Evinrude E Tec 2009 200 225 250 300 SM 04120
Evinrude E Tec 2009 200 225 250 300 SM 04120
Evinrude E Tec 2009 200 225 250 300 SM 04120
BRP US Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® Nut Lock™
2
INTRODUCTION
INTRODUCTION
CONTENTS
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE EMISSIONS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MANUFACTURER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DEALER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OWNER’S RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EPA EMISSION REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MODELS COVERED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3
SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained Always follow common shop safety practices. If
technicians who are already familiar with the use you have not had training related to common shop
of Evinrude®/Johnson® Special Tools. This man- safety practices, you should do so to protect your-
ual is not a substitute for work experience. It is an self, as well as the people around you.
organized guide for reference, repair, and mainte-
It is understood that this manual may be trans-
nance of the outboard(s).
lated into other languages. In the event of any dis-
This manual uses the following signal words iden- crepancy, the English version shall prevail.
tifying important safety messages.
To reduce the risk of personal injury, safety warn-
DANGER ings are provided at appropriate times throughout
the manual.
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in DO NOT make any repairs until you have read the
death or serious injury. instructions and checked the pictures relating to
the repairs.
WARNING
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support
the outboard’s weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Twist and remove all spark plug leads.
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully
relieve fuel system pressure.
Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent.
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
6
INTRODUCTION
ENGINE EMISSIONS INFORMATION
7
INTRODUCTION
MODEL DESIGNATION
MODEL DESIGNATION
STYLE: LENGTH:
J = Johnson = 15” Std.
E = Evinrude L = 20” Long
Y = 22.5” Special
X = 25” X-long MODEL RUN
PREFIX HORSEPOWER or SUFFIX
Z = 30” XX-long
B E 200 DP X SE E
DESIGN FEATURES: MODEL YR:
AP = Advanced Propulsion I =1
B = Blue Paint N=2
C = Counter Rotation T =3
D = Evinrude E-TEC™ R=4
E = Electric Start w/Remote Steering O=5
F = Direct-Injection D=6
G = Graphite Paint U=7
H = High Output C=8
J = Jet Drive E=9
M = Military S=0
P = Power Trim and Tilt Ex: SE = 2009
R = Rope Start w/Tiller Steering
S = Saltwater Edition
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
8
INTRODUCTION
MODELS COVERED IN THIS MANUAL
9
INTRODUCTION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
HP 200 225 250
Full Throttle
4500–5800 RPM
Operating Range
200 HP 225 HP
250 HP (187 kw)
Power (149 kw) (168 kw)
@ 5150 RPM
@ 5150 RPM @ 5150 RPM
Idle RPM in Gear 500 ± 50
Standard Rotation Models: P/N 436080 or P/N 396277
Test Propeller
Counter Rotation Models: P/N 436081 or P/N 398674
Weight 20 in. (L) Models: 503 lbs. (228 kg)
(may vary depending 25 in. (X) Models: 524 lbs. (238 kg)
on model) 30 in. (Z) Models: 530 lbs. (240 kg)
ENGINE
10
INTRODUCTION
SERVICE SPECIFICATIONS
Minimum Battery
750 CCA (940 MCA) below 32°F (0°C)
Requirements
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuse P/N 967545 – 10 A
Thermostat 143°F (62°C)
COOLING
11
INTRODUCTION
SERVICE SPECIFICATIONS
HP 250 H 300
Full Throttle
4500–6000 RPM 5000–6000 RPM
Operating Range
250 HP 300 HP
Power (187 kw) (234 kw)
@ 5250 RPM @ 5500 RPM
Idle RPM in Gear 500 ± 50
Standard Rotation Models: P/N 436080 or P/N 396277
Test Propeller
Counter Rotation Models: P/N 436081 or P/N 398674
Weight 20 in. (L) Models: 507 lbs. (230 kg)
(may vary depending 25 in. (X) Models: 528 lbs. (239 kg)
on model) 30 in. (Z) Models: 534 lbs. (242 kg)
ENGINE
12
INTRODUCTION
SERVICE SPECIFICATIONS
HP 250 H 300
675 CCA (845 MCA); or
ELECTRICAL
Minimum Battery
750 CCA (940 MCA) below 32°F (0°C)
Requirements
(Use a 107 amp-hr battery for extreme applications.)
Alternator Dual Voltage 50 Amp with Voltage Regulator and Battery Isolation
Tachometer Setting 6 pulse (12 pole)
Charging Isolator Integral, Terminal on Engine Harness
Engine Fuses P/N 967545 – 10 A
Thermostat 143°F (62°C)
COOLING
13
INTRODUCTION
STANDARD TORQUE SPECIFICATIONS
14
SPECIAL TOOLS
SPECIAL TOOLS
1
TABLE OF CONTENTS
DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
UNIVERSAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ELECTRICAL / IGNITION TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL /OIL SYSTEM TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
POWERHEAD TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GEARCASE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRIM AND TILT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SHOP AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
15
SPECIAL TOOLS
DIAGNOSTIC TOOLS
DIAGNOSTIC TOOLS
Diagnostic Software P/N 765011 765011 Bootstrap tool P/N 586551 002276 Interface cable P/N 437955 45583
UNIVERSAL TOOLS
Universal Puller Set P/N 378103 32885 Lifting eye P/N 321537 23701 Lifting ring assembly P/N 396748 000669
Slide hammer P/N 391008 CO1577 Slide hammer P/N 432128 15345 Flywheel holder P/N 771311 42938
Small puller jaws P/N 432131 23150 Large puller jaws P/N 432129 23148 Bearing puller jaws P/N 432130 23149
16
SPECIAL TOOLS
UNIVERSAL TOOLS
Slide hammer adapter P/N 390898 15356 Puller Bridge – 432127 23146 Syringe P/N 346936 50243
Tilt tube nut wrench P/N 342680 46879 Tilt tube service kit P/N 434523 33249 Oetiker† pincers, P/N 787145 001081
Temperature gun P/N 772018 45240 Fresh water flusher P/N 500542 50110
17
SPECIAL TOOLS
ELECTRICAL / IGNITION TOOLS
Digital multimeter DRC7265 Peak reading voltmeter 49799 Test probe kit P/N 342677 45241
Ohms resolution 0.01 P/N 507972
Purchase through local supplier
Crimping pliers P/N 322696 30387 Stator Test Adapter P/N 5006211 004222 Tachometer/timing light P/N 507980 49789
18
SPECIAL TOOLS
FUEL /OIL SYSTEM TOOLS
Fuel pressure gauge (60 PSI) 005339 Fuel pressure gauge (15 PSI) 004560 Injector test fitting kit 002465
P/N 5007100 P/N 5006397 P/N 5005844
90° fitting, P/N 353322 90° fitting, P/N 353322
POWERHEAD TOOLS
Cylinder bore gauge P/N 771310 45303 Rod cap alignment fixture 21596 Torquing socket P/N 346187 50242
P/N 396749
Piston stop tool P/N 342679 46543 Guide rods 000828 Crankshaft bearing and sleeve 21953C
Replacement tip P/N 5006098 P/N 383175 installer P/N 338649
19
SPECIAL TOOLS
GEARCASE TOOLS
1 2
Wrist pin pressing tool 23668 1. Wrist pin retaining ring driver DR1641 Seal installation tool P/N 325453 23651
P/N 396747 P/N 396747
2. Wrist pin cone P/N 331913
GEARCASE TOOLS
Universal Driveshaft Shimming Tool 002601 Universal Pinion Bearing Remover 002805 Universal shift rod height gauge 32872
P/N 5005925 and installer kit P/N 5005927 P/N 389997
1. Lower Driveshaft Shimming Bolt
(S2 gearcase) P/N352878
20
SPECIAL TOOLS
GEARCASE TOOLS
Prop shaft bearing housing 006783 Prop shaft bearing housing 006784 Prop shaft bearing housing 006788
installers P/N 354058 (L2) remover/puller P/N 354060 alignment pins P/N 354140
P/N 354057 (M2)
Gearcase Alignment Gauge Kit 004315 Gauging Head, “M2” Type 006822 Gauging Head, “L2” Type 006823
P/N 5006349 Gearcases, P/N 5007749 Gearcases, P/N 5007750
Backing plate P/N 325867 23621 Bearing Installation Tool 32519 Spanner wrench P/N 432400 15358
P/N 339778
Driveshaft socket P/N 311875 23261 Driveshaft Puller P/N 390706 32884 Prop shaft bearing installer 15355
P/N 432401
21
SPECIAL TOOLS
GEARCASE TOOLS
1 2
Slide hammer adapter P/N 432398 15356 Driveshaft seal protector 23692 1. Pinion nut holder P/N 334455 40371
P/N 318674 2. Wrench retainer P/N 341438
Lower Driveshaft Puller P/N 342681 47257 Prop shaft bearing installer 32880 Seal installation tool P/N 330268 32924
P/N 339750
Pinion nut starting tool P/N 342216 40372 Prop shaft housing seal installer 32973 Seal installation tool P/N 354056 006824
P/N 336311
22
SPECIAL TOOLS
TRIM AND TILT TOOLS
Gauge and collar assembly 33023 Trim/tilt service kit P/N 390010 33013 Tilt cylinder seal protector 23694
P/N 983975 P/N 326005
Hydraulic cylinder rod holder 23665 Tilt cylinder end cap remover 005340 Spanner wrench P/N 912084 32213
P/N 983213 P/N 352932, for single-piston
tilt systems
2 1 1 2
1. Trim/tilt service kit P/N 434524 27340 Tilt cylinder end cap remover 33741 1. Trim cylinder end cap 33742A
2. Replacement o-ring kit for P/N 326485, for three-piston remover/installer P/N 436710
adapter tips P/N 434729 tilt systems 2. Replacement tip for 436710
23
SPECIAL TOOLS
SHOP AIDS
SHOP AIDS
Cleaning Solvent P/N 771087 D.P.L. Spray P/N 777183 Oil - XD30™ P/N 764349
“6 in 1” Multi-Purpose Lubricant P/N 777192 Oil - XD50™ P/N 764354 HPF XR™ Gear Lube P/N 778749
Oil - XD100™ P/N 764357 Anti-Corrosion Spray P/N 777193 HPF PRO Gearcase Lube P/N 778755
Engine Tuner P/N 777185 Silicone spray P/N 775630 Moly Lube P/N 175356
24
SPECIAL TOOLS
SHOP AIDS
Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Electrical Grease P/N 503243
P/N 777186 P/N 775612
Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 2 + 4™ Fuel conditioner P/N 775613
Triple-Guard® Grease P/N 508298 Starter Bendix Lube P/N 337016 Gel-Seal and Gasket Remover P/N 771050
Needle Bearing Grease, P/N 378642 Biodegradeable TNT Fluid Permatex† No. 2, P/N 910032
P/N 763439
25
SPECIAL TOOLS
SHOP AIDS
RTV Silicone Sealant P/N 263753 Gasket Sealing Compound P/N 508235 Thermal Joint Compound P/N 322170
Fuel System Cleaner P/N 763681 Pipe Sealant with Teflon P/N 910048 Instant Bonding Adhesive P/N 509955
26
INSTALLATION AND PREDELIVERY
27
INSTALLATION AND PREDELIVERY
BOAT RIGGING
WARNING
The remote control used must have start-
in-gear prevention. This feature can pre-
vent injuries resulting from unexpected
boat movement when the outboard starts.
