500
Port Electric Start Models....1500
Starboard Electric Start Models....1500
Port Rope Start Models....1501
Starboard Rope Start Models....1501
Front....1502
Rear....1503
Top....1504
NOTES....1505
Technician’s Notes....1505
Related Documents....1505
MIDSECTION....1506
SERVICE CHART....1507
EXHAUST HOUSING SERVICE....1512
Exhaust Housing Removal....1512
Exhaust Housing Installation....1512
Mount Service....1513
Exhaust Relief Muffler....1515
EXTENSION SERVICE - 25” Models....1516
Removal....1516
Installation....1516
STERN BRACKET - Power Tilt Models....1517
Stern Bracket Disassembly (Power Tilt)....1517
Stern Bracket Assembly (Power Tilt)....1519
Trim Sending Unit Removal....1523
Trim Sending Unit Installation....1524
STERN BRACKET - Manual Tilt Models....1525
Clamp Screw Service....1525
Stern Bracket Disassembly (Manual Tilt)....1525
Stern Bracket Assembly (Manual Tilt)....1530
TILLER HANDLE SERVICE....1536
Removal....1536
Disassembly....1537
Inspection....1541
Assembly....1541
Installation....1548
Control Cable Installation....1549
GEARCASE....1552
SERVICE CHART....1553
PROPELLER SERVICE....1554
Inspection....1554
Propeller Selection....1554
Propeller Hardware Installation....1555
GEARCASE LEAK TEST....1556
TRIM TAB SERVICE....1556
Removal....1556
Installation....1556
GEARCASE REMOVAL AND INSTALLATION....1557
Gearcase Removal....1557
Gearcase Installation....1557
WATER PUMP SERVICE....1559
Disassembly....1559
Inspection....1559
Assembly....1559
GEARCASE DISASSEMBLY....1562
Pre-Disassembly Inspection....1562
Propeller Shaft Bearing Housing Removal....1563
Shifter, Gear and Propeller Shaft Removal....1564
BEARING AND SEAL REMOVAL....1565
Driveshaft Seals....1565
Driveshaft Bearing....1565
Pinion Bearings....1566
Forward Bearing....1566
Shift Rod Bushing and O-ring....1566
Propeller Shaft Bearing Housing Seals and O-ring....1567
BEARING AND SEAL INSTALLATION....1567
Propeller Shaft Bearing Housing Bearings....1567
Propeller Shaft Bearing Housing Seals and O-ring....1568
Shift Rod Bushing and O-ring....1568
Forward Bearing....1568
Pinion Bearings....1569
Driveshaft Bearing....1569
Driveshaft Seals....1570
GEARCASE ASSEMBLY....1570
Propeller Shaft, Gear and Shifter Installation....1570
Propeller Shaft Bearing Housing Installation....1573
TRIM AND TILT....1576
SERVICE CHART....1577
SYSTEM DESCRIPTION....1578
Manual Adjustment....1578
Trailering Bracket And Tilt Support....1578
ROUTINE INSPECTIONS....1579
General....1579
Reservoir Fluid....1579
Manual Release Valve....1579
Stern Brackets....1579
TROUBLESHOOTING....1579
ELECTRICAL CIRCUIT TESTS....1580
Relay Testing....1580
Trim and Tilt Motor Current Draw Tests....1580
Trim and Tilt Motor No Load Test....1581
Trim Gauge Test....1581
Trim Sender Test....1582
TRIM AND TILT REPLACEMENT....1582
Removal....1582
Installation....1583
TRIM AND TILT SERVICE....1584
Disassembly....1584
Assembly....1585
NOTES....1587
Technician’s Notes....1587
Related Documents....1587
MANUAL STARTER....1588
SERVICE CHART....1589
RECOIL STARTER REMOVAL....1590
RECOIL STARTER INSTALLATION....1591
RECOIL STARTER DISASSEMBLY....1592
RECOIL STARTER CLEANING AND INSPECTION....1594
RECOIL STARTER ASSEMBLY....1595
SAFETY....1598
TABLE OF CONTENTS....1598
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....1600
Outboard Shift Systems and Safety....1601
Outboard Speed Control System and Safety....1602
Outboard Steering Control System and Safety....1603
Outboard Fuel, Electrical System, and Safety....1605
Outboard Mounting System and Safety....1608
If weakened, parts could fail later on the water, when not expected....1609
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....1610
Outboard Emergency Stop System and Safety....1611
Summing up....1613
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....1614
Handling Outboards....1614
Handling Lead/Acid Batteries....1618
Gasoline - Handle With Care!....1619
Hazardous Products....1620
Safety Awareness Test....1621
INDEX....1622
TROUBLE CHECK CHART....1630
OUTBOARD WILL NOT START....1630
OUTBOARD WILL NOT START....1631
OUTBOARD HARD TO START....1632
OUTBOARD WILL NOT SHUT OFF....1633
OUTBOARD STARTS AND STALLS....1633
OUTBOARD STARTS, LOW MAXIMUM RPM....1634
EXCESSIVE SMOKING....1634
OUTBOARD SURGES, RUNS ROUGH....1635
Evinrude E-tec 200, 225, 250, 300 HP (V6 90 degr.) 2010 Service Manual....1650
INTRODUCTION....1654
ABBREVIATIONS USED IN THIS MANUAL....1657
Units of Measurement....1657
List of Abbreviations....1657
EMISSION-RELATED INSTALLATION INSTRUCTIONS....1658
Manufacturer’s Responsibility....1658
Dealer’s Responsibility....1658
Owner’s Responsibility....1658
EPA Emission Regulations....1658
MODEL DESIGNATION....1659
MODELS COVERED IN THIS MANUAL....1660
SERVICE SPECIFICATIONS....1661
STANDARD TORQUE SPECIFICATIONS....1665
PRODUCT REFERENCE AND ILLUSTRATIONS....1665
SPECIAL TOOLS....1666
DIAGNOSTIC TOOLS....1667
UNIVERSAL TOOLS....1667
ELECTRICAL / IGNITION TOOLS....1669
FUEL /OIL SYSTEM TOOLS....1670
POWERHEAD TOOLS....1670
GEARCASE TOOLS....1671
TRIM AND TILT TOOLS....1674
SHOP AIDS....1675
INSTALLATION AND PREDELIVERY....1678
BOAT RIGGING....1679
Remote Controls....1679
Information Display Systems....1681
Battery Installation....1686
Auxiliary Battery Charging....1688
Battery and Switch Wiring Diagrams....1689
Fuel System Requirements....1691
Remote Oil Tank Installation....1694
Cable and Hose Installation....1697
Oetiker Clamp Servicing....1699
OUTBOARD INSTALLATION....1701
Hull Preparation....1701
Transom Measuring and Drilling....1703
Drilling and Hardware Diagrams....1705
Lifting the Outboard....1707
Steering Systems....1707
Outboard Mounting....1709
OUTBOARD RIGGING....1710
Common Practices - All Models....1710
Cable, Hose, and Wire Routing....1711
Control Cable Installation....1712
Battery Cable Connections....1713
SystemCheck Harness Connections....1713
I-Command Network Connections....1714
ICON Network Connections....1715
Water Pressure Gauge....1716
FUEL AND OIL PRIMING....1717
Fuel Requirements....1717
Fuel System Priming....1718
Oil Requirements....1718
Oil Injection Rate....1719
Break-In Oiling....1720
Oil Supply Priming....1720
BEFORE START-UP....1722
Gearcase Lubricant....1722
Oil Level....1722
Trim and Tilt Fluid....1722
RUNNING CHECKS....1723
Engine Monitoring System....1723
Fuel System....1723
Emergency Stop / Key Switch....1723
Remote Control Operation....1723
Start-In-Gear Prevention....1723
Tachometer Pulse Setting....1724
I-Command Set up....1724
Water Pump Overboard Indicator....1724
Operating Temperature....1724
Idle Speed....1724
Break-In....1724
PROPELLERS....1725
Propeller Selection....1725
Propeller Hardware Installation....1726
WATER TEST AND FINAL ADJUSTMENTS....1727
Engine Mounting Height and Jack Plate Adjustment....1727
Fuel System Vacuum....1727
Engine Water Pressure....1727
Water Pressure Chart....1728
Tilt Limit Switch Adjustment....1729
Trim Sending Unit Adjustment....1730
Trim Tab Adjustment....1731
Dual-Outboard Alignment....1732
NOTES....1733
Technician’s Notes....1733
Related Documents....1733
MAINTENANCE....1734
INSPECTION AND MAINTENANCE SCHEDULE....1735
ANTI-CORROSION PROTECTION....1736
Sacrificial Anodes....1736
Testing Procedure - Continuity....1736
Metallic Component Protection....1736
Exterior Finishes....1736
COOLING SYSTEM....1737
Flushing....1737
Water Intake Screens....1738
Additional Maintenance....1738
LUBRICATION....1739
Steering System....1739
Swivel Bracket and Trailering Bracket....1739
Tilt Tube....1739
Throttle and Shift Linkage....1740
Propeller Shaft....1740
Gearcase Lubricant....1740
Trim and Tilt....1742
BATTERY AND BATTERY CONNECTIONS....1743
FUEL AND OIL SYSTEMS....1743
Fuel Filter....1743
Oil Filters and Oil Reservoir....1744
Air Silencer....1744
Hoses and Connections....1744
SPARK PLUGS....1745
Indexing....1745
EXHAUST PRESSURE FITTING....1746
Operation Test....1746
Cleaning....1746
STORAGE....1747
Fuel System Treatment....1747
Internal Engine Treatment....1747
Additional Recommendations....1748
PRE-SEASON SERVICE....1749
Outboard Mounting Bolts....1749
Gearcase Lubricant....1749
Battery(s)....1749
Power Trim and Tilt....1749
Operational Checks....1749
SUBMERGED ENGINES....1750
Engine Dropped Overboard (Not Running)....1750
Engine Dropped Overboard (Running)....1750
Engine Dropped Overboard (In Salt Water)....1750
Prolonged Submersion (Fresh or Salt Water)....1750
NOTES....1751
Technician’s Notes....1751
Related Documents....1751
ENGINE COVER SERVICE....1752
UPPER COVER SERVICE....1753
Latch Hook Installation....1753
Upper Cover Cap Replacement....1753
LOWER COVER SERVICE....1754
Lower Cover Removal....1754
Lower Cover Installation....1754
Latch Handle Installation....1755
Trim Switch Installation....1755
ENGINE MANAGEMENT MODULE (EMM)....1756
DESCRIPTION....1757
EMM Functions....1757
EMM Connections....1757
LED Indicators....1757