3
1. Emergency stop clip 002817
2. Safety lanyard
3. Key switch with emergency stop feature
28
INSTALLATION AND PREDELIVERY
BOAT RIGGING
29
INSTALLATION AND PREDELIVERY
BOAT RIGGING
2 40–250 HP
1 to 10 Ft. 4 Gauge
(.3 to 3 m)
1
Marine Style Battery Post DR5103
11 to 15 Ft. 2 Gauge
1. Starwasher (3.4 to 4.6 m)
2. Hex nut
3. Terminal Insulator 16 to 20 Ft. 1 Gauge
(4.9 to 6.1 m)
IMPORTANT: Do not use wing nuts to fasten
ANY battery cables. Wing nuts can loosen and
cause electrical system damage not covered
Battery Switches and Multiple
under warranty. Batteries
A multiple battery setup, including marine battery
Tighten all connections securely. Apply Triple-
selector switches, can provide flexibility in single
Guard grease to prevent corrosion.
and dual outboard installations.
30
INSTALLATION AND PREDELIVERY
BOAT RIGGING
31
INSTALLATION AND PREDELIVERY
BOAT RIGGING
32
INSTALLATION AND PREDELIVERY
BOAT RIGGING
2
S
S
BOTH
ON
1 2
OFF OFF
+ #1 + #1 + #2
PRIMARY PRIMARY SECONDARY
000135rev1
#1 #2
S
BOTH BOTH
1 1 2 1 2 2
OFF OFF
+ + #1 + #2 + #2
#1
PRIMARY SECONDARY SECONDARY PRIMARY
33
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Two outboards: One primary starting battery for each outboard; one isolated accessory battery
#1 #2
S
S
BOTH BOTH
1 2 1 2
OFF OFF
+ #1 + + #2
PRIMARY ACCESSORY PRIMARY
Two outboards: One primary starting battery for each outboard; two isolated accessory batteries
#1 #2
S
S
BOTH BOTH
1 2 1 2
OFF OFF
+ #1 + #1 + #2 + #2
PRIMARY ACCESSORY ACCESSORY PRIMARY
34
INSTALLATION AND PREDELIVERY
BOAT RIGGING
35
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Fuel Filters
Boat-mounted fuel filters and water-separating
fuel filter assemblies must meet the required fuel
flow and filter specification. The filter must be
mounted to a rigid surface above the “full” level of
the fuel tank and accessible for servicing.
1 2 3
Typical Fuel Supply Configuration DRC6797
1. Primer bulb
2. Water separating fuel filter
3. Anti-siphon valve, in fuel pick-up of tank
36
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Select a mounting location that provides: IMPORTANT: Be sure box includes drain holes
• A solid place to mount the tank; so it does not fill with water and contaminate oil.
• A dry location that prevents exposure to rain or
spraying water;
• Access for adding oil;
• Access to oil-primer bulb; and
• Interference-free hose and wire routing to out-
board.
If necessary, the oil tank can be mounted further
from the outboard than the supplied hoses and
harness allow. The maximum length of oil supply
hose that can be fitted to the oil tank is 25 ft.
(7.6 m).
2 2
37
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Place floor bracket on center line between end 1.8 GALLON TANK
lines. Use the inner bracket holes as guides to drill Place rods into floor bracket and secure floor
two 5/32 in. (4 mm) pilot holes. bracket with lag bolts.
1 1
2 2
COB5381
1. Rods 22149A
2. Lag bolts
3 GALLON (11.4 L) TANK
Place rods into floor bracket and secure floor Place oil tank onto floor bracket. If cover is not
bracket with lag bolts. pre-assembled, route oil supply hose and harness
through the cover and position cover on the oil
tank. Attach spring-loaded rods to cover.
1 1
2 2
1. Rods 22241B
2. Lag bolts
1. Crossbar DRC7418
38
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Installation Recommendations
• Select a location on the deck of the boat that is
above the oil tank fill cap.
• Select a deck location which allows the required
length of 1½ in. I.D. fill hose to route as directly
and as vertically as possible.
• Avoid inappropriate hose routings that could
distort the fill tube or tank tube.
• Refer to installation instructions provided with
remote oil fill kit.
A slanted area of the deck will allow water to DRC8123
drain away from the fill and is best suited for
the installation. Additional Items Required
• 1½ in. I.D. fill hose cut to required length. Fill
hose (P/N 123956) is available in 25 ft. (7.6 m)
lengths.
• Two corrosion resistant 2 in. (50 mm) hose
clamps.
39
INSTALLATION AND PREDELIVERY
BOAT RIGGING
6 7 8 9
Typical outboard installation DRC6487
1. Oil tank
2. Anti-siphon valve
3. Water separating fuel filter
4. Starting battery
5. Accessory battery Typical Large Splash Well DRC7797
6. Flexweave protective sleeve
7. Access cover
8. Primer bulb
9. Battery switch
40
INSTALLATION AND PREDELIVERY
BOAT RIGGING
Fuel Hose
The fuel hose may be routed outside of the pro-
tective sleeve or conduit. Electric primers or man-
ual primers may not require this consideration.
1 2
Battery Cables 1. Fuel supply hose and fuel fitting - 3/8 in. (9 mm) 003963
Evinrude outboards are equipped with premium 2. Oil supply hose and fitting - 1/4 in. (6 mm)
quality battery cables that should be long enough
for most installations.
41
INSTALLATION AND PREDELIVERY
BOAT RIGGING
42
INSTALLATION AND PREDELIVERY
BOAT RIGGING
000108
DP0886
1 2
1. Open clamp 000092
2. Closed clamp
000091
43
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
1029A
Mounting Surface
30501 Inspect transom surface before drilling mounting
holes.
• The transom should meet ABYC Standards.
• The transom must be flat.
• The transom angle should be approximately 14
degrees.
• Check transom strength and height.
The stern brackets must contact the flat surface of
the transom. Modify trim that prevents the stern
brackets from resting against the transom surface.
Do not modify stern brackets.
44
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
45
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
1 2 3 4
1. Chine DR5568
2. Strake
3. Keel
4. Hull centerline
Dual-Outboard Centerlines
The following table lists standard ABYC centerline
spacing between outboards in dual installations:
1 2 3
V4 and V6 26 in. (660 mm) 1. Port centerline DRC5527B
2. Hull centerline
3. Starboard centerline
Some applications may require changes in this
dimension to avoid strakes, to adjust for transom
height, or for performance reasons. Best perfor-
mance can be determined only through testing.
Refer to boat manufacturer for recommendations.
46
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
Transom drill fixture, P/N 434367 or P/N 385368, IMPORTANT: Be sure to drill the required holes
may be used as a guide for correct hole place- perpendicular to transom surface.
ment. If drill fixture is unavailable, refer to Drilling
and Hardware Diagrams on p. 48 for measure-
ments.
47
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
2 1 2
6 7/16" 6 7/16"
2'' (136.5mm) (136.5mm) 2"
(50.8mm)
(50.8mm)
3 3
90˚
9
5 10 11 12
8" 6 8"
(203.2mm) 7 (203.2mm)
90˚ 8
3 4 15/16" 3
4 15/16"
(125.4mm) (125.4mm)
1
000133m
Quantity
1. Center of Transom 5. Bolt * 4 * Choose from the following bolt sizes:
2. Top of Transom 6. 318272 Plate 2 327053 3 in. (76 mm)
3. 1/2” Bolt Hole Locations 7. 318273 Retainer 2 318573 3 1/2 in. (89 mm)
4. Outside of Transom 8. 319886 Screw 4 313327 4 in. (102 mm)
9. 307238 Washer 2 336676 4 1/2 in. (114 mm)
10. 320248 Washer 4 331578 5 in. (127 mm)
11. 313623 Nut 4 321577 6 in. (152 mm)
12. 318572 Cap 4
48
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
WARNING
DO NOT use cable over pulley steering on
40 HP and larger outboards.
1. Lifting fixture 002419
2. 1 3/4 in.screws
49
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
50
INSTALLATION AND PREDELIVERY
OUTBOARD INSTALLATION
Test outboard and boat performance at different Position the square aluminum transom mounting
heights until the best performance is achieved. plates (when applicable) so the retainer holes are
horizontal.