EMM INPUTS AND OUTPUTS DIAGRAM....1758
INTERNAL SENSORS....1759
EMM Temperature Sensor....1759
55 V Circuit Sensor....1759
12 V Circuit Sensor....1759
5 V Circuit Sensor....1760
Barometric Pressure Sensor....1760
Exhaust Pressure Sensor....1760
EXTERNAL SENSORS....1761
Air Temperature Sensor....1761
Engine Temperature Sensor....1761
Shift Interrupt Switch....1761
Oil Pressure Sensor....1762
Throttle Position Sensor....1762
Crankshaft Position Sensor....1763
Knock Sensor....1763
INTERNAL EMM FUNCTIONS....1764
Start Assist Circuit (SAC)....1764
ROM Verification....1764
Idle Controller....1764
RPM Limiter....1764
Shift Interrupt....1764
Engine Monitor and Warning Systems....1764
Fault Code Creation and Storage....1764
ENGINE MONITOR SYSTEM....1765
System Self-Test....1765
Service Mode....1765
Engine Running....1765
S.A.F.E. WARNING SYSTEM....1766
Activation....1766
Recovery....1766
SHUTDOWN MODE....1766
Recovery....1766
DIAGNOSTIC SOFTWARE FUNCTIONS....1767
Communication....1767
Static Information....1767
Dynamic Information....1768
Stored Service Codes (Faults)....1768
Hard Faults....1768
Persistent Faults....1768
Static Tests....1768
Dynamic Tests....1769
Oil Control Settings....1770
Ignition Timing....1771
TPS Calibration....1771
Fuel Injector Servicing....1771
Reports....1772
Software Replacement....1772
EMM Transfer....1772
EMM SERVICING....1773
Removal....1773
Installation....1773
SYSTEM ANALYSIS....1774
DIAGNOSTIC PROCEDURES....1775
Visual Inspections....1775
Diagnostic Software Inspections....1775
Operational Inspections....1776
Troubleshooting....1777
DYNAMIC TESTS....1778
Cylinder Drop Tests....1778
Fuel Control Adjustment....1778
Inductive Amp Meter Test....1778
EMM LED INDICATORS....1779
Key ON....1779
Starting....1779
Running....1780
IGNITION OUTPUT TESTS....1781
Required Ignition Systems....1781
Wiring Inspection....1781
Crankshaft Position Sensor (CPS) Test....1782
System Voltage Test....1782
Static Ignition Test....1783
Running Ignition Tests....1784
Ignition Control Circuit Tests....1785
Ignition Coil Tests....1785
Capacitor Test....1785
FUEL DELIVERY TESTS....1786
Fuel Pump Static Test....1786
Fuel Injector Static Test....1786
Running Fuel System Tests....1787
ELECTRICAL AND IGNITION....1788
SERVICE CHART....1789
IGNITION SYSTEM CIRCUIT DIAGRAM....1791
ELECTRICAL HARNESS CONNECTIONS....1792
Engine Harness to Stator Connector....1792
EMM J1-A Connector....1792
EMM J1-B Connector....1793
EMM J2 Connector....1793
GROUND CIRCUITS....1794
EMM Ground Tests....1794
Additional Ground Tests....1794
FUSE....1794
SENSOR TESTS....1795
Crankshaft Position Sensor (CPS) Test....1795
Throttle Position Sensor (TPS) Test....1795
Engine Temperature Sensor Test....1796
Air Temperature Sensor (AT) Test....1796
Knock Sensor Test....1796
STATOR TESTS....1797
Stator Resistance Tests....1797
Stator Voltage Output Test....1797
CHARGING SYSTEM TESTS....1798
12 V Charging Circuit....1798
Auxiliary Battery Charge Wire....1799
55 V Alternator Circuit....1799
ELECTRIC START CIRCUIT....1800
Start Circuit Diagram....1800
Start Circuit Operation....1801
ELECTRIC START TESTS....1802
Starter Solenoid Test....1802
No Load Current Draw Test....1803
REMOTE CONTROL SWITCH TESTS....1804
Key Switch Test....1804
Neutral Start Circuit Test....1804
Neutral Start Switch Test....1805
Emergency Stop Switch Test....1805
TILT/TRIM RELAY TEST....1806
Operation....1806
Test Procedure....1806
SystemCheck CIRCUIT TESTS....1807
Gauge Self-Test Check....1807
CHECK ENGINE Circuit Test....1808
WATER TEMP/ HOT Circuit Test....1808
LOW OIL Circuit Test....1809
NO OIL Circuit....1809
TACHOMETER CIRCUIT TESTS....1809
FLYWHEEL AND STATOR SERVICING....1810
Flywheel Removal....1810
Stator Service....1810
Flywheel Installation....1811
IGNITION COIL SERVICING....1812
Ignition Coil Removal....1812
Ignition Coil Bracket Removal....1812
Ignition Coil Bracket Installation....1812
Ignition Coil Installation....1812
TIMING ADJUSTMENTS....1813
Timing Pointer....1813
Timing Verification....1814
TPS CALIBRATION....1814
ELECTRIC STARTER SERVICING....1816
Starter Removal....1816
Starter Disassembly....1816
Starter Cleaning and Inspection....1819
Starter Assembly....1820
Starter Installation....1822
CONNECTOR SERVICING....1823
DEUTSCH Connectors....1823
AMP Connectors....1824
Packard Connectors....1826
NOTES....1827
Technician’s Notes....1827
Related Documents....1827
FUEL SYSTEM....1828
SERVICE CHART....1829
FUEL SYSTEM HOSE ROUTING....1832
FUEL SYSTEM CIRCUIT DIAGRAM....1833
COMPONENTS....1834
Fuel Lift Pump....1834
Fuel Filter....1834
Vapor Separator....1834
Fuel Circulation Pump....1835
Fuel Manifolds....1836
Fuel Injectors....1836
FUEL SYSTEM TESTS....1837
Fuel System Pressure Test....1837
Pressure Regulator Test....1838
Vapor Separator Vent Check....1838
Fuel Injector Pressure Test....1838
Fuel Injector Resistance Test....1839
Circulation Pump Resistance Test....1839
Lift Pump Pressure Test....1839
Lift Pump Vacuum Test....1840
Lift Pump Diaphragm Test....1840
Anti-Siphon Valve Test....1841
FUEL COMPONENT SERVICING....1841
Relieving Fuel System Pressure....1841
Fuel Filter Service....1842
Fuel Lift Pump Service....1843
Vapor Separator Service....1844
Fuel Manifold Service....1844
Fuel Injector Service....1845
Intake Manifold Service....1848
NOTES....1851
Technician’s Notes....1851
Related Documents....1851
OILING SYSTEM....1852
SERVICE CHART....1853
OILING SYSTEM CIRCUIT DIAGRAM....1854
OIL SUPPLY DIAGRAMS....1855
OIL RECIRCULATION DIAGRAMs....1857
COMPONENTS....1859
Oil Tank Assembly....1859
Oil Injection Pump....1859
Oil Pressure Sensor....1859
Electrical Circuit (55 V)....1860
LOW OIL Warning....1860
NO OIL Warning....1860
Cylinder and Crankcase....1860
Oil Recirculation System....1861
OIL CONTROL SETTINGS....1862
Oil Priming....1862
Oiling Rates....1862
Break-in Oiling....1862
OILING SYSTEM TESTS....1863
Oil Injection Pump Static Test....1863
Oil Injection Pump Voltage Test....1863
Oil Injection Pump Circuit Resistance Test....1864
Oil Supply Vacuum Test....1864
Oil Injection Pump Function Test....1865
Oil Injection Fittings Flow Test....1865
LOW OIL Sending Unit Test....1865
OIL COMPONENT SERVICING....1866
Oil Distribution Hoses....1866
Oil Injection Pump....1867
NOTES....1869
Technician’s Notes....1869
Related Documents....1869
COOLING SYSTEM....1870
HOSE ROUTING AND WATER FLOW DIAGRAM....1871
COMPONENTS....1872
Water Pump and Intakes....1872
Water Supply Tube....1872
Adapter Housing....1872
Pressure Relief Valve....1873
Thermostats....1873
Block Venting....1873
OPERATION....1874
Cylinder Block / Cylinder Head Cooling....1874
EMM and Vapor Separator Cooling....1875
ENGINE TEMPERATURE CHECK....1875
Software Method....1876
Pyrometer Method....1876
Idle Operating Temperature Troubleshooting (Below Range)....1876
TEMPERATURE SENDER SERVICING....1878
Removal....1878
Installation....1878
THERMOSTAT SERVICING....1878
Disassembly....1878
Inspection....1878
Assembly....1878
PRESSURE RELIEF VALVE SERVICING....1879
Disassembly....1879
Inspection....1879
Assembly....1879
EVINRUDE ICON REMOTE CONTROL SYSTEM....1880
SERVICE CHART....1881
COMPONENTS....1882
Electronic Servo Module (ESM)....1882
Shift Actuator....1882
Throttle Actuator....1883
ICON System Failsafe Mode....1883
ICON COMPONENT SERVICING....1884
Electronic Servo Module (ESM)....1884
Shift Actuator....1887
Throttle Actuator....1889
ICON SYSTEM SETTINGS....1892
Set Engine Identity (Instance)....1892
Calibrate Actuator Stroke....1892
ICON Remote Control System Troubleshooting Chart....1895
ICON Remote Control System Fault Messages....1897
POWERHEAD....1900
SERVICE CHART....1901
TAPER PIN TOOL....1903
COMPRESSION TESTING....1903
POWERHEAD REMOVAL....1904
POWERHEAD DISASSEMBLY....1906
Systems Removal....1906
Throttle Linkage Removal....1906
Shift Linkage Removal....1906
Crankcase Disassembly....1907
Cylinder Head Removal....1908
Connecting Rods and Pistons....1908
Crankshaft Removal....1909
CYLINDER BLOCK CLEANING....1912
POWERHEAD INSPECTION....1913
Cylinder Head....1913
Crankshaft....1913
Cylinder Bore....1914
Pistons....1914
Piston Rings....1914
Bearings....1915
POWERHEAD ASSEMBLY....1915
Crankshaft....1915
Pistons and Connecting Rods....1918
Cylinder Head Installation....1919
Crankshaft and Connecting Rods....1920
Crankcase Assembly....1923
Shift Linkage Installation....1924
Throttle Linkage Installation....1925
Final Powerhead Assembly....1925
POWERHEAD INSTALLATION....1926
Pre-Service Adjustments....1928
POWERHEAD VIEWS....1929
Port Hose Routings....1929
Starboard Hose Routings....1930
Port - 3.3 L models....1931
Starboard - 3.3 L models....1932
Port - 3.4 L models....1933
Starboard - 3.4 L models....1934
Front - 3.3 L models....1935
Front - 3.4 L models....1936
Rear....1937
Top....1938
Starboard - ICON models....1939
MIDSECTION....1940
SERVICE CHART....1941