IMPORTANT: Be sure that outboard water
pressure is not adversely affected by the mount- Position hex head of bolt with flats toward holes in
ing height of the outboard. the mounting plates. Install retainer over hex head
of the bolt and secure it with screws provided.
Mounting Bolt Installation
Install all washers and nuts. Tighten to a torque of
IMPORTANT: Use a marine sealant rated for 40 ft. lbs. (54 N·m).
above or below waterline use. RTV silicone is not
approved for below waterline use. Polyurethane WARNING
sealants are not easily removed and may damage If either side of the transom deforms or
outboard or boat mounting surfaces. cracks when the bolts are tightened to
Apply marine sealer under hex heads of bolts, on their recommended torque, the transom
the mounting plates, and to the bolt shanks. construction may not be adequate or may
be deteriorated. Structural failure of the
transom could result in loss of boat control
and injury to the occupants.
0078A
51
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
CAUTION
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads.
52
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
board side of the powerhead. Secure all cables • Use long nose pliers to insert straight section of
with clamps. clip into linkage pin hole.
53
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
Install trunnion cover and screw. Tighten retaining Place throttle cable on throttle lever pin and install
screw to a torque of 60 to 80 in. lbs. (7 to 9 N·m). washer and retainer clip.
1 2
1. Shift cable retainer clip and washer 005038 1. Throttle linkage, idle stop against crankcase 003968
2. Shift cable trunnion
54
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
Electrical Harness Connections Install battery cables on starter solenoid and main
ground stud.
Remove harness connector cover.
2 1
2
Before installing electrical connectors, check that IMPORTANT: BE SURE all harnesses and
the seal is in place. Clean off any dirt from con- wires are not pinched, cannot contact flywheel,
nectors. Apply a light coat of Electrical Grease™ and do not interfere with moving throttle or shift
to the seal. linkages.
55
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
Use a CANbus Ignition Harness, in place of the Route the harnesses around the starboard side of
standard MWS harness, to connect the outboard the powerhead along the same path as the battery
to the key switch and trim/tilt control. Seal unused cables.
SystemCheck connector with 6-Pin Connector
Seal, P/N 586076.
56
INSTALLATION AND PREDELIVERY
OUTBOARD RIGGING
If a CANbus water pressure gauge is used, install Use Evinrude Diagnostics software to activate
Water Pressure Transducer Kit, P/N 5006214, in CANbus control functions in the EMM. From the
the cylinder block. Settings screen, select Engine Options.
2
1
57
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
58
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
Fuel System Priming Observe all fuel lines, both in the boat and on the
outboard. Repair any fuel leaks.
Vent Line Clamp
In compliance with Federal Regulations, all out- WARNING
boards with a fuel vapor separator must be
Failure to check for fuel leaks could allow a
shipped with a vent line clamp installed. This 2
leak to go undetected, resulting in fire or
clamp must be removed before priming the fuel
explosion and may cause personal injury
system or starting the outboard for the first time.
or property damage.
Oil Requirements
Evinrude/Johnson XD100, XD50, or XD30 out-
board oils are recommended for use in Evinrude
E-TEC outboards. If these oils are not available,
you must use a TC-W3 certified oil.
59
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
The XD100 setting provides an option to run the An XD100 Outboard Oil Decal, P/N 352369, is
outboard at a reduced oil injection rate. This set- available to label boats equipped with outboards
ting REQUIRES the use of Evinrude XD100 out- that have been programmed for the reduced oil
board lubricant and is not recommended for all injection ratio.
applications.
60
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
61
INSTALLATION AND PREDELIVERY
FUEL AND OIL PRIMING
Observe oil flow through the oil distribution hoses. Small bubbles are acceptable. Large bubbles
must be eliminated through continued priming.
1
3 2
1. Oil distribution hose 004398
2. Small bubbles
3. Large bubbles
1. Oil distribution hoses (7) 004224 IMPORTANT: All clear “blue” oil distribution
hoses on the powerhead should fill with oil as the
Make sure that oil flows through the rear oil distri- air is purged from the lines.
bution manifold to the cylinder block fittings.
Repair any fuel or oil leaks.
62
INSTALLATION AND PREDELIVERY
BEFORE START-UP
63
INSTALLATION AND PREDELIVERY
RUNNING CHECKS
64
INSTALLATION AND PREDELIVERY
RUNNING CHECKS
Break-In
When the outboard is delivered, refer the cus-
tomer to the break-in information in the Opera-
tor’s Guide.
65
INSTALLATION AND PREDELIVERY
PROPELLERS
6 7
2
4
1. Percentage of horsepower (kw) DR1261
2. Engine RPM
3. Horsepower curve
4. Full throttle operating range
5. Midpoint of full throttle operating range, horse-
power rating in kilowatts (kw)
6. Engine is overloaded at full throttle
7. Engine is overspeeding at full throttle
2 1
IMPORTANT: If the propeller blades have too 1. Right-hand rotation (clockwise) 000033
2. Left-hand rotation (counterclockwise)
much pitch, the engine will operate below its nor-
mal range at full throttle. Power will be lost, and
powerhead damage could occur. If the propeller WARNING
blades have too little pitch, the engine will operate
For dual-outboard installations, always
above its normal range and damage from over-
check to be sure propellers are installed on
speeding could occur.
the correct engines before aggressively
operating the boat.
66
INSTALLATION AND PREDELIVERY
PROPELLERS
Install propeller on propeller shaft by aligning Wedge a block of wood between propeller blade
splines and pushing until seated on the thrust and the anti-ventilation plate.
bushing.
1 001992
67
INSTALLATION AND PREDELIVERY
FINAL ADJUSTMENTS
Check the clearance between outboard(s) and the 1. Lower adjustment tab DR4268
boat’s motor well and transom area. Tilt out- 2. Upper adjustment tab
board(s) to highest point of clearance and turn the
steering system lock to lock. Check the adjustment by tilting the outboard fully.
If the outboard contacts the boat's motor well Repeat this procedure until the tilt limit switch
when fully tilted, adjust the tilt limit cam to reduce stops the outboard's upward travel before it con-
full-tilt position. tacts the motor well.
IMPORTANT: The tilt limit cam will not prevent To prevent damage to equipment, provide addi-
the outboard from overriding the adjustment if the tional motor well clearance when it is needed.
outboard is tilted manually. Consider either changing the outboard mounting
position or modifying the boat if the possibility for
interference and damage exists.
WARNING
Adjusting the tilt limit cam will NOT pre-
vent the outboard from tilting fully and
contacting the motor well if the gearcase
hits an object at high speed. Such contact
could damage the outboard and boat and
injure boat occupants.
DR3916
68
INSTALLATION AND PREDELIVERY
FINAL ADJUSTMENTS
Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not
show center position, tilt the outboard up and
Tilt the outboard and engage the tilt support.
adjust the sending unit by pivoting it up or down.
Temporarily install a thrust rod, P/N 436541, in the
number 3 hole.
2
1
29072
Lower the outboard against the thrust rod to check
adjustment. Repeat adjustment, if necessary.
Loosen the sending unit screws, to allow the
After adjustment is correct, tilt the outboard up,
sending unit to pivot.
tighten the two sending unit screws, and remove
the thrust rod.
WARNING
1 When the outboard is returned to the cus-
tomer, the trim limiter rod must be
installed and in the same location as it
was when the motor was brought in for
service. Leaving the trim limiter rod out, or
changing the adjustment, could allow the
motor to unexpectedly trim in too far and
cause loss of control.
1. Screws 27339
69
INSTALLATION AND PREDELIVERY
FINAL ADJUSTMENTS
IMPORTANT: A single trim tab adjustment will Test the boat and, if needed, repeat the procedure
relieve steering effort under only one set of speed, until steering effort is as equal as possible.
outboard angle and load conditions. No single
adjustment can relieve steering effort under all Outboards with High Transom Heights
conditions. The trim tab may be above the surface of the
water when the outboard is trimmed out. Steering
WARNING effort might increase. Lower the trim setting to
submerge the trim tab and to reduce steering
To prevent accidental starting while servic- effort.
ing, twist and remove all spark plug leads.
Dual Standard Rotation Outboards
If the boat pulls to the left or right when its load is Move both trim tabs equally and in the same
evenly distributed, adjust the trim tab as follows: direction.
• With the engine OFF, loosen the trim tab screw.
If the boat pulled to the right, move rear of the Dual Outboards, One Counter and One
trim tab slightly to the right. If the boat pulled to Standard Rotation
the left, move rear of the trim tab slightly to the Set both trim tabs to the center position.
left.
• Tighten the trim tab screw to a torque of 35 to
40 ft. lbs. (47 to 54 N·m).