Stern Bracket....1941
Exhaust Housing - 3.3 L models....1942
Exhaust Housing - 3.4 L models....1943
Muffler....1944
TILT TUBE....1945
Removal....1945
Installation....1946
EXHAUST HOUSING SERVICE....1947
Exhaust Housing Removal....1947
Lower Mount Service....1947
Exhaust Housing Installation....1948
Exhaust Housing Disassembly - 3.3 L models....1949
Exhaust Housing Disassembly - 3.4 L models....1950
Cleaning and Inspection....1951
Exhaust Housing Assembly - 3.3 L models....1952
Exhaust Housing Assembly - 3.4 L models....1954
STERN BRACKET....1956
Removal....1956
Stern Bracket Disassembly....1956
Stern Bracket Assembly....1958
EXHAUST RELIEF MUFFLER ASSEMBLY....1961
GEARCASE....1962
SERVICE CHART....1963
GEARCASE TYPES....1966
Housing Identification....1966
Housing Profiles....1966
PROPELLER SERVICE....1967
Inspection....1967
GEARCASE LEAK TEST....1967
SHIFT INTERRUPT SWITCH....1968
GEARCASE REMOVAL AND INSTALLATION....1968
Gearcase Removal....1968
Gearcase Installation....1969
WATER PUMP SERVICE....1971
Disassembly....1971
Inspection....1971
Assembly....1972
SHIFT ROD ADJUSTMENT....1975
GEARCASE - STANDARD ROTATION....1975
GEARCASE DISASSEMBLY....1975
Pre-Disassembly Inspection....1975
Propeller Shaft Bearing Housing Removal - “L2” and “M2” Type....1976
Pinion Gear and Driveshaft Removal....1978
Driveshaft Service....1979
Shift Housing, Gear, and Propeller Shaft Removal....1980
Water Intake Screens....1980
GEARCASE HOUSING INSPECTION....1981
SHIFTER, BEARING AND SEAL SERVICING....1982
Pinion Bearing Removal....1982
Pinion Bearing Installation....1982
Shift Housing Disassembly....1983
Shift Housing Assembly....1984
Driveshaft Bearing Housing Service....1986
Propeller Shaft Bearing Housing Service....1987
DRIVESHAFT SHIMMING....1990
GEARCASE ASSEMBLY....1991
Water Intake Screens....1991
Shift Housing, Gear, and Propeller Shaft Installation....1991
Shift Rod Housing Installation....1992
Pinion Gear and Driveshaft Installation....1993
Propeller Shaft Bearing Housing and Gear Installation - “L2” Type....1994
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....1996
Final Assembly and Adjustment....1997
GEARCASE - COUNTER ROTATION....1998
GEARCASE DISASSEMBLY....1998
Pre-Disassembly Inspection....1998
Propeller Shaft Bearing Housing Removal - “M2” Type....1998
Pinion Gear Removal and Driveshaft Servicing....1999
Shift Housing, Gear and Propeller Shaft Removal....1999
Water Intake Screens....1999
GEARCASE HOUSING INSPECTION....1999
SHIFTER, BEARING AND SEAL SERVICING....2000
Shift Housing Disassembly....2000
Shift Housing Assembly....2001
Pinion Bearing....2003
Propeller Shaft Bearing Housing and Forward Gear....2003
DRIVESHAFT SHIMMING....2006
GEARCASE ASSEMBLY....2008
Water Intake Screens....2008
Shift Housing, Gear, and Propeller Shaft Installation....2008
Shift Rod Cover....2008
Pinion Gear and Driveshaft Installation....2008
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....2008
Final Assembly and Adjustment....2009
TRIM AND TILT....2010
SERVICE CHART....2011
SYSTEM DESCRIPTION....2012
Manual Adjustment....2012
Trailering Bracket and Tilt Support....2012
MODES OF OPERATION....2013
Trim-OUT / Tilt-UP Mode....2013
2....2013
Tilt-DOWN / Trim-IN Mode....2014
Impact Relief....2015
1....2015
Shallow Water Drive Tilt Relief....2016
Thermal Expansion Relief....2016
Manual Release - UP....2017
Manual Release - DOWN....2018
ROUTINE INSPECTIONS....2019
General....2019
Reservoir Fluid....2019
Manual Release Valve....2019
Stern Brackets....2019
TROUBLESHOOTING....2019
Symptoms Chart....2020
Service Procedures....2020
Pressure Leakdown Test....2020
ELECTRICAL CIRCUIT TESTS....2023
Relay Testing....2023
Trim and Tilt Motor Current Draw Tests....2023
Trim and Tilt Motor No Load Test....2024
Trim Gauge Test....2025
Trim Sender Test....2025
TRIM AND TILT SERVICE....2026
Removal....2026
Installation....2027
Disassembly....2028
Tilt Piston Removal....2031
Tilt Piston Identification....2032
Tilt Piston Assembly....2032
Tilt Rod Assembly....2033
Trim Rod Removal....2034
Trim Rod Assembly....2035
Manifold and Reservoir Installation....2036
Trim Rod Installation....2037
Tilt Rod Installation....2038
Motor Installation....2038
ADJUSTMENTS....2040
NOTES....2041
Technician’s Notes....2041
Related Documents....2041
SAFETY....2042
TABLE OF CONTENTS....2042
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....2044
Outboard Shift Systems and Safety....2045
Outboard Speed Control System and Safety....2046
Outboard Steering Control System and Safety....2047
Outboard Fuel, Electrical System, and Safety....2049
Outboard Mounting System and Safety....2052
If weakened, parts could fail later on the water, when not expected....2053
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....2054
Outboard Emergency Stop System and Safety....2055
Summing up....2057
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....2058
Handling Outboards....2058
Handling Lead/Acid Batteries....2062
Gasoline - Handle With Care!....2063
Hazardous Products....2064
Safety Awareness Test....2065
INDEX....2066
NOTES....2075
Technician’s Notes....2075
Related Documents....2075
TROUBLE CHECK CHART....2076
OUTBOARD WILL NOT START....2076
OUTBOARD WILL NOT START....2077
OUTBOARD HARD TO START....2078
OUTBOARD WILL NOT SHUT OFF....2079
OUTBOARD STARTS AND STALLS....2079
OUTBOARD STARTS, LOW MAXIMUM RPM....2080
EXCESSIVE SMOKING....2080
OUTBOARD SURGES, RUNS ROUGH....2081
DIAGRAMS....2082
Evinrude E-tec 40, 50, 60 HP 2007 Service Manual....2093
INTRODUCTION....2097
MODELS COVERED IN THIS MANUAL....2098
Identifying Model and Serial Numbers....2098
MODEL DESIGNATION....2099
TYPICAL PAGE - A....2100
TYPICAL PAGE - B....2101
TYPICAL PAGE - C....2102
TYPICAL PAGE - D....2103
ABBREVIATIONS USED IN THIS MANUAL....2104
Units of Measurement....2104
List of Abbreviations....2104
ENGINE EMISSIONS INFORMATION....2105
Manufacturer’s Responsibility....2105
Dealer’s Responsibility....2105
Owner’s Responsibility....2105
EPA Emission Regulations....2105
PRODUCT REFERENCE AND ILLUSTRATIONS....2106
SYMBOLS....2106
Electrical....2106
Values....2107
NOTES....2108
Technician’s Notes....2108
Related Documents....2108
SERVICE SPECIFICATIONS AND SPECIAL TOOLS....2109
TECHNICAL DATA....2110
STANDARD TORQUE SPECIFICATIONS....2112
SPECIAL TOOLS....2113
Electrical / Ignition....2113
Fuel System....2114
Gearcase....2115
Powerhead....2116
Starter....2117
Universal....2118
SHOP AIDS....2120
INSTALLATION AND PREDELIVERY....2123
BOAT RIGGING....2124
Remote Controls....2124
Battery Installation....2126
Battery Switches and Multiple Batteries....2127
Battery and Switch Wiring Diagrams....2129
Fuel System Requirements....2131
Cable and Hose Installation....2133
OUTBOARD INSTALLATION....2138
Hull Preparation....2138
Transom Measuring and Drilling....2139
Drilling and Hardware Diagrams....2142
Lifting the Outboard....2144
Steering Systems....2144
Outboard Mounting....2146
OUTBOARD RIGGING....2148
Cable, Hose, and Wire Routing....2148
Control Cable Adjustments....2148
Electrical Harness Connections....2150
Water Pressure Gauge....2150
FUEL AND OIL PRIMING....2151
Fuel Requirements....2151
Fuel System Priming....2152
Oil Requirements....2153
Oil Injection Rate....2153
SystemCheck Low Oil Warning Test....2153
Oil Supply Priming....2154
Break-In Oiling....2154
BEFORE START-UP....2155
Gearcase Lubricant....2155
Oil Level....2155
Trim and Tilt Fluid....2155
RUNNING CHECKS....2156
SystemCheck Operation....2156
Fuel System....2156
Emergency Stop / Key Switch....2156
Remote Control Operation....2156
Start-In-Gear Prevention....2156
Tachometer Pulse Setting....2157
Water Pump Overboard Indicator....2157
Operating Temperature....2157
Idle Speed....2157
Break-In....2157
PROPELLERS....2158
Propeller Selection....2158
Propeller Hardware Installation....2159
FINAL ADJUSTMENTS....2160
Trim Sending Unit Adjustment....2160
Trim Tab Adjustment....2161
Dual-Outboard Alignment....2162
MAINTENANCE....2163
INSPECTION AND MAINTENANCE SCHEDULE....2164
ANTI-CORROSION PROTECTION....2165
Sacrificial Anodes....2165
Testing Procedure - Continuity....2165
Metallic Component Protection....2165
Exterior Finishes....2165
COOLING SYSTEM....2166
Flushing....2166
Water Intake Screens....2167
Additional Maintenance....2167
LUBRICATION....2167
Steering System....2167
Swivel Bracket and Trailering Bracket....2168
Tilt Tube....2168
Throttle and Shift Linkage....2168
Propeller Shaft....2169
Gearcase Lubricant....2169
Trim and Tilt....2170
BATTERY AND BATTERY CONNECTIONS....2170
FUEL AND OIL SYSTEMS....2171
Fuel Filter....2171
Oil Reservoir....2171
Air Silencer....2171
Hoses and Connections....2171
SPARK PLUGS....2172
Indexing....2172
STORAGE....2173
Fuel System Treatment....2173
Internal Engine Treatment....2173
Additional Recommendations....2174
PRE-SEASON SERVICE....2174
Outboard Mounting Bolts....2174
Gearcase Lubricant....2174
Battery(s)....2174
Power Trim and Tilt....2174
Operational Checks....2174
SUBMERGED ENGINES....2175
Engine Dropped Overboard (Not Running)....2175
Engine Dropped Overboard (Running)....2175
Engine Dropped Overboard (In Salt Water)....2175
Prolonged Submersion (Fresh or Salt Water)....2175
NOTES....2176
Technician’s Notes....2176
Related Documents....2176
ENGINE MANAGEMENT MODULE (EMM)....2177
DESCRIPTION....2178
EMM Functions....2178
EMM Connections....2178
SENSORS AND FUNCTIONS....2179
Internal Sensors....2179
External Sensors....2180
Internal Functions....2182
EMM INPUTS AND OUTPUTS DIAGRAM....2183
S.A.F.E. WARNING SYSTEM....2184
Activation....2184
Recovery....2184
SHUTDOWN MODE....2184
EMM DIAGNOSTICS....2185
LED Indicators....2185
Diagnostic Software Program....2186
Communication....2186
Program Information....2187
Service Codes (Faults)....2187
Static Tests....2188
Dynamic Tests....2189
Oil Control....2190
Starter Mode (Tiller/Remote Programming)....2190
Timing Verification....2190
TPS Calibration....2191
Idle Speed....2191
Fuel Injector Servicing....2191
Fuel Control Adjustment....2192
Reports....2192
Software Replacement....2193
EMM Transfer....2193
SystemCheck ENGINE MONITOR....2193
System Self-Test....2194
Service Mode....2194
Engine Running....2194
SYSTEM ANALYSIS....2195
ELECTRICAL CONNECTIONS....2196
GROUND CIRCUITS....2198
Test Procedure....2198
FUSE....2198
EMM DIAGNOSTICS....2199
LED Indicators....2199
Software Programs....2199
DIAGNOSTIC PROCEDURES....2200
Symptoms....2201
SPECIALIZED TEST PROCEDURES....2202
Dynamic Tests....2202
Testing with Timing Light....2202
Inductive Amp Meter Test....2203
Engine Monitoring Information....2203
Voltage Testing....2204
START CIRCUIT....2204
Electric Starter Operation....2204
Starter Solenoid Activation....2205
IGNITION AND ELECTRICAL CIRCUITS....2206
Stop Circuit....2206
Neutral Switch....2206
Stator Output Voltage....2206
EMM....2206
Crankshaft Position Sensor....2206
Alternator Output Voltage....2206
Capacitor....2206
Ignition Power Supply to EMM....2206
Ignition Primary Voltage....2206
Ignition Coil....2206
IGNITION OUTPUT....2207
Wiring Inspection....2207
Ignition Voltage....2207
System Voltage....2208
Static Spark Test....2208
Running Ignition Tests....2209
Ignition Primary Circuit Resistance Test....2210
Crankshaft Position Sensor (CPS) Test....2210
FUEL DELIVERY....2211
Manifold Pressure Test....2211
Vapor Separator Checks....2212
Fuel Delivery to Lift Pump....2212
FUEL INJECTOR OPERATION....2212
Neutral Switch....2212
Static Tests....2212
Dynamic Tests....2213
EXHAUST WATER VALVE....2214
Static Test....2214
Dynamic Test....2214
ELECTRICAL AND IGNITION....2215
SERVICE CHART....2216
DASH CONNECTIONS, INSTRUMENT HARNESS....2218
IGNITION SYSTEM TESTS....2219
Sensor Resistance Tests....2219
Ignition Coil Tests....2220
Stator Tests....2221
Capacitor Test....2222
EXHAUST WATER VALVE TEST....2222
CHARGING SYSTEM TESTS....2222
12 V Charging Circuit....2222
55 V Alternator Circuit....2223
SystemCheck CIRCUIT TESTS....2224
Gauge Self-Test Check....2224
CHECK ENGINE Circuit Test....2225
WATER TEMP/ HOT Circuit Test....2225
LOW OIL Circuit Test....2226
NO OIL Circuit Test....2226
REMOTE CONTROL SWITCH TESTS....2226
Key Switch Test....2226
Neutral Start Circuit Test....2227
Neutral Start Switch Test....2227
Emergency Stop Switch Test....2228
ELECTRIC STARTER TESTS....2228
Starter Solenoid Test....2228
No Load Current Draw Test....2229
TILT/TRIM RELAY TEST....2230
Operation....2230
Test Procedure....2230
TACHOMETER CIRCUIT TESTS....2231
FLYWHEEL SERVICING....2232
Removal....2232
Installation....2233
TIMING ADJUSTMENTS....2234
Timing Pointer....2234
Timing Verification....2235
TPS Calibration....2235
SPARK PLUGS....2236
Inspection....2236
Indexing....2236
ELECTRIC STARTER SERVICING....2237
Removal....2237
Disassembly....2237
Cleaning and Inspection....2238
Assembly....2239
Installation....2240
CONNECTOR SERVICING....2241
DEUTSCH Connectors....2241
AMP Connectors....2242
Packard † Connectors....2244
NOTES....2246
Technician’s Notes....2246
Related Documents....2246
FUEL SYSTEM....2247
SERVICE CHART....2248
COMPONENTS....2250
Fuel Lift Pump....2250
Fuel Filter....2250
Vapor Separator....2250
Fuel Circulation Pump....2252
Fuel Manifolds....2252
Fuel Injectors....2253
FUEL SYSTEM HOSE ROUTING....2254
DIRECT INJECTION ELECTRICAL CIRCUITS....2255
Injector / Circulation Pump Circuits Diagram....2255
FUEL COMPONENT TESTS....2256
Injectors....2256
Fuel Supply....2257
FUEL COMPONENT SERVICING....2260
Relieving Fuel System Pressure....2260
Fuel Filter....2261
Fuel Lift Pump....2261
Vapor Separator....2262
Fuel Injectors....2262
Fuel Manifolds....2266
INTAKE MANIFOLD....2266
Removal....2266
Disassembly....2266
Inspection....2267
Assembly....2267
Installation....2268
OILING SYSTEM....2269
SERVICE CHART....2270
COMPONENTS....2271
Oil Tank Assembly....2271
Electrical Circuit (55 V)....2272
SystemCheck LOW and NO OIL Warning Signals....2272
Oiling System Electrical Diagram....2273
Cylinder and Crankcase....2274
Oil Supply and Distribution Diagram....2274
Oil Recirculation System....2275
Recirculation Hose Diagram....2275
PRIMING....2276
OILING RATES....2276
Oil Injection Rate....2276
Break-in Oiling....2276
OILING SYSTEM TESTS....2277
Oil Injection Pump Static Test....2277
Oil Injection Pump Voltage Test....2277
Oil Injection Pump Circuit Resistance Test....2278
Oil Flow Tests....2278
Oil-to-Fuel Check Valve Test....2280
LOW OIL Sending Unit Test....2280
NO OIL Warning Test....2280
OIL COMPONENT SERVICING....2281
Oil Distribution Hoses....2281
Oil Tank Assembly....2282
COOLING SYSTEM....2283
HOSE ROUTING AND WATER FLOW DIAGRAM....2284
ENGINE TEMPERATURE CHECK....2285
Software Method....2285
Pyrometer Method....2285
Idle Operating Temperature Troubleshooting (Below Range)....2286
COMPONENTS....2287
General Description....2287
Water Pump and Intakes....2287
Exhaust Housing....2288
Pressure Relief Valve....2288
Thermostat....2288
Block Venting....2289
Water Pressure Connection....2289
OPERATION....2289
Cylinder Block / Cylinder Head Cooling....2289
EMM and Vapor Separator Cooling....2290
THERMOSTAT SERVICING....2290
Disassembly....2290
Inspection....2291
Assembly....2291
PRESSURE RELIEF VALVE SERVICING....2291
Disassembly....2291
Inspection....2292
Assembly....2292
POWERHEAD....2293
SERVICE CHART....2294
GENERAL....2296
Cylinder Compression Testing....2296
Retaining Ring Pliers....2296
REMOVAL....2297
DISASSEMBLY....2299
General....2299
Shift Linkage....2299
Throttle Linkage....2299
Crankcase....2300
Cylinder Head....2301
Connecting Rods and Pistons....2301
Crankshaft....2302
CLEANING....2304
INSPECTION....2305
Cylinder Head....2305
Crankshaft....2306
Cylinder Bore....2306
Pistons....2306
Piston Rings....2306
Bearings....2307
ASSEMBLY....2308
Crankshaft....2308
Pistons and Connecting Rods....2310
Cylinder Head....2312
Crankshaft and Connecting Rods....2313
Crankcase....2316
Shift Linkage....2318
Throttle Linkage....2319
General....2319
INSTALLATION....2320
POWERHEAD VIEWS....2324
Port Short Block....2324
Starboard Short Block....2324
Port Dressed Powerhead....2325
Starboard Dressed Powerhead....2325
Port Rope Start Models....2326
Starboard Rope Start Models....2326
Front....2327
Rear....2328
Top....2329
Top, Rope Start Models....2330
MIDSECTION....2331
SERVICE CHART....2332
CLEANING AND INSPECTION....2335
General....2335
Clamp Screw....2335
Exhaust Housing....2335
EXHAUST HOUSING....2336
Removal....2336
Servicing....2337
Installation....2338
STERN BRACKET-Power Tilt Models....2339
Disassembly....2339
Assembly....2340
STERN BRACKET- Manual Tilt Models....2341
Disassembly....2341
Assembly....2344
Tilt Assist Cylinder (Optional)....2347
STEERING HANDLE....2348
Removal....2348
Disassembly....2349
Inspection....2350
Assembly....2350
Installation....2352
MIDSECTION AND TILLER ADJUSTMENTS....2354
Steering Friction Adjustment....2354
Throttle Friction Adjustment....2354
GEARCASE....2355
SERVICE CHART....2356
PROPELLER....2357
Inspection....2357
LUBRICANT....2357
Draining....2357
Inspection....2357
Filling....2358
LEAK TEST....2358
REMOVAL AND INSTALLATION....2359
Removal....2359
Installation....2360
WATER PUMP....2361
Disassembly....2361
Inspection....2361
Assembly....2362
SHIFT ROD ADJUSTMENT....2364
DISASSEMBLY....2364
Pre-Disassembly Inspection....2364
Propeller Shaft Bearing Housing Removal....2365
Pinion Gear and Driveshaft Removal....2366
Shift Housing, Gear and Propeller Shaft Removal....2367
BEARING AND SEAL REMOVAL....2368
Shift Housing....2368
Pinion Gear Bearing....2369
Water Intake Screen....2370
Driveshaft Bearing Housing....2370
Propeller Shaft Bearing Housing....2370
BEARING AND SEAL INSTALLATION....2372
Shift Housing....2372
Water Intake Screen....2373
Pinion Gear Bearing....2373