70
INSTALLATION AND PREDELIVERY
FINAL ADJUSTMENTS
6340
71
INSTALLATION AND PREDELIVERY
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
72
MAINTENANCE
MAINTENANCE
TABLE OF CONTENTS
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SACRIFICIAL ANODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TESTING PROCEDURE – CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 3
METALLIC COMPONENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
EXTERIOR FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ADDITIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
EXHAUST PRESSURE FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
OUTBOARD MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
BATTERY(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
POWER TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE DROPPED OVERBOARD (NOT RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE DROPPED OVERBOARD (RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE DROPPED OVERBOARD (IN SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PROLONGED SUBMERSION (FRESH OR SALT WATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
73
MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE
IMPORTANT: Outboards used in rental, commercial, or other high hour applications require more fre-
quent inspections and maintenance. Adjust schedule for operating and environmental conditions.
Engine Every 300 hours
Care Routine or every three
Description Product Inspection years (1)
Engine Monitor self-test and warning horn, check 3
Emergency stop circuit and lanyard, check operation 3
Controls, steering and tilting; check operation 3
Engine mounting hardware, re-tighten (40 ft. lbs.) 3
Fasteners, tighten any loosened components 3
Water intake screens, check condition 3
Cooling system; check water pump indicator / water pressure 3
Anticorrosion anodes, check condition 3
Gearcase, check condition 3
Propeller, check condition 3
Fuel and oil systems, inspect and repair leaks (2) 3
Check battery connections and condition 3
Access EMM information, resolve any service codes 3
Electrical and ignition wires, inspect for wear or chafing 3
Fuel filter, replace 3
Oil filters, replace 3
Gearcase lubricant, replace A 3
Spark plugs, inspect or replace (2) 3
(2)
Thermostats, inspect and check operation 3
Grease fittings, lubricate (3) C 3
Power trim/tilt and fluid level, inspect B 3
(3) C
Propeller shaft splines, inspect and lubricate 3
Starter pinion shaft, inspect and lubricate (3) D 3
Control cables, inspect and adjust 3
Steering cable, inspect and lubricate C 3
Water pump, inspect / replace (more often if water pressure loss or overheating occurs) 3
(1) Average recreational use. Commercial use, heavy use, or use in salt or polluted water requires more frequent inspection and maintenance.
(2) Emission-related component
(3) Annually in salt water applications
74
MAINTENANCE
ANTI-CORROSION PROTECTION
75
MAINTENANCE
COOLING SYSTEM
Flushing 004263
Refer to Propeller Hardware Installation on Shut OFF the outboard. Turn off water supply and
p. 67. remove garden hose.
Place outboard in VERTICAL (DOWN) position in Reinstall plug and nozzle. Position the plug and
a well ventilated area. nozzle to allow the water stream to be seen from
the helm.
Reinstall propeller.
76
MAINTENANCE
COOLING SYSTEM
Additional Maintenance
• Check Engine Monitor function.
• Check operation or visually inspect thermostats
and pressure relief valve. Clean or replace as
needed.
• Check that all water passages, hoses, and fit-
tings for both the EMM and the vapor separator
flow water freely.
• Replace water pump.
77
MAINTENANCE
LUBRICATION
Failure to regrease as recommended Apply grease until the grease begins to flow from
could result in steering system corrosion. the upper or lower swivel bracket areas.
Corrosion can affect steering effort, mak- Coat the pivot points of the trailering bracket with
ing operator control difficult. Triple-Guard grease.
2 Tilt Tube
1 Lubricate the tilt tube grease fittings with Triple-
Guard grease.
1 1
1. Tilt tube fittings DR38798
78
MAINTENANCE
LUBRICATION
Gearcase Lubricant
1 Draining
2
WARNING
Gearcase lubricant may be under pressure
1. Attachment pins, throttle and shift cables DRC6500R and/or hot. If plug is removed from a
2. Shift shaft grease fitting recently operated outboard, take precau-
3. Brass inner casings, throttle and shift cables
tions to avoid injury.
Shift the remote control to the NEUTRAL/IDLE
position. IMPORTANT: Always check the fill level of the
gearcase lubricant at the upper plug before
Install control cables.
Check proper throttle and shift function.
79
MAINTENANCE
LUBRICATION
removing the lower, drain/fill plug. A tie strap can amount of water from normal water vapor conden-
be used to check lubricant level. sation within the gearcase.
Inspect the lubricant for water contamination. 1. Lubricant level plug 002386
Water can make the lubricant milky in appear- 2. Lubricant drain/fill plug
80
MAINTENANCE
LUBRICATION
1
3
Three Ram Trim System 004277
1. Fill cap
81
MAINTENANCE
BATTERY AND BATTERY CONNECTIONS
WARNING
Keep battery connections clean, tight, and
insulated to prevent their shorting or arc-
ing and causing an explosion. If the bat-
tery mounting system does not cover the
connections, install covers.
82
MAINTENANCE
FUEL AND OIL SYSTEMS
004218
WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
83
MAINTENANCE
SPARK PLUGS
2 1
84
MAINTENANCE
EXHAUST PRESSURE FITTING
2
1. Exhaust pressure fitting 005026
85
MAINTENANCE
STORAGE
86
MAINTENANCE
PRE-SEASON SERVICE
WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
87
MAINTENANCE
SUBMERGED ENGINES
Remove spark plug leads and spark plugs. Run outboard below 1500 RPM for one-half hour.
88
ENGINE COVER SERVICE
89
ENGINE COVER SERVICE
UPPER COVER SERVICE
006815
1
1
006963
90
ENGINE COVER SERVICE
LOWER COVER SERVICE
1
1
1
1 4
1. Lower cover screws 004122
005246
005246
91
ENGINE COVER SERVICE
LOWER COVER SERVICE
006746
1. Triple-Guard grease 006827
Install nut on switch. Tighten nut to a torque of 10
Apply Ultra-Lock to screw threads. Place spring to 16 in. lbs. (1 to 2 N·m).
washer and hook into position and tighten screw
to a torque of 180 in. lbs. (20 N·m).
006747
006748
92
ENGINE MANAGEMENT MODULE (EMM)
93
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
94
ENGINE MANAGEMENT MODULE (EMM)
EMM INPUTS AND OUTPUTS DIAGRAM
4 123
AB C
A B
1 2 2 1
345
CBA
14
INPUTS
5
3 J2
+ 1
2
2 3
A
B
4
J1-A 15
25
12
1 J1-B
TnT
OUTPUTS
24
+
2 1
22 A B
17
21 19 18 16
20
23
1. Engine Management Module (EMM) 10. Oil Pressure Sensor (component of 18) 19. Ignition Coil
2. Battery (12 volt) 11. Engine Temperature Sensor(s) 20. Fuel Injector
3. Key switch (switched B+, start signal) 12. Water in Fuel Sensor / Fuel Filter 21. Tachometer/SystemCheck Gauge
4. Stator 13. Trim / Tilt Sending Unit 22. Diagnostic Connector
5. Knock sensor 14. Water Pressure Sensor w/adaptor harness 23. I-Command harness
6. Crankshaft Position Sensor (CPS) 15. LED indicators 24. Trim and Tilt Relay Module
7. Throttle Position Sensor (TPS) 16. Fuel Pump (high pressure) 25. Oil Level Switch
8. Shift Interrupt Switch 17. Starter Solenoid
9. Air Temperature Sensor (AT) 18. Oil Injection Pump and Manifold
95
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL SENSORS
96
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If the sensor reads less than -85 in. water, or Engine Temperature Sensor
greater than 85 in. water, or the sensor or circuit
Monitors cylinder head temperature.
fails, the EMM:
Stores service code 87 If cylinder head temperature exceeds 212° F
EMM LED 3: OFF (Cranking) (100° C) below 2000 RPM for 3 seconds, the
EMM:
EMM LED 3: ON (Running)
Activates S.A.F.E.
If exhaust pressure is less than 40 in. water, the Stores service code 40 (port sensor)
EMM: Stores service code 70 (stbd sensor)
Stores service code 88 EMM LED 4: ON (Running)
EMM LED 3: OFF (Cranking) Engine Monitor TEMP display: ON
EMM LED 3: ON (Running)
If cylinder head temperature exceeds 185°F
(85°C) above 2000 RPM for 60 seconds, the
If exhaust pressure is greater than 80 in. water,
EMM:
the EMM:
Stores service code 43 (port sensor)
Stores service code 89
Stores service code 69 (stbd sensor)
EMM LED 3: OFF (Cranking)
EMM LED 4: ON (Running)
EMM LED 3: ON (Running)
Engine Monitor TEMP display: ON
97
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
98
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If the TPS or TPS circuit fails (less than 0.14 volts Use the Evinrude Diagnostics software Monitor
or greater than 4.92 volts), the EMM: screen to check CPS operation. The software
should show an RPM reading while the outboard
Stores service code 12 is cranking. If the CPS or its circuit fails, no RPM
Limits engine RPM to IDLE reading will appear and the outboard cannot run.
EMM LED 3: OFF (Cranking)
EMM LED 3: ON (Running) Knock Sensor – 3.4 L Models
Engine Monitor CHECK ENGINE display: ON Knock sensors (one per cylinder head) detect the
presence of knock (pre-ignition or detonation) dur-
ing the combustion cycle.
IMPORTANT: When a TPS circuit fault has
been detected, the outboard will not accelerate When knock is detected, the EMM temporarily
above idle speed. To reset, stop the outboard and increases fuel flow and retards ignition timing for
correct the fault. the affected cylinder. Up to four levels of protec-
tion are provided.
If the TPS circuit reads below 0.2 volts, the EMM:
Stores service code 13 If knock continues, the EMM:
EMM LED 3: OFF (Cranking) Activates S.A.F.E.