Driveshaft Bearing Housing....2374
Propeller Shaft Bearing Housing....2374
DRIVESHAFT SHIMMING....2375
ASSEMBLY....2377
Shift Housing, Gear, and Propeller Shaft Installation....2377
Shift Rod Housing Installation....2377
Pinion Gear and Driveshaft Installation....2378
Propeller Shaft Bearing Housing and Gear Installation....2379
TRIM AND TILT....2381
SYSTEM DESCRIPTION....2382
ROUTINE INSPECTIONS....2383
General....2383
Reservoir Fluid....2383
Manual Release Valve....2383
Stern Brackets....2383
ELECTRICAL CIRCUIT TESTS....2384
Relay Testing....2384
Trim and Tilt Motor Current Draw Tests....2384
Trim and Tilt Motor No Load Test....2385
Trim Gauge Test....2385
Trim Sender Test....2386
SERVICING....2386
Removal....2386
Disassembly....2387
Assembly....2388
Installation....2389
ADJUSTMENTS....2390
MANUAL STARTER....2391
SERVICE CHART....2392
REMOVAL....2393
DISASSEMBLY....2393
CLEANING AND INSPECTION....2395
ASSEMBLY....2395
INSTALLATION....2399
NOTES....2400
Technician’s Notes....2400
Related Documents....2400
SAFETY....2401
TABLE OF CONTENTS....2401
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....2403
Outboard Shift Systems and Safety....2404
Outboard Speed Control System and Safety....2405
Outboard Steering Control System and Safety....2406
Outboard Fuel, Electrical System, and Safety....2408
Outboard Mounting System and Safety....2411
If weakened, parts could fail later on the water, when not expected....2412
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....2413
Outboard Emergency Stop System and Safety....2414
Summing up....2416
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....2417
Handling Outboards....2417
Handling Lead/Acid Batteries....2421
Gasoline - Handle With Care!....2422
Hazardous Products....2423
Safety Awareness Test....2424
INDEX....2425
TROUBLE CHECK CHART....2433
OUTBOARD WILL NOT START....2433
OUTBOARD WILL NOT START....2434
OUTBOARD HARD TO START....2435
OUTBOARD WILL NOT SHUT OFF....2436
OUTBOARD STARTS AND STALLS....2436
OUTBOARD STARTS, LOW MAXIMUM RPM....2437
EXCESSIVE SMOKING....2437
OUTBOARD SURGES, RUNS ROUGH....2438
DIAGRAMS....2439
Evinrude E-tec 75, 90 HP 2007 Service Manual....2449
INTRODUCTION....2453
MODELS COVERED IN THIS MANUAL....2454
Identifying Model and Serial Numbers....2454
MODEL DESIGNATION....2455
TYPICAL PAGE - A....2456
TYPICAL PAGE - B....2457
TYPICAL PAGE - C....2458
TYPICAL PAGE - D....2459
ABBREVIATIONS USED IN THIS MANUAL....2460
Units of Measurement....2460
List of Abbreviations....2460
ENGINE EMISSIONS INFORMATION....2461
Manufacturer’s Responsibility....2461
Dealer’s Responsibility....2461
Owner’s Responsibility....2461
EPA Emission Regulations....2461
PRODUCT REFERENCE AND ILLUSTRATIONS....2461
SYMBOLS....2462
Electrical....2462
Values....2463
NOTES....2464
Technician’s Notes....2464
Related Documents....2464
SERVICE SPECIFICATIONS AND SPECIAL TOOLS....2465
TECHNICAL DATA....2466
STANDARD TORQUE SPECIFICATIONS....2468
SPECIAL TOOLS....2469
Electrical / Ignition....2469
Fuel System....2470
Gearcase....2470
Powerhead....2472
Universal....2473
SHOP AIDS....2475
INSTALLATION AND PREDELIVERY....2479
BOAT RIGGING....2480
Remote Controls....2480
Battery Installation....2482
Battery Switches and Multiple Batteries....2483
Battery and Switch Wiring Diagrams....2485
Fuel System Requirements....2487
Cable and Hose Installation....2489
OUTBOARD INSTALLATION....2494
Hull Preparation....2494
Transom Measuring and Drilling....2495
Drilling and Hardware Diagram....2498
Lifting the Outboard....2499
Steering Systems....2499
Outboard Mounting....2501
OUTBOARD RIGGING....2502
Cable, Hose, and Wire Routing....2502
Control Cable Adjustments....2502
Electrical Harness Connections....2504
Water Pressure Gauge....2504
FUEL AND OIL PRIMING....2505
Fuel Requirements....2505
Fuel System Priming....2506
Oil Requirements....2507
Oil Injection Rate....2507
SystemCheck Low Oil Warning Test....2507
Oil Supply Priming....2508
Break-In Oiling....2508
BEFORE START-UP....2509
Gearcase Lubricant....2509
Oil Level....2509
Trim and Tilt Fluid....2509
RUNNING CHECKS....2510
SystemCheck Operation....2510
Fuel System....2510
Emergency Stop / Key Switch....2510
Remote Control Operation....2510
Start-In-Gear Prevention....2510
Tachometer Pulse Setting....2511
Water Pump Overboard Indicator....2511
Operating Temperature....2511
Idle Speed....2511
Break-In....2511
PROPELLERS....2512
Propeller Selection....2512
Propeller Hardware Installation....2513
FINAL ADJUSTMENTS....2514
Tilt Limit Switch Adjustment....2514
Trim Sending Unit Adjustment....2515
Trim Tab Adjustment....2516
Dual-Outboard Alignment....2517
NOTES....2518
Technician’s Notes....2518
Related Documents....2518
MAINTENANCE....2519
INSPECTION AND MAINTENANCE SCHEDULE....2520
ANTI-CORROSION PROTECTION....2521
Sacrificial Anodes....2521
Testing Procedure - Continuity....2521
Metallic Component Protection....2521
Exterior Finishes....2521
COOLING SYSTEM....2522
Flushing....2522
Water Intake Screens....2523
Additional Maintenance....2523
LUBRICATION....2523
Steering System....2523
Swivel Bracket and Trailering Bracket....2524
Tilt Tube....2524
Throttle and Shift Linkage....2524
Propeller Shaft....2525
Gearcase Lubricant....2525
Trim and Tilt....2526
BATTERY AND BATTERY CONNECTIONS....2526
FUEL AND OIL SYSTEMS....2527
Fuel Filter....2527
Oil Reservoir....2527
Air Silencer....2527
Hoses and Connections....2527
SPARK PLUGS....2528
Indexing....2528
STORAGE....2529
Fuel System Treatment....2529
Internal Engine Treatment....2529
Additional Recommendations....2530
PRE-SEASON SERVICE....2530
Outboard Mounting Bolts....2530
Gearcase Lubricant....2530
Battery(s)....2530
Power Trim and Tilt....2530
Operational Checks....2530
SUBMERGED ENGINES....2531
Engine Dropped Overboard (Not Running)....2531
Engine Dropped Overboard (Running)....2531
Engine Dropped Overboard (In Salt Water)....2531
Prolonged Submersion (Fresh or Salt Water)....2531
NOTES....2532
Technician’s Notes....2532
Related Documents....2532
ENGINE MANAGEMENT MODULE (EMM)....2533
DESCRIPTION....2534
EMM Functions....2534
EMM Connections....2534
SENSORS AND FUNCTIONS....2535
Internal Sensors....2535
External Sensors....2536
Internal Functions....2538
EMM INPUTS AND OUTPUTS DIAGRAM....2539
S.A.F.E. WARNING SYSTEM....2540
Activation....2540
Recovery....2540
SHUTDOWN MODE....2540
EMM DIAGNOSTICS....2541
LED Indicators....2541
Diagnostic Software Program....2542
Communication....2542
Program Information....2543
Service Codes (Faults)....2543
Static Tests....2544
Dynamic Tests....2545
Oil Control....2546
Starter Mode (Tiller/Remote Programming)....2546
Timing Verification....2546
TPS Calibration....2547
Idle Speed....2547
Fuel Injector Servicing....2547
Fuel Control Adjustment....2548
Reports....2548
Software Replacement....2549
EMM Transfer....2549
SystemCheck ENGINE MONITOR....2549
System Self-Test....2550
Service Mode....2550
Engine Running....2550
SYSTEM ANALYSIS....2551
ELECTRICAL CONNECTIONS....2552
GROUND CIRCUITS....2554
Test Procedure....2554
FUSE....2554
EMM DIAGNOSTICS....2555
LED Indicators....2555
Software Programs....2555
DIAGNOSTIC PROCEDURES....2556
Symptoms....2557
SPECIALIZED TEST PROCEDURES....2558
Dynamic Tests....2558
Testing with Timing Light....2558
Inductive Amp Meter Test....2559
Engine Monitoring Information....2559
Voltage Testing....2560
START CIRCUIT....2560
Electric Starter Operation....2560
Starter Solenoid Activation....2561
IGNITION AND ELECTRICAL CIRCUITS....2562
Stop Circuit....2562
Neutral Switch....2562
Stator Output Voltage....2562
EMM....2562
Crankshaft Position Sensor....2562
Alternator Output Voltage....2562
Capacitor....2562
Ignition Power Supply to EMM....2562
Ignition Primary Voltage....2562
Ignition Coil....2562
IGNITION OUTPUT....2563
Wiring Inspection....2563
Ignition Voltage....2563
System Voltage....2564
Static Spark Test....2564
Running Ignition Tests....2565
Ignition Primary Circuit Resistance Test....2566
Crankshaft Position Sensor (CPS) Test....2566
FUEL DELIVERY....2567
Manifold Pressure Test....2567
Vapor Separator Checks....2568
Fuel Delivery to Lift Pump....2568
FUEL INJECTOR OPERATION....2568
Neutral Switch....2568
Static Tests....2568
Dynamic Tests....2569
NOTES....2570
Technician’s Notes....2570
Related Documents....2570
ELECTRICAL AND IGNITION....2571
SERVICE CHART....2572
DASH CONNECTIONS, INSTRUMENT HARNESS....2574
IGNITION SYSTEM TESTS....2575
Sensor Resistance Tests....2575
Ignition Coil Tests....2576
Stator Tests....2577
Capacitor Test....2578
CHARGING SYSTEM TESTS....2578
12 V Charging Circuit....2578
55 V Alternator Circuit....2579
SystemCheck CIRCUIT TESTS....2580
Gauge Self-Test Check....2580
CHECK ENGINE Circuit Test....2581
WATER TEMP/ HOT Circuit Test....2581
LOW OIL Circuit Test....2582
NO OIL Circuit....2582
REMOTE CONTROL SWITCH TESTS....2582
Key Switch Test....2582