EMM LED 3: ON (Running) Stores service code 1-6 (code indicates cyl)
Engine Monitor CHECK ENGINE display: ON EMM LED 3: ON (Running)
Engine Monitor CHECK ENGINE display: ON
If the TPS circuit reads above 4.85 volts, the
EMM: If the sensor circuit is OPEN, the EMM:
Stores service code 14 Stores service code 7 (port sensor)
EMM LED 3: OFF (Cranking) Stores service code 8 (stbd sensor)
EMM LED 3: ON (Running) EMM LED 3: ON (Running)
Engine Monitor CHECK ENGINE display: ON Engine Monitor CHECK ENGINE display: ON
99
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL EMM FUNCTIONS
100
ENGINE MANAGEMENT MODULE (EMM)
ENGINE MONITORING SYSTEM
Engine Running
All warning circuits are active when the engine is
running. The horn circuit is active when engine
Typical I-Command and SystemCheck gauges 006707
speed exceeds 500 RPM.
101
ENGINE MANAGEMENT MODULE (EMM)
S.A.F.E. WARNING SYSTEM
Activation WARNING
When one of these conditions occurs, the EMM If the engine shuts OFF and the “CHECK
interrupts fuel injector and ignition operation, ENGINE” light or EMM SENSOR FAULT
reducing engine speed to 1200 RPM. The warning LED is flashing, the engine cannot be
horn sounds and an Engine Monitor message dis- restarted. A hazardous fuel condition may
plays. When S.A.F.E. is active, the engine will run exist which could result in a fire or explo-
normally below 1200 RPM. Above 1200 RPM, the sion.
engine will shake excessively.
Recovery Recovery
The engine will operate in S.A.F.E. as long as the To recover from shutdown mode, the EMM must
fault condition exists. To recover normal operation, NOT detect the related fault at start-up. The out-
two conditions must be met: board will not restart until the cause of the stored
• Sensor or switch readings must be back within service code is resolved (code 29 and 31) and the
limits code is cleared using diagnostics software (code
• The EMM must be reset—stop and restart 33 and 57). Then, the EMM must be turned OFF
and ON again.
102
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication 5
Locate the diagnostic connector on the engine.
Remove the cover and install the Diagnostic Inter-
face Cable (P/N 437955).
1. Cover 005021
2. Engine harness diagnostic connector
103
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
104
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Oil Injector
Use the diagnostics software to test the oil injec-
tion pump circuit. Refer to OILING SYSTEM
TESTS on p. 200.
Fuel Pump
Use the diagnostics software to test the fuel pump
circuit. Refer to Fuel Pump Static Test on p. 123. 5
Overheat Dynamic Tests Screen 006808
This test is used to check the “ENG TEMP” or
“HOT” circuit of the Engine Monitoring system. Ignition Test
This test momentarily disables the ignition and
Oil Fault fuel injection circuits to one cylinder. By dropping
This test is used to check the “NO OIL” circuit of one cylinder, RPM and running quality changes
the Engine Monitoring system. can be observed. Refer to DYNAMIC TESTS on
p. 115.
Check Engine
This test is used to check the “CHECK ENGINE” Fuel Test
circuit of the Engine Monitoring system. This test momentarily disables one fuel injector
circuit. By dropping one cylinder, RPM and run-
Tachometer
ning quality changes can be observed. Refer to
This test is used to check operation of the tachom- DYNAMIC TESTS on p. 115.
eter circuit.
Prime Oil
This test is used to cycle the oil injection pump for
priming the oiling system. Perform this test with
outboard running to activate oil injection pump.
105
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
• Moderate applications
CAUTION
Running an Evinrude E-TEC outboard on
other grades of oil while set to the XD100
oil ratio will result in increased engine
wear and shortened outboard life.
106
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
5
1. TPS Calibration button 006810
107
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
108
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
002383
EMM Transfer
EMM Transfer is used to save engine history data
when the EMM must be replaced. Select EMM
Data Transfer from the Utilities menu. Select the
5
Collect EMM data to FILE option and follow the
instructions provided with the program.
109
ENGINE MANAGEMENT MODULE (EMM)
EMM SERVICING
Removal
Disconnect exhaust pressure hose and cooling
hoses from EMM.
110
SYSTEM ANALYSIS
SYSTEM ANALYSIS
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
VISUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DIAGNOSTIC SOFTWARE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
OPERATIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CYLINDER DROP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
EMM LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
KEY ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
IGNITION OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
REQUIRED IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 6
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SYSTEM VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
STATIC IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
IGNITION CONTROL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FUEL DELIVERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
FUEL PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
FUEL INJECTOR STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
RUNNING FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
111
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
112
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
• Check the RPM Profile for long periods of low first on the list. As each new record is added,
speed operation or periods of over-revving rpm. the oldest record is removed.
• Check the Engine Temperature Profile for evi-
dence of cold running or overheating.
Engine Temperature Profile 007200 The Engine Identity Report provides a snap-shot
of current engine and sensor conditions. From the
• Check the Knock Profile for high knock levels. Identity screen, press the Print button. Next, press 6
High knock levels may be due to high operating Print to Printer to print, or Print to PDF to save the
temperatures, incorrect ignition timing, poor- report.
quality fuel, or a loose knock sensor.
113
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
114
SYSTEM ANALYSIS
DYNAMIC TESTS
115
SYSTEM ANALYSIS
EMM LED INDICATORS
116
SYSTEM ANALYSIS
EMM LED INDICATORS
117
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
EMM 1
• Controls ignition grounds, injector grounds, and
ignition timing.
• Start Assist Circuit (SAC) converts battery volt- 1. Main engine harness ground 004128
age (12 V) to 30 V for system circuit (55 V).
Clean or repair all ground circuits, wiring, and con-
nections as needed.
118
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
6
Engine Monitor Screen, System Voltage 006958
Results:
• KEY ON (not running) - 30 V ± 2, system volt-
Engine Monitor Screen, Engine RPM display 006958 age is GOOD.
• KEY ON (not running) - less than 30 V ± 2,
If the Monitor screen says “Check CPS Sync,” check 12 V power to EMM. Repair connection
refer to Crankshaft Position Sensor (CPS) Test or wiring. Possible fault in EMM SAC circuit.
on p. 133. • RUNNING - 55 V ± 2, system voltage is GOOD.
• RUNNING - less than 55 V ± 2, check stator
output to EMM. Repair connection or wiring.
Possible faulty stator or EMM. Refer to STATOR
TESTS on p. 135.
119
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
Results:
No spark on one or more cylinders:
• Inspect or replace spark plugs
• Refer to Ignition Control Circuit Tests on
p. 122
• Refer to Ignition Coil Tests on p. 122.
Steady spark on all cylinders:
Testing, Static Test Screen 006960
• Refer to Running Ignition Tests on p. 121 and
DYNAMIC TESTS on p. 115.
Connect timing light pickup to the secondary cir-
cuit (spark plug lead) of the cylinder being tested.
Activate test and observe timing light strobe for
consistent flash.
120
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
121
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
122
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Inspect all fuel hoses, filters, and connections. Fuel Injector Static Test
Check quality of fuel supply. Use the Evinrude Diagnostics software Fuel Injec-
tor Static Test to activate each fuel injector. Listen
Fuel Pump Static Test
Use the Evinrude Diagnostics software Fuel Pump
for an audible “click” from each injector when it is
actuated. If the injector activates, the EMM and
6
test to activate the electric fuel pump. If the pump injector circuits are not at fault.
runs, the EMM and fuel pump circuit are not at
fault.
Static Tests Screen 006813 IMPORTANT: This test is operating the injectors
with 30 V on the system voltage (55 V) circuit. The
start assist circuit (SAC) of the EMM converts bat-
tery voltage (12 V) to 30 V of system voltage. Bat-
tery must be fully charged and connections must
be clean and tight. Injector activation should be
carefully confirmed.
123
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Results: Results:
No injectors actuate: No light activation on any injector wires (outboard
• Use the Monitor screen of the diagnostics soft- cranks and starter turns flywheel):
ware to make sure voltage is present on the • Check stator input to EMM, CPS operation, and
system voltage circuit. all grounds and wiring connections.
• Refer to Running Fuel System Tests on • Eliminate all other possibilities to isolate a faulty
p. 124. EMM.
Some injectors actuate; some do not: Irregular or no light activation on some injector
• Test the resistance of individual injector circuits wires:
between the injector connector and injector con- • Test the resistance of individual injector circuits
trol wire at the EMM. between the injector connector and injector con-
• See Fuel Injector Resistance Test on p. 176. trol wire at the EMM.
• Check battery cable connections.
All injectors actuate: • Make sure all grounds are clean and tight.
• Refer to Running Fuel System Tests on • See Fuel Injector Resistance Test on p. 176.
p. 124.
Steady light activation on all injector wires and
Running Fuel System Tests consistent voltage readings, EMM injector control
Run or crank the outboard. function is good:
• Use the diagnostics software Dynamic Fuel
Use the Evinrude Diagnostics software Monitor Test to isolate a faulty cylinder. See DYNAMIC
screen to check system voltage. If voltage is low, TESTS on p. 115.
or drops as RPM increases, refer to Stator Volt-
age Output Test on p. 135.
124
ELECTRICAL AND IGNITION
125
ELECTRICAL AND IGNITION
SERVICE CHART
SERVICE CHART
60-84 In. lbs.
(7-9.5 N·m)
F
30-42 In. lbs.
(3.5-4.7 N·m)
F B
30-42 In. lbs. 140-160 Ft. lbs.
(3.5-4.7 N·m) (190-217 N·m)
X
15-30 Ft. lbs.
(20-41 N·m) F
F Apply to inner flywheel taper
60 to 84 in lbs. 24-36 In. lbs.