Neutral Start Circuit Test....2583
Neutral Start Switch Test....2583
Emergency Stop Switch Test....2584
ELECTRIC STARTER TESTS....2584
Starter Solenoid Test....2584
No Load Current Draw Test....2585
TILT/TRIM RELAY TEST....2586
Operation....2586
Test Procedure....2586
TACHOMETER CIRCUIT TESTS....2587
FLYWHEEL SERVICING....2588
Removal....2588
Installation....2589
TIMING ADJUSTMENTS....2590
Timing Pointer....2590
Timing Verification....2591
TPS Calibration....2591
SPARK PLUGS....2592
Inspection....2592
Indexing....2592
ELECTRIC STARTER SERVICING....2593
Removal....2593
Disassembly....2593
Cleaning and Inspection....2594
Assembly....2595
Installation....2596
CONNECTOR SERVICING....2597
DEUTSCH Connectors....2597
AMP Connectors....2598
Packard † Connectors....2600
NOTES....2602
Technician’s Notes....2602
Related Documents....2602
FUEL SYSTEM....2603
SERVICE CHART....2604
COMPONENTS....2606
Fuel Lift Pump....2606
Fuel Filter....2606
Vapor Separator....2606
Fuel Circulation Pump....2608
Fuel Manifolds....2608
Fuel Injectors....2609
FUEL SYSTEM HOSE ROUTING....2610
DIRECT INJECTION ELECTRICAL CIRCUITS....2611
Injector / Circulation Pump Circuits Diagram....2611
FUEL COMPONENT TESTS....2612
Injectors....2612
Fuel Supply....2613
FUEL COMPONENT SERVICING....2616
Relieving Fuel System Pressure....2616
Fuel Filter....2617
Fuel Lift Pump....2617
Vapor Separator....2618
Fuel Injectors....2618
Fuel Manifolds....2622
INTAKE MANIFOLD....2622
Removal....2622
Disassembly....2622
Inspection....2623
Assembly....2623
Installation....2624
OILING SYSTEM....2625
SERVICE CHART....2626
COMPONENTS....2627
Oil Tank Assembly....2627
Electrical Circuit (55 V)....2628
SystemCheck LOW and NO OIL Warning Signals....2628
Oiling System Electrical Diagram....2629
Cylinder and Crankcase....2630
Oil Supply and Distribution Diagram....2630
Oil Recirculation System....2631
Recirculation Hose Diagram....2631
PRIMING....2632
OILING RATES....2632
Oil Injection Rate....2632
Break-in Oiling....2632
OILING SYSTEM TESTS....2633
Oil Injection Pump Static Test....2633
Oil Injection Pump Voltage Test....2633
Oil Injection Pump Circuit Resistance Test....2634
Oil Flow Tests....2634
Oil-to-Fuel Check Valve Test....2636
LOW OIL Sending Unit Test....2636
NO OIL Warning Test....2636
OIL COMPONENT SERVICING....2637
Oil Distribution Hoses....2637
Oil Tank Assembly....2638
COOLING SYSTEM....2639
HOSE ROUTING AND WATER FLOW DIAGRAM....2640
ENGINE TEMPERATURE CHECK....2641
Software Method....2641
Pyrometer Method....2641
Idle Operating Temperature Troubleshooting (Below Range)....2642
COMPONENTS....2643
General Description....2643
Water Pump and Intakes....2643
Water Supply Tube....2643
Adapter Housing....2644
Pressure Relief Valve....2644
Thermostat....2645
Block Venting....2645
Water Pressure Connection....2645
OPERATION....2646
Cylinder Block / Cylinder Head Cooling....2646
EMM and Vapor Separator Cooling....2646
THERMOSTAT SERVICING....2647
Disassembly....2647
Inspection....2647
Assembly....2647
PRESSURE RELIEF VALVE SERVICING....2648
Disassembly....2648
Inspection....2648
Assembly....2648
POWERHEAD....2649
SERVICE CHART....2650
GENERAL....2652
Cylinder Compression Testing....2652
Retaining Ring Pliers....2652
REMOVAL....2653
DISASSEMBLY....2655
General....2655
Shift Linkage....2655
Throttle Linkage....2655
Crankcase....2656
Cylinder Head....2657
Connecting Rods and Pistons....2657
Crankshaft....2658
CLEANING....2660
INSPECTION....2661
Cylinder Head....2661
Crankshaft....2662
Cylinder Bore....2662
Pistons....2662
Piston Rings....2662
Bearings....2663
ASSEMBLY....2664
Crankshaft....2664
Pistons and Connecting Rods....2666
Cylinder Head....2668
Crankshaft and Connecting Rods....2669
Crankcase....2672
Shift Linkage....2674
Throttle Linkage....2675
General....2675
UPPER MOUNT SERVICING....2676
Removal....2676
Installation....2676
INSTALLATION....2677
POWERHEAD VIEWS....2681
Port Short Block....2681
Starboard Short Block....2681
Port Dressed Powerhead....2682
Starboard Dressed Powerhead....2682
Front....2683
Rear....2684
Top....2685
NOTES....2686
Technician’s Notes....2686
Related Documents....2686
MIDSECTION....2687
SERVICE CHART....2688
TILT TUBE....2690
Removal....2690
Installation....2691
EXHAUST HOUSING....2692
Removal....2692
Disassembly....2692
Cleaning and Inspection....2694
Assembly....2694
Installation....2697
STERN BRACKET....2697
Removal....2697
Disassembly....2697
Assembly....2700
GEARCASE....2703
SERVICE CHART....2704
GEARCASE TYPES....2706
PROPELLER....2706
Inspection....2706
LUBRICANT....2706
Draining....2706
Inspection....2707
Filling....2707
LEAK TEST....2707
REMOVAL AND INSTALLATION....2708
Removal....2708
Installation....2709
WATER PUMP....2710
Disassembly....2710
Inspection....2710
Assembly....2711
SHIFT ROD ADJUSTMENT....2713
DISASSEMBLY....2714
Pre-Disassembly Inspection....2714
Propeller Shaft Bearing Housing Removal....2715
Pinion Gear and Driveshaft Removal....2715
Driveshaft Service....2717
Shift Housing, Gear and Propeller Shaft Removal....2718
Water Intake Screens....2718
GEARCASE HOUSING INSPECTION....2718
BEARING AND SEAL REMOVAL....2719
Shift Housing....2719
Pinion Gear Bearing....2720
Driveshaft Bearing Housing....2721
Propeller Shaft Bearing Housing....2721
BEARING AND SEAL INSTALLATION....2722
Shift Housing....2722
Pinion Gear Bearing....2724
Driveshaft Bearing Housing....2725
Propeller Shaft Bearing Housing....2726
DRIVESHAFT SHIMMING....2727
ASSEMBLY....2728
Water Intake Screens....2728
Shift Housing, Gear, and Propeller Shaft Installation....2728
Shift Rod Housing Installation....2729
Pinion Gear and Driveshaft Installation....2730
Propeller Shaft Bearing Housing and Gear Installation....2731
TRIM AND TILT....2733
SYSTEM DESCRIPTION....2734
Manual Adjustment....2734
Trailering Bracket And Tilt Support....2734
ROUTINE INSPECTIONS....2735
General....2735
Reservoir Fluid....2735
Manual Release Valve....2735
Stern Brackets....2735
TROUBLESHOOTING....2736
ELECTRICAL CIRCUIT TESTS....2736
Relay Testing....2736
Trim and Tilt Motor Current Draw Tests....2736
Trim and Tilt Motor No Load Test....2737
Trim Gauge Test....2738
Trim Sender Test....2739
REMOVAL AND INSTALLATION....2739
Removal....2739
Installation....2741
SERVICING....2742
Disassembly....2742
Assembly....2743
ADJUSTMENTS....2744
SAFETY....2745
TABLE OF CONTENTS....2745
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....2747
Outboard Shift Systems and Safety....2748
Outboard Speed Control System and Safety....2749
Outboard Steering Control System and Safety....2750
Outboard Fuel, Electrical System, and Safety....2752
Outboard Mounting System and Safety....2755
If weakened, parts could fail later on the water, when not expected....2756
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....2757
Outboard Emergency Stop System and Safety....2758
Summing up....2760
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....2761
Handling Outboards....2761
Handling Lead/Acid Batteries....2765
Gasoline - Handle With Care!....2766
Hazardous Products....2767
Safety Awareness Test....2768
INDEX....2769
TROUBLE CHECK CHART....2777
OUTBOARD WILL NOT START....2777
OUTBOARD WILL NOT START....2778
OUTBOARD HARD TO START....2779
OUTBOARD WILL NOT SHUT OFF....2780
OUTBOARD STARTS AND STALLS....2780
OUTBOARD STARTS, LOW MAXIMUM RPM....2781
EXCESSIVE SMOKING....2781
OUTBOARD SURGES, RUNS ROUGH....2782
DIAGRAMS....2783
Evinrude E-tech 200, 225, 250 HP (V6, 3.3L, 90 degr.) Service Manual....2793
INTRODUCTION....2797
ABBREVIATIONS USED IN THIS MANUAL....2800
Units of Measurement....2800
List of Abbreviations....2800
ENGINE EMISSIONS INFORMATION....2801
Manufacturer’s Responsibility....2801
Dealer’s Responsibility....2801
Owner’s Responsibility....2801
EPA Emission Regulations....2801
MODEL DESIGNATION....2802
MODELS COVERED IN THIS MANUAL....2803
Identifying Model and Serial Numbers....2803
SERVICE SPECIFICATIONS....2804
STANDARD TORQUE SPECIFICATIONS....2806
PRODUCT REFERENCE AND ILLUSTRATIONS....2806
SPECIAL TOOLS....2807
DIAGNOSTIC TOOLS....2808
UNIVERSAL TOOLS....2808
ELECTRICAL / IGNITION TOOLS....2810
FUEL /OIL SYSTEM TOOLS....2811
POWERHEAD TOOLS....2811
GEARCASE TOOLS....2812
TRIM AND TILT TOOLS....2815
SHOP AIDS....2816
INSTALLATION AND PREDELIVERY....2819
BOAT RIGGING....2820
Remote Controls....2820
Battery Installation....2821
Battery Switches and Multiple Batteries....2822
Auxiliary Battery Charging....2824
Battery and Switch Wiring Diagrams....2825
Fuel System Requirements....2827
Oiling System Set-Up....2829
Cable and Hose Installation....2832
OUTBOARD INSTALLATION....2836
Hull Preparation....2836
Transom Measuring and Drilling....2838
Drilling and Hardware Diagrams....2840
Lifting the Outboard....2841
Steering Systems....2841
Outboard Mounting....2843
OUTBOARD RIGGING....2844
Cable, Hose, and Wire Routing....2844
Control Cable Installation....2845
Electrical Harness Connections....2847
Water Pressure Gauge....2847
CANbus Connections....2848
FUEL AND OIL PRIMING....2850
Fuel Requirements....2850
Fuel System Priming....2851
Oil Requirements....2851
Oil Injection Rate....2852
Break-In Oiling....2853
Oil Supply Priming....2853
BEFORE START-UP....2855
Gearcase Lubricant....2855
Oil Level....2855
Trim and Tilt Fluid....2855
RUNNING CHECKS....2856
Engine Monitoring System....2856
Fuel System....2856
Emergency Stop / Key Switch....2856
Remote Control Operation....2856
Start-In-Gear Prevention....2856
Tachometer Pulse Setting....2857
Water Pump Overboard Indicator....2857
Operating Temperature....2857
Idle Speed....2857
Break-In....2857
PROPELLERS....2858
Propeller Selection....2858
Propeller Hardware Installation....2859
FINAL ADJUSTMENTS....2860
Tilt Limit Switch Adjustment....2860
Trim Sending Unit Adjustment....2861
Trim Tab Adjustment....2862
Dual-Outboard Alignment....2863
NOTES....2864
Technician’s Notes....2864
Related Documents....2864
MAINTENANCE....2865
INSPECTION AND MAINTENANCE SCHEDULE....2866
ANTI-CORROSION PROTECTION....2867
Sacrificial Anodes....2867
Testing Procedure - Continuity....2867
Metallic Component Protection....2867
Exterior Finishes....2867
COOLING SYSTEM....2868
Flushing....2868
Water Intake Screens....2869
Additional Maintenance....2869
LUBRICATION....2870
Steering System....2870
Swivel Bracket and Trailering Bracket....2870
Tilt Tube....2870
Throttle and Shift Linkage....2871
Propeller Shaft....2871
Gearcase Lubricant....2871
Trim and Tilt....2873
BATTERY AND BATTERY CONNECTIONS....2874
FUEL AND OIL SYSTEMS....2874
Fuel Filter....2874
Oil Filters and Oil Reservoir....2875
Air Silencer....2875
Hoses and Connections....2875
SPARK PLUGS....2876
Indexing....2876
EXHAUST PRESSURE FITTING....2877
Operation Test....2877
Cleaning....2877
STORAGE....2878
Fuel System Treatment....2878
Internal Engine Treatment....2878
Additional Recommendations....2879
PRE-SEASON SERVICE....2879
Outboard Mounting Bolts....2879
Gearcase Lubricant....2879
Battery(s)....2879
Power Trim and Tilt....2879
Operational Checks....2879
SUBMERGED ENGINES....2880
Engine Dropped Overboard (Not Running)....2880
Engine Dropped Overboard (Running)....2880
Engine Dropped Overboard (In Salt Water)....2880
Prolonged Submersion (Fresh or Salt Water)....2880
ENGINE COVER SERVICE....2881
UPPER COVER SERVICE....2882
Latch Hook Installation....2882
Upper Cover Cap Replacement....2882
LOWER COVER SERVICE....2883
Lower Cover Removal....2883
Lower Cover Installation....2883
Latch Handle Installation....2884
Trim Switch Installation....2884
ENGINE MANAGEMENT MODULE (EMM)....2885
DESCRIPTION....2886
EMM Functions....2886
EMM Connections....2886
LED Indicators....2886
EMM INPUTS AND OUTPUTS DIAGRAM....2887
INTERNAL SENSORS....2888
EMM Temperature Sensor....2888
55 V Circuit Sensor....2888
12 V Circuit Sensor....2888
Barometric Pressure Sensor....2889
Exhaust Pressure Sensor....2889
EXTERNAL SENSORS....2889
Air Temperature Sensor....2889
Engine Temperature Sensor....2889
Oil Pressure Sensor....2890
Throttle Position Sensor....2891
Crankshaft Position Sensor....2891
INTERNAL EMM FUNCTIONS....2892
Start Assist Circuit (SAC)....2892
ROM Verification....2892
Idle Controller....2892
RPM Limiter....2892
Shift Interrupt....2892
Engine Monitor and Warning Systems....2892
Fault Code Creation and Storage....2892
ENGINE MONITORING SYSTEM....2893
System Self-Test....2893
Service Mode....2893
Engine Running....2893
S.A.F.E. WARNING SYSTEM....2894
Activation....2894
Recovery....2894
SHUTDOWN MODE....2894
Recovery....2894
DIAGNOSTIC SOFTWARE FUNCTIONS....2895
Communication....2895
Static Information....2895
Dynamic Information....2896
Stored Service Codes (Faults)....2896
Hard Faults....2896
Persistent Faults....2896
Static Tests....2896
Dynamic Tests....2897
Oil Control Settings....2898
Ignition Timing....2899
TPS Calibration....2899
Fuel Injector Servicing....2900
Reports....2900
Software Replacement....2901
EMM Transfer....2901
EMM SERVICING....2902
Removal....2902
Installation....2902
SYSTEM ANALYSIS....2903
DIAGNOSTIC PROCEDURES....2904
Visual Inspections....2904
Operational Inspections....2904
Troubleshooting....2905
DYNAMIC TESTS....2906
Cylinder Drop Tests....2906
Fuel Control Adjustment....2906
Inductive Amp Meter Test....2906
EMM LED INDICATORS....2907
Key ON....2907
Starting....2907
Running....2908
IGNITION OUTPUT TESTS....2909
Required Ignition Systems....2909
Wiring Inspection....2909
Crankshaft Position Sensor (CPS) Test....2910
System Voltage Test....2910
Ignition Voltage Test....2911
Static Ignition Test....2911
Running Ignition Tests....2912
Ignition Primary Circuit Resistance Test....2913
Ignition Coil Tests....2913
Capacitor Test....2914
FUEL DELIVERY TESTS....2914
Fuel Pump Static Test....2914
Fuel Injector Static Test....2915
Running Fuel System Tests....2915
ELECTRICAL AND IGNITION....2917
SERVICE CHART....2918
DASH CONNECTIONS, INSTRUMENT HARNESS....2920
ELECTRICAL HARNESS CONNECTIONS....2921
Engine Harness to Stator Connector....2921
EMM J1-A Connector....2921
EMM J1-B Connector....2922
EMM J2 Connector....2922
GROUND CIRCUITS....2923
EMM Ground Tests....2923
Additional Ground Tests....2923
FUSE....2923
SENSOR TESTS....2924
Crankshaft Position Sensor (CPS) Test....2924
Throttle Position Sensor (TPS) Test....2924
Engine Temperature Sensor Test....2925
Air Temperature Sensor (AT) Test....2925
STATOR TESTS....2926
Stator Resistance Tests....2926
Stator Voltage Output Test....2926
CHARGING SYSTEM TESTS....2927
12 V Charging Circuit....2927
Auxiliary Battery - Charge Wire....2928
55 V Alternator Circuit....2928
ELECTRIC START CIRCUIT....2929
Start Circuit Diagram....2929
Start Circuit Operation....2930
ELECTRIC START TESTS....2931
Starter Solenoid Test....2931
No Load Current Draw Test....2932
REMOTE CONTROL SWITCH TESTS....2933
Key Switch Test....2933
Neutral Start Circuit Test....2933
Neutral Start Switch Test....2934
Emergency Stop Switch Test....2934
TILT/TRIM RELAY TEST....2935
Operation....2935
Test Procedure....2935
SystemCheck CIRCUIT TESTS....2936
Gauge Self-Test Check....2936
CHECK ENGINE Circuit Test....2937
WATER TEMP/ HOT Circuit Test....2937
LOW OIL Circuit Test....2938
NO OIL Circuit....2938
TACHOMETER CIRCUIT TESTS....2938
FLYWHEEL AND STATOR SERVICING....2939
Flywheel Removal....2939
Stator Service....2939
Flywheel Installation....2940
TIMING ADJUSTMENTS....2941
Timing Pointer....2941
Timing Verification....2942
TPS CALIBRATION....2942
ELECTRIC STARTER SERVICING....2943
Starter Removal....2943
Starter Disassembly....2943
Starter Cleaning and Inspection....2946
Starter Assembly....2947
Starter Installation....2949
CONNECTOR SERVICING....2950
DEUTSCH Connectors....2950
AMP Connectors....2951
Packard † Connectors....2953
FUEL SYSTEM....2955
SERVICE CHART....2956
FUEL SYSTEM HOSE ROUTING....2959
FUEL SYSTEM CIRCUIT DIAGRAM....2960
COMPONENTS....2961
Fuel Lift Pump....2961
Fuel Filter....2961
Vapor Separator....2961
Fuel Circulation Pump....2962
Fuel Manifolds....2963
Fuel Injectors....2963
FUEL SYSTEM TESTS....2964
Fuel System Pressure Test....2964
Pressure Regulator Test....2965
Vapor Separator Vent Check....2965
Fuel Injector Pressure Test....2965
Fuel Injector Resistance Test....2966
Circulation Pump Resistance Test....2966
Lift Pump Pressure Test....2966
Lift Pump Vacuum Test....2967
Lift Pump Diaphragm Test....2967
Anti-Siphon Valve Test....2968
FUEL COMPONENT SERVICING....2968
Relieving Fuel System Pressure....2968
Fuel Filter Service....2969
Fuel Lift Pump Service....2970
Vapor Separator Service....2971
Fuel Manifold Service....2971
Fuel Injector Service....2972
Intake Manifold Service....2975
Installation....2976
NOTES....2978
Technician’s Notes....2978
Related Documents....2978
OILING SYSTEM....2979
SERVICE CHART....2980
OILING SYSTEM CIRCUIT DIAGRAM....2981
OIL SUPPLY DIAGRAMS - V6....2982
OIL RECIRCULATION DIAGRAMS - V6....2984
COMPONENTS....2985
Oil Tank Assembly....2985
Oil Injection Pump....2985
Oil Pressure Sensor....2985
Electrical Circuit (55 V)....2986
LOW OIL Warning....2986
NO OIL Warning....2986
Cylinder and Crankcase....2986
Oil Recirculation System....2987
OIL CONTROL SETTINGS....2988
Oil Priming....2988
Oiling Rates....2988
Break-in Oiling....2988
OILING SYSTEM TESTS....2989
Oil Injection Pump Static Test....2989
Oil Injection Pump Voltage Test....2989
Oil Injection Pump Circuit Resistance Test....2990
Oil Supply Vacuum Test....2990
Oil Injection Pump Function Test....2991
Oil Injection Fittings Flow Test....2991
LOW OIL Sending Unit Test....2991
OIL COMPONENT SERVICING....2992
Oil Distribution Hoses....2992
Oil Injection Pump....2993
COOLING SYSTEM....2995
HOSE ROUTING AND WATER FLOW DIAGRAM....2996
COMPONENTS....2997
Water Pump and Intakes....2997
Water Supply Tube....2997
Adapter Housing....2997