(2.7-4 N·m)
(7 to 9.5 N ·m)
F
30-42 In. lbs.
(3.5-4.7 N·m)
T
60-84 In. lbs.
(7-9.5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F F Blue Nut Lock
30-42 In. lbs.
(3.5-4.7 N·m) J Thermal Grease
T Liquid Neoprene
004116 X See Service Manual Text
126
ELECTRICAL AND IGNITION
SERVICE CHART
F
(7-9.5 N·m)
7
168-192 in. lbs
(19-21.5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
N Starter Bendix Lube
T Liquid Neoprene 004100
127
ELECTRICAL AND IGNITION
IGNITION SYSTEM CIRCUIT DIAGRAM
6 2
5
B A
1 2 3
3
4 5 6
123
+
8
9
11 12 13
1 2 3 4
20 21 22 23
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
4
16 17
18 19
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
4
3
5
J1-A
2
6
1
1
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B
2 1
7 7
321
321
4 3
321
321
6 5
321
321
128
ELECTRICAL AND IGNITION
DASH CONNECTIONS, INSTRUMENT HARNESS
DASH CONNECTIONS,
INSTRUMENT HARNESS
3-pin connector – Connect to trim switch located
in the handle of the remote control or to trim
switch mounted on the boat dash.
129
ELECTRICAL AND IGNITION
ELECTRICAL HARNESS CONNECTIONS
130
ELECTRICAL AND IGNITION
ELECTRICAL HARNESS CONNECTIONS
001876 004046
Pin Pin
Description of Circuit Wire Color Description of Circuit Wire Color
No. No.
1 Injector, cylinder 1 Blue 1 B+ Red
2 Injector, cylinder 2 Blue 2 vacant
3 Injector, cylinder 3 Purple 3 Isolated B+ Red/Black
4 vacant 4 Battery ground Black
5 Fuel pump Red/White 5 Battery ground Black
6 Ignition, cylinder 4 Orange/Purple 6 vacant
7
8
Ignition, cylinder 3
Injector, cylinder 6
Orange/Purple
Green
7
8
Winding 1S
Winding 2S
Yellow
Brown
7
9 Injector ground Black 9 Injector, generator ground Black
10 Injector ground Black 10 Winding 3S Orange
11 Starter solenoid OUT Brown/White 11 B+ Red
12 vacant 12 B+ Red
13 Ignition, cylinder 5 Orange/Green 13 Isolated B+ Red/Black
14 Injector, cylinder 5 Green 14 Battery ground Black
15 Injector ground Black 15 Battery ground Black
16 Injector ground Black 16 Battery ground Black
17 Trim relay, UP Blue/White 17 Winding 1F Yellow/White
18 Trim relay, DOWN Green/White 18 Winding 3F Orange/White
19 Ignition, cylinder 2 Orange/Blue 19 +55V White/Red
20 Injector, cylinder 4 Purple 20 B+ Red
21 Switched B+ (12V) Purple 21 Isolated B+ Red/Black
22 Injector ground Black 22 Isolated B+ Red/Black
23 Oil solenoid Blue 23 Battery ground Black
24 vacant 24 Battery ground Black
25 Ignition, cylinder 6 Orange/Green 25 Battery ground Black
26 Ignition, cylinder 1 Orange/Blue 26 vacant
27 Injector, generator ground Black
28 Winding 2F Brown/White
29 +55V White/Red
131
ELECTRICAL AND IGNITION
GROUND CIRCUITS
1
2
132
ELECTRICAL AND IGNITION
SENSOR TESTS
Sensor Resistance
Sensor Resistance (between “A” and “C”)
560 Ω ± 10% @ 77°F (25°C)
4000 to 8000 Ω @ 77°F (25°C)
133
ELECTRICAL AND IGNITION
SENSOR TESTS
Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test
meter lead to terminal “C.” Rotate the sensor lever
Remove the electrical connector from the air tem-
through its range of travel. Resistance reading
perature sensor.
must change evenly as the sensor lever is moved.
Use a digital multimeter to measure sensor resis-
Connect red meter lead on terminal “B” and black
tance.
meter lead to terminal “C.” Rotate the sensor
lever. Resistance reading must change evenly as AT Sensor Resistance
the sensor lever is moved. 680 Ω ± 5.25% @ 212°F (100°C)
10000 Ω ± 1.5% @ 77°F (25°C)
Engine Temperature Sensor Test 32654 Ω ± 3.0% @ 32°F (0°C)
Remove the electrical connector from the engine
temperature sensor.
1. AT sensor 004216
1
Knock Sensor Test
There are no tests for the knock sensor. If
Evinrude Diagnostics reports Service Code 7 or 8,
replace with a new sensor.
134
ELECTRICAL AND IGNITION
STATOR TESTS
135
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
CHARGING SYSTEM
4 3
TESTS
12 V Charging Circuit 1
To test the operation of the regulator in the EMM,
you must be able to run the outboard continuously
5
at approximately 5000 RPM, such as in a test tank
or on a marine dynamometer. 2
136
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
Auxiliary Battery Charge Wire With outboard running at 1000 RPM, voltage must
read higher than with key OFF and increase
The auxiliary battery charge feature requires aux- steadily to approximately 14.5 V as the outboard
iliary battery charge kit, P/N 5006253 (or equiva- RPM increases.
lent).
If there is no increase, turn the key switch to OFF
IMPORTANT: Disconnect all accessories from and test red/black wire between the EMM and
the auxiliary battery. Auxiliary battery must read a auxiliary battery connection.
minimum of 8.5 V at the beginning of these tests • Continuity indicates faulty output from EMM.
and remain connected to the outboard during the Check 12 V alternator output before replacing
tests. EMM for faulty auxiliary battery, charge isolator
Check battery ground cable for continuity. circuit.
• No continuity indicates faulty wiring.
With the key switch OFF, check battery voltage at
auxiliary battery, then check voltage at auxiliary 55 V Alternator Circuit
battery connection. If the readings are not the Check battery ground cable for continuity.
same, replace wire to auxiliary battery. The auxil-
iary battery wire must be at least 10-gauge and it With the key switch ON, check battery voltage at
must be protected by a 50 A fuse or circuit battery (12 V), then check voltage on white/red
breaker at the battery. wires at J2 connector of EMM. Use Electrical Test
Probe Kit, P/N 342677 and a multimeter set to
read 55 VDC. Voltage at EMM connector should
be approximately 30 V.
7
1
1
137
ELECTRICAL AND IGNITION
ELECTRIC START CIRCUIT
8 B M
M C S
A
9
15
13
61 4 3 5 2
NEG FUSE 5
7
B A
17 6 1 4 3 5 2
16
6
4
A POS 2
B
+
11 12 13
20 21 22 23
1 2 3 4
3
14 15
J2
24 25 26 27 28 29
5 6 7 8 9 10
3
16 17
13
18 19
12
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
11
J1-A
14
9
20 21 22 23 24 25 26
10
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B
+
1
004112
138
ELECTRICAL AND IGNITION
ELECTRIC START CIRCUIT
to instrument harness. M
C
M
3 2 1
3
1. Key switch, ON position – Continuity between ter- 000691
minals “B” and “A”
2. Terminal “B”, 12 V (Red/purple)
3. Terminal “A”, 12 V (Purple)
139
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
B
1 3
M
C
M
S
A
4 5 6
3 2 1
2 3
1. Ignition switch, START position – Continuity 000691R
between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V
3. Neutral safety switch
2 4
1. “A” terminal, B+ (purple) 004121
2. “B” terminal, NEG (brown/white)
3. Starter positive (+) cable terminal
4. Battery positive cable (B+) terminal
140
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
After re-installing the solenoid, coat all wires and Use an inductive ammeter or connect a 0 to 100
terminals with Black Neoprene Dip. amp ammeter in series with a heavy jumper
between the battery positive (+) terminal and the
starter positive (+) terminal.
004182
141
ELECTRICAL AND IGNITION
REMOTE CONTROL SWITCH TESTS
142
ELECTRICAL AND IGNITION
REMOTE CONTROL SWITCH TESTS
2
3 7
1. Lanyard and clip assembly 000444
2. Emergency stop switch, separate from key switch
3. Stop circuit wire (black/yellow)
4. Ground wire (black)
TYPICAL 3224
1. Plunger Install the clip on the emergency stop switch or
2. Neutral start switch
key switch. Start the outboard. Pull the clip from
the switch. The outboard must stop running.
Replace switch if results are incorrect.
143
ELECTRICAL AND IGNITION
TILT/TRIM RELAY TEST
3
1. Tilt and trim module 004183
Operation
The relay activates when B+ input from the switch 1
is supplied to terminal 86 of the internal relays.
Terminal 87a connects to ground (B–). 2
Terminal 87 connects to B+.
144
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
145
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test
gauge.
The tan wire of engine harness and the MWS har-
ness receives a signal from the EMM. The EMM
receives information from the temperature sensor
on the cylinder head.
2 1
1. Purple wire DRC6280
2. Tan/blue wire
002079
Turn the key switch OFF and reconnect all discon-
nected circuits.
Turn the key switch ON. After the normal self-test
sequence, the gauge WATER TEMP / HOT indi-
CHECK ENGINE Circuit Test cator should stay on.
Separate the 6-pin SystemCheck connector of • If LED is not on, test circuit for continuity. Test
MWS instrument harness from engine harness. for continuity of both the engine harness (tan
Black wire (pin 3) must be grounded. wire) and the MWS instrument harness (tan
Using a jumper wire, connect tan/orange wire (pin wire).
2) to a clean engine ground. Turn the key switch OFF and reconnect all discon-
Turn the key switch ON. After the normal self-test nected circuits.
sequence, the CHECK ENGINE light should stay IMPORTANT: To test the temperature sensor
on. itself, refer to Engine Temperature Sensor Test
• If the CHECK ENGINE light is not on, test circuit on p. 134.
for continuity. Check continuity of the MWS
instrument harness (tan/orange wire).
• Check continuity of the engine wire harness
between terminal 2 (tan/orange wire) of the
SystemCheck connector and pin 17 of the EMM
J1-A connector.
146
ELECTRICAL AND IGNITION
TACHOMETER CIRCUIT TESTS
1 2
002079
NO OIL Circuit Connect the red meter lead to the tachometer pur-
Separate the 6-pin SystemCheck connector of ple wire and the black meter lead to the tachome-
MWS instrument harness from engine harness. ter black wire (key ON, outboard NOT running).
Black wire (pin 3) must be grounded. • If meter shows battery voltage, go to next step.
• If meter shows less than battery voltage, check
Using a jumper wire, connect tan/yellow wire (pin
the purple, red/purple, and black wiring circuits;
5) to a clean engine ground.
fuse, key switch, and battery connections.
Turn the key switch ON. After the normal self-test
Disconnect gray and black wires at tachometer.
sequence, the NO OIL light should stay on.
Set Fluke 29 Series II meter, or equivalent, to Hz
• If the NO OIL light is not on, test circuit for conti-
scale. Connect meter between gray wire and
nuity. Test for continuity of the MWS instrument
black wire. With outboard running at 1000 RPM,
harness (tan/yellow wire).
meter should indicate 90 to 105 Hz.
• Test for continuity of the engine wire harness
• If meter reads 90 to 105 Hz, replace tachome-
between terminal 5 (tan/yellow wire) of the Sys-
ter.
temCheck connector and pin 24 of the EMM J1-
• If meter reads low or no signal, confirm output
A connector.
on gray wire at pin 16 of EMM J1-A connector.
Turn the key switch OFF and reconnect all discon- – Reading OK – Check condition of tachometer
nected circuits. circuit (gray wire). Repair as needed.
– Reading not OK – Check connection at EMM;
replace faulty EMM.
147
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
Flywheel Removal
WARNING
To prevent accidental starting while ser-
vicing, disconnect battery cables at the
battery.
Stator Service
Remove six allen head screws to remove stator.
148
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
49623
149
ELECTRICAL AND IGNITION
IGNITION COIL SERVICING
150
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
WARNING
To prevent accidental starting while ser- 1. Timing pointer 005025
vicing, disconnect the battery cables at
the battery. Twist and remove all spark Rotate the flywheel clockwise until the piston
plug leads. contacts the tool. Mark the flywheel directly across
from the pointer. Label this mark “B.” Rotate fly-
wheel counterclockwise slightly to release tool
Disconnect the battery cables at the battery. then remove it from spark plug hole.
Remove spark plugs. Rotate the flywheel clock-
7
Use a flexible measuring device to find the exact
wise to 30° ATDC. center between marks “A” and “B.” Measure along
Install Piston Stop Tool, P/N 342679, into the the edge of the flywheel. Mark and label the cen-
spark plug hole of the number 1 cylinder. ter point “C.”
151
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
location to align with the cast-in TDC boss on the Check ignition timing after any of the following
flywheel. Tighten retaining screw. procedures:
• Powerhead replacement
• Crankshaft replacement
• Flywheel removal or replacement
• CPS replacement
• EMM replacement
• EMM software replacement (reprogramming)
IMPORTANT: Make sure the timing pointer is
set and the outboard reaches operating tempera-
2 3 1 ture before making any timing adjustments.
1. Mark “A’” DR1233
2. Mark “B”
3. Mark “C”
TPS CALIBRATION
Use Evinrude Diagnostics software to tell the
Repeat the entire adjustment process to make EMM what throttle position sensor voltage is when
sure pointer is aligned correctly. the throttle plates begin to open.
Install spark plugs. Refer to Spark Plug Indexing Remove the air silencer.
on p. 84.
On the Settings screen of the diagnostic software,
Timing Verification click the “Set TPS Calibration” button.
Use Evinrude Diagnostics software to synchronize
the mechanical timing of the outboard with the
electronic timing of the EMM.
Timing Adjustment Screen 006547 Click the “Working” button in the software to cali-
brate the TPS.
152
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
004181
30374
153
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Hit the socket with a mallet to lower the spacer Remove pinion and plastic weather cover from
and expose the retaining ring under the spacer. pinion shaft.
30368
30367
30360
Using No. 2 external retaining ring pliers, remove
Remove the retaining ring, spacer, and spring the retaining ring and drive gear from the arma-
from pinion shaft. ture shaft.
30366
30369
154
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Remove the two thru-bolts. Mark the end cap ori- Note the alignment marks by the positive terminal
entation, and remove the cap. stud. Hold the armature in place, and slide the
frame away from the gear housing.
30365
30354B
30351
155
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Starter Cleaning and Inspection matter which could contribute to failure of wind-
ings.
Inspect the brushes for wear and damage.
Replace brushes if damaged or worn. Replace
weak brush springs.
TYPICAL 24058
TYPICAL 24057
30345
After disassembling the drive, clean each part with
Clean the commutator with 300-grade emery Cleaning Solvent and inspect for wear and distor-
cloth. If commutator surface is unevenly worn or tion.
pitted, turn it on a lathe. Remove any trace of oil or
metal dust from the commutator. If the pinion does not properly engage the fly-
wheel, the pinion and screw shaft assembly could
Check the armature on a growler for shorted turns be worn, distorted, or dirty. Locate the cause of
using a test light or meter. Inspect armature insu- binding and correct it before completing the
lation for indications of overheating or damaged assembly.
windings. Clean off any carbon deposits or foreign
Inspect and replace end cap thrust washer if dis-
torted or worn excessively.
156
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Starter Assembly Align the starter frame and make sure the long
alignment mark matches the mark next to the pos-
IMPORTANT: If removed, apply Locquic Primer itive terminal stud on the gear housing.
and Screw Lock to the brush card screws before
installing. Push the armature down firmly and slide the
frame into place. Align the notches in the gear
Route the brush leads and install the springs and housing and frame.
brushes. Compress the spring with a modified
putty knife.
30364
30352
30354B
30351
157
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Install the two thru-bolts. Tighten to a torque of 50 Guard grease. Install the thrust washer and driven
to 65 in. lbs. (5.6 to 7.3 N·m). gear.
30362
30363
Install the weather cover.
Lightly coat the drive gear with Triple-Guard
grease, and install it on the armature shaft. Install
the retaining ring (flat side up) with No. 2 external
retaining ring pliers.
30361
30369
158
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Lightly coat the pinion shaft splines (helix) with Install the bracket. Apply Nut Lock to the thru-
Starter Bendix Lube. Lower the pinion into place bolts. Install the nuts and tighten to a torque of 50
without displacing the driven gear or thrust to 65 in. lbs. (5.6 to 7.3 N·m).
washer.
30357
30358
004201
159
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
1
2
1
1. Latch 42079A 1. Ledge of plug 42330
2. Seal 2. End of plug
2 1
1. Wedge 42327
3 4
1. End of wire strands DRC6205
2. Insulation crimp area
3. End of insulation
4. Wire crimp area
160
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
AMP Connectors
IMPORTANT: Always use the appropriate
meter test probes and adapters when testing com-
ponents fitted with these terminals. Electrical
grease is NOT used on AMP connectors. 1 2
SUPERSEAL† 1.5
Disconnect
Lift latch. Pull connectors apart.
1. Locking tab, plug 002447
2. Locking tab, receptacle
Connect
Confirm the seal is in place. Push connectors Terminal Installation
together until latched. Align terminal with connector housing. Push con-
1 nector and seal into housing until seated.
2
1. Latch 002448
2. Seal
7
1. Terminal and seal 002451
Terminal Removal
Use Secondary Lock Tool, P/N 777078, to release Align anti-backout device with connector housing
anti-backout device of connector housing. Next, and terminals. Use Secondary Lock Installer,
use Primary Lock Tool, P/N 777077, to release P/N 777079, to seat device in connector.
locking tab of connector housing. Release locking
tab and pull on wire to remove from connector Crimping Terminals
housing. Crimping Superseal 1.5 terminals requires the
PRO-CRIMPER II † with a specific crimping die
set.
1
1
161
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
Disconnect Disconnect
Depress BOTH latches and pull connector from Use a screw driver to open latch. Pull connector
plug. from plug.
Connect Connect
Push connector into plug until latches engage. Push connector until seated in plug. Close latch
completely.
1
1
2
1. Latch 002118
1. J2 connector 002120
Terminal Removal 2. Latch (closed)
1 1
1. Latch 002453
2. Lock mechanism
1
Terminal Installation
1. Locking mechanism(s) 002455
Push terminal through seal until it is seated in con-
nector housing. Close lock mechanism.
162
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
1. Latch 002456
2. Terminal with seal
Packard † Connectors
TYPICAL DRC5940
IMPORTANT: Always use the appropriate meter
test probes and adapters when testing compo-
nents fitted with these terminals.
Disconnect 7
Lift latch(s). Remove connector.
Connect
Confirm the seal is in place. Push connector onto
housing until latched.
163
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
Terminal Installation
Install wire gasket on wires and feed wires
through the correct terminal position of the con-
nector housing. Terminal is crimped onto wire and
then pulled back into connector housing until lock-
ing tab engages and terminal is seated.