Pressure Relief Valve....2997
Thermostats....2998
Block Venting....2998
OPERATION....2998
Cylinder Block / Cylinder Head Cooling....2998
EMM and Vapor Separator Cooling....2999
ENGINE TEMPERATURE CHECK....3000
Software Method....3000
Pyrometer Method....3000
Idle Operating Temperature Troubleshooting (Below Range)....3001
THERMOSTAT SERVICING....3002
Disassembly....3002
Inspection....3002
Assembly....3002
PRESSURE RELIEF VALVE SERVICING....3003
Disassembly....3003
Inspection....3003
Assembly....3003
NOTES....3004
Technician’s Notes....3004
Related Documents....3004
POWERHEAD....3005
SERVICE CHART....3006
Taper Pin Tool....3008
POWERHEAD REMOVAL....3009
POWERHEAD DISASSEMBLY....3011
General....3011
Throttle Linkage Removal....3011
Shift Linkage Removal....3011
Crankcase Disassembly....3012
Cylinder Head Removal....3013
Connecting Rods and Pistons....3013
Crankshaft Removal....3014
CYLINDER BLOCK CLEANING....3017
POWERHEAD INSPECTION....3018
Cylinder Head....3018
Crankshaft....3018
Cylinder Bore....3019
Pistons....3019
Piston Rings....3019
Bearings....3020
POWERHEAD ASSEMBLY....3020
Crankshaft....3020
Pistons and Connecting Rods....3023
Cylinder Head Installation....3024
Crankshaft and Connecting Rods....3025
Crankcase Assembly....3028
Shift Linkage Installation....3029
Throttle Linkage Installation....3030
Final Powerhead Assembly....3030
POWERHEAD INSTALLATION....3031
POWERHEAD VIEWS....3034
Port Hose Routings....3034
Starboard Hose Routings....3035
Port....3036
Starboard....3037
Front....3038
Rear....3039
Top....3040
MIDSECTION....3041
SERVICE CHART....3042
TILT TUBE....3045
Removal....3045
Installation....3046
EXHAUST HOUSING....3047
Exhaust Housing Removal....3047
Exhaust Housing Disassembly....3048
Cleaning and Inspection....3049
Exhaust Housing Assembly....3049
Exhaust Housing Installation....3052
STERN BRACKET....3053
Removal....3053
Stern Bracket Disassembly....3053
Stern Bracket Assembly....3055
EXHAUST RELIEF MUFFLER ASSEMBLY....3058
GEARCASE....3059
SERVICE CHARTS....3060
GEARCASE TYPES....3066
Housing Identification....3066
Housing Profiles....3067
PROPELLER SERVICE....3068
Inspection....3068
GEARCASE LEAK TEST....3068
SHIFT INTERRUPT SWITCH....3069
GEARCASE REMOVAL AND INSTALLATION....3069
Gearcase Removal....3069
Gearcase Installation....3070
WATER PUMP SERVICE....3072
Disassembly....3072
Inspection....3072
Assembly....3073
SHIFT ROD ADJUSTMENT....3075
GEARCASE - STANDARD ROTATION....3076
GEARCASE DISASSEMBLY....3076
Pre-Disassembly Inspection....3076
Propeller Shaft Bearing Housing Removal - “L” and “M” Type....3077
Propeller Shaft Bearing Housing Removal - “L2” and “M2” Type....3078
Pinion Gear and Driveshaft Removal....3079
Driveshaft Service....3081
Shift Housing, Gear and Propeller Shaft Removal....3081
Water Intake Screens....3082
GEARCASE HOUSING INSPECTION....3082
SHIFTER, BEARING AND SEAL SERVICING....3083
Shift Housing Disassembly....3083
Shift Housing Assembly....3084
Pinion Bearing Removal....3086
Pinion Bearing Installation....3086
Driveshaft Bearing Housing Service....3087
Propeller Shaft Bearing Housing Service....3088
DRIVESHAFT SHIMMING....3091
GEARCASE ASSEMBLY....3093
Water Intake Screens....3093
Shift Housing, Gear, and Propeller Shaft Installation....3093
Shift Rod Cover....3093
Pinion Gear and Driveshaft Installation....3095
Propeller Shaft Bearing Housing and Gear Installation - “L” and “M” Type....3096
Propeller Shaft Bearing Housing and Gear Installation - “L2” Type....3097
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....3098
Final Assembly and Adjustment....3099
GEARCASE - COUNTER ROTATION....3100
GEARCASE DISASSEMBLY....3100
Pre-Disassembly Inspection....3100
Propeller Shaft Bearing Housing Removal - “M” Type....3100
Propeller Shaft Bearing Housing Removal - “M2” Type....3100
Pinion Gear Removal and Driveshaft Servicing....3101
Shift Housing, Gear and Propeller Shaft Removal....3102
Water Intake Screens....3102
GEARCASE HOUSING INSPECTION....3102
SHIFTER, BEARING AND SEAL SERVICING....3103
Shift Housing Disassembly....3103
Shift Housing Assembly....3104
Pinion Bearing....3106
Propeller Shaft Bearing Housing and Forward Gear....3106
DRIVESHAFT SHIMMING....3109
GEARCASE ASSEMBLY....3111
Water Intake Screens....3111
Shift Housing, Gear, and Propeller Shaft Installation....3111
Shift Rod Cover....3111
Pinion Gear and Driveshaft Installation....3111
Propeller Shaft Bearing Housing and Gear Installation - ”M” Type....3111
Propeller Shaft Bearing Housing and Gear Installation - “M2” Type....3112
Final Assembly and Adjustment....3113
NOTES....3114
Technician’s Notes....3114
Related Documents....3114
TRIM AND TILT....3115
SERVICE CHART....3116
SYSTEM DESCRIPTION....3117
Manual Adjustment....3117
Trailering Bracket and Tilt Support....3117
MODES OF OPERATION....3118
Trim-OUT / Tilt-UP Mode....3118
2....3118
Tilt-DOWN / Trim-IN Mode....3119
Impact Relief....3120
1....3120
Shallow Water Drive Tilt Relief....3121
Thermal Expansion Relief....3121
Manual Release - UP....3122
Manual Release - DOWN....3123
ROUTINE INSPECTIONS....3124
General....3124
Reservoir Fluid....3124
Manual Release Valve....3124
Stern Brackets....3124
TROUBLESHOOTING....3124
Symptoms Chart....3125
Service Procedures....3125
Pressure Leakdown Test....3125
ELECTRICAL CIRCUIT TESTS....3128
Relay Testing....3128
Trim and Tilt Motor Current Draw Tests....3128
Trim and Tilt Motor No Load Test....3129
Trim Gauge Test....3130
Trim Sender Test....3130
TRIM AND TILT SERVICE....3131
Removal....3131
Installation....3132
Disassembly....3134
Tilt Piston Removal....3136
Tilt Piston Identification....3137
Tilt Piston Assembly....3138
Tilt Rod Assembly....3138
Trim Rod Removal....3140
Trim Rod Assembly....3141
Manifold and Reservoir Installation....3142
Trim Rod Installation....3143
Tilt Rod Installation....3143
Motor Installation....3144
ADJUSTMENTS....3145
NOTES....3146
Technician’s Notes....3146
Related Documents....3146
SAFETY....3147
TABLE OF CONTENTS....3147
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM....3149
Outboard Shift Systems and Safety....3150
Outboard Speed Control System and Safety....3151
Outboard Steering Control System and Safety....3152
Outboard Fuel, Electrical System, and Safety....3154
Outboard Mounting System and Safety....3157
If weakened, parts could fail later on the water, when not expected....3158
Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety....3159
Outboard Emergency Stop System and Safety....3160
Summing up....3162
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM....3163
Handling Outboards....3163
Handling Lead/Acid Batteries....3167
Gasoline - Handle With Care!....3168
Hazardous Products....3169
Safety Awareness Test....3170
INDEX....3171
TROUBLE CHECK CHART....3181
OUTBOARD WILL NOT START....3181
OUTBOARD WILL NOT START....3182
OUTBOARD HARD TO START....3183
OUTBOARD WILL NOT SHUT OFF....3184
OUTBOARD STARTS AND STALLS....3184
OUTBOARD STARTS, LOW MAXIMUM RPM....3185
EXCESSIVE SMOKING....3185
OUTBOARD SURGES, RUNS ROUGH....3186
DIAGRAMS....3187
Evinrude_Johnson 1.5-70HP Outboard Engine_Motor Service Manual....3197
Evinrude_Johnson 1.5HP thru 40HP Outboard Engine Tune-Up & Repair Manual....3749
Evinrude_Johnson 2HP-40HP Outboard Engine Shop Manual (incld. Electric Motor) 1973-1990....4155
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual (incld. Sea Drives) 1973-1989....4531
Quick Reference Data....4538
General Information....4543
Tools & Techniques....4563
Troubleshooting....4575
Lubrication, Maintenance & Tune Up....4734
Engine Sychronisation & Linkage Adjustments....4758
Fuel System....4806
Ignition & Electrical Systems....4833
Power Head....4858
Gearcase....4919
Power Trim & Tilt Systems....4956
Sea Drives....4984
Wiring Diagrams....4998
Evinrude_Johnson 48HP-235HP Outboard Engine Service Manual....5090
TOC....5090
Quick Reference Data....5094
Introduction....5099
1 - General Information....5100
2 - Tools and Techniques....5119
3 - Troubleshooting....5132
4 - Lubrication, Maintenance and Tune-up....5292
5 - Engine Syncronization and Linkage Adjustments....5316
6 - Fuel System....5364
7 - Ignition and Electrical Systems....5391
8 - Power Head....5416
9 - Gearcase....5474
10 - Power Trim and Tilt Systems....5519
11 - Oil Injection Systems....5547
12 - Sea Drives....5560
Index....5574
Wiring Diagrams....5577
Evinrude_Johnson Outboards 1992-2001 Service Manual 65-300HP SM-05190....5669
Contents....5669
Chapt 1 - General Info, Safety & Tools....5671
Chapt 2 - Maintenance....5699
Chapt 3 - Fuel System....5785
Chapt 4 - Ignition & Electrical Systems....5881
Chapt 5 - Lubrication & Cooling....6003
Chapt 6 - Engine Mechanical....6041
Chapt 7 - Gearcase....6081
Chapt 8 - Trim & Tilt Systems....6119
Chapt 9 - Remote Controls....6149
Chapt 10 - Hand Rewind Starter....6165
Glossary....6177
Master Index....6181