002304
Crimping Terminals
Strip insulation back 3/16 in. (5 mm). Position end
of wire strands in terminal past the wire crimp area
and the end of insulation in the insulation crimp
area of the terminal.
164
FUEL SYSTEM
FUEL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
FUEL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
VAPOR SEPARATOR VENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
FUEL INJECTOR PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
CIRCULATION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
LIFT PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
LIFT PUMP VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
LIFT PUMP DIAPHRAGM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
ANTI-SIPHON VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8
FUEL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
FUEL LIFT PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
VAPOR SEPARATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
FUEL MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INTAKE MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
165
FUEL SYSTEM
SERVICE CHART
SERVICE CHART
FUEL PUMP, FUEL FILTER, VAPOR SEPARATOR
F
30-42 In. lbs. L
(3.5-4.7 N·m)
P
(Lower screw only)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
E Red Ultra Lock
F
F Blue Nut Lock
H Outboard Engine Lubricant
L Pipe Thread Sealing Compound
006971
P Permatex #2
166
FUEL SYSTEM
SERVICE CHART
B
10-18 in. lbs.
(1-2 N·m)
F
96-120 in. lbs.
(11-13.5 N·m)
167
FUEL SYSTEM
SERVICE CHART
Tighten in 3 stages
R R R
S
R
R
S = Supply
R R = Return
S
S
S
S
R
R
S S
S
S
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
H Outboard Engine Lubricant
S STP Oil Treatment 004101
168
FUEL SYSTEM
FUEL SYSTEM HOSE ROUTING
3 3
3 11
2 7
2 5 10 8
10
3 14
1 4 10
6 10
Fuel Supply 8
10
Fuel Return
10
13 12
3.4 L Models 9
006977
1. Fuel supply from boat fuel system 8. Electric fuel circulation pump (20 to 35 psi)
2. Fuel lift pump (2 to 8 psi) 9. Fuel supply manifold
3. Pulse hose(s) from cylinder/crankcase 10. Fuel injector(s)
4. Water Separator / Fuel filter 11. Fuel return manifold
5. Fuel supply to vapor separator 12. Pressure regulator (high pressure)
6. Vapor separator 13. Test fitting (low pressure)
7. Vent hose to throttle body 14. Test fitting (high pressure)
169
FUEL SYSTEM
FUEL SYSTEM CIRCUIT DIAGRAM
11 12 13
2 1
1 2 3 4
20 21 22 23
1 2
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
2
16 17
18 19
7
8 3
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
J1-A
6
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
J1-B
1 2
12
2 1
1 1
1 2
12
4
3
12
12
6 5
007109
170
FUEL SYSTEM
COMPONENTS
Vacuum from the fuel lift pump pulls fuel from the
fuel tank. Once fuel reaches the pump, internal 1
pump pressure forces the fuel from the pump
through the fuel filter and into the vapor separator.
171
FUEL SYSTEM
COMPONENTS
Fuel Supply
The pump is mounted to the vapor separator and
draws fuel from the fuel chamber. It pumps pres-
surized fuel through a fuel supply manifold con-
nected to the fuel injectors.
1. Vent 004187
Electrical Circuit
The circulation pump is controlled by the EMM
and operates on the 12 V circuit. The circulation
1 pump is activated momentarily when the EMM
powers up. The EMM controls pump operation by
rapidly connecting and disconnecting the pump’s
internal coil to ground.
172
FUEL SYSTEM
COMPONENTS
Fuel Injectors 8
Fuel injectors are fuel metering, electric solenoids
(55 V) bolted directly to the cylinder head. The
EMM controls the activation of each injector by
rapidly connecting and disconnecting the injec-
tor’s internal coil to ground.
number.
173
FUEL SYSTEM
FUEL SYSTEM TESTS
No pressure
1 • Check electrical circuit and ground connections
for circulation pump.
• If voltage is present and pump does not run,
repair connection or replace vapor separator
assembly.
174
FUEL SYSTEM
FUEL SYSTEM TESTS
Make sure filter is not clogged. Clean or replace Disconnect the battery cables at the battery.
as needed.
Relieve fuel system pressure. See Relieving Fuel
Apply oil to valve and connect pressure pump and System Pressure on p. 178.
hose to the fuel return fitting of vapor separator.
WARNING
Apply pressure to check regulator operation. The
pressure should open check valve at approxi- Protect against hazardous fuel spray.
mately 15 psi (103 kPa). Before starting any fuel system service,
carefully relieve fuel system pressure.
Use cap and tie strap to seal off outlet fitting. Con-
nect a 0 to 30 psi (0 to 207 kPa) pressure tester to
the inlet fitting. Pressurize the injector to 30 psi
(207 kPa). Pressure must hold for at least five
minutes.
1 8
2
3 1
1. Filter 000249
2. Fuel return fitting
3. Pressure regulator 1. Outlet fitting 002379
2. Inlet fitting
Vapor Separator Vent Check Refer to FUEL DELIVERY TESTS on p. 123 for
Monitor the vapor separator vent hose. No fuel or additional test procedures.
a trace of fuel is acceptable. Excessive fuel dis-
charge indicates a vapor separator vent malfunc-
tion. Monitor vent for presence of fuel during
testing. Temporarily install clear tubing for moni-
toring. Replace vapor separator if the venting of
fuel is continuous.
175
FUEL SYSTEM
FUEL SYSTEM TESTS
Use a digital multimeter to measure the injector Use a digital multimeter to measure the fuel pump
coil resistance. circuit and coil resistance.
Fuel Injector Coil Resistance Fuel Pump Resistance
2 to 3 Ω @ 72°F (22°C) 3 Ω @ 77°F (25°C)
006865 004217
Use a digital multimeter with appropriate adapter Lift Pump Pressure Test
leads to measure the injector circuit resistance.
Install a 0 to 15 psi (0 to 103 kPa) Fuel Pressure
Measure resistance between pin 2 of injector con- Gauge, P/N 5006397 or equivalent, to the lower
nector and the appropriate pin location of EMM fuel pressure test fitting.
J1-B connector. Refer to engine wiring diagram
for specific EMM J1-B connector pin location for
the injector circuit being tested.
1
176
FUEL SYSTEM
FUEL SYSTEM TESTS
000243
177
FUEL SYSTEM
FUEL COMPONENT SERVICING
178
FUEL SYSTEM
FUEL COMPONENT SERVICING
Pressure Gauge, P/N 5007100, to top test fitting Fuel Filter Service
of fuel pump/vapor separator assembly.
Removal
Disconnect the battery cables at the battery.
179
FUEL SYSTEM
FUEL COMPONENT SERVICING
1. Screws 004220
1
Connect the fuel lift pump pulse hoses to the
crankcase. Secure with tie straps.
004333
180
FUEL SYSTEM
FUEL COMPONENT SERVICING
Relieve fuel system pressure. Refer to Relieving Relieve fuel system pressure. Refer to Relieving
Fuel System Pressure on p. 178. Fuel System Pressure on p. 178.
Disconnect circulation pump electrical connector. Remove clamps and disconnect the fuel mani-
folds as follows:
Remove clamp and fuel supply manifold from top • Fuel supply manifold to circulation pump
of circulation pump. Remove clamp and vapor
• Fuel return manifold to vapor separator
vent hose from separator cover.
Installation
Installation is the reverse of removal. Pay close
attention when performing the following addi-
tional tasks. 1. Retainer screw 004266
2. Fuel supply manifold fitting
3. Fuel return manifold fitting
Install all hoses and manifolds to original locations
and secure with appropriate clamps. Squeeze
primer bulb to prime fuel system. Hold pressure
on bulb and observe for fuel leaks.
181
FUEL SYSTEM
FUEL COMPONENT SERVICING
Disconnect fuel manifold fittings from fuel injector Fuel Injector Service
ports, then remove the manifold assemblies.
Mark fuel injectors to show cylinder locations.
Installation
IMPORTANT: Fuel injectors must be installed in
Check condition of sealing O-rings on fuel mani- the correct cylinder locations. Use Evinrude Diag-
fold fittings. Lubricate O-rings with outboard lubri- nostics Software to make sure that EMM program-
cant and insert fuel manifold fittings into injector. ming matches injector positioning. The Injector
Both fittings must be fully seated into the injector Coefficients screen displays injector serial num-
fuel ports. bers.
Install retainer and screw. Retainer must engage
the outer groove of the manifold fittings.
1. Retainer 005342
2. Manifold fitting groove Injector Coefficients Screen 006959
182
FUEL SYSTEM
FUEL COMPONENT SERVICING
Remove injector screws. tor filter. Install new crush ring and O-rings. Lubri-
cate O-rings with STP † Oil Treatment.
002345
183
FUEL SYSTEM
FUEL COMPONENT SERVICING
005157
184
FUEL SYSTEM
FUEL COMPONENT SERVICING
004191
004192
004190 Inspection
Inspect the leaf plate assemblies for damage or
contamination:
• Leaf plates must not be distorted.
• Leaf valve must not be cracked or chipped.
• Leaf plate stops must not be distorted or loose.
• Leaf plate assemblies must be clean.
185
FUEL SYSTEM
FUEL COMPONENT SERVICING
1. Straight-edge 004193
Assembly
Remove old adhesive from reed valve retaining 004205
screws.
Place gasket on throttle body. Install throttle body,
Prime screw threads with Locquic Primer and let with oil pump bracket on reed plate and install
dry. Apply Nut Lock to threads. Position reed screws.
valve on reed plate and install screws. Tighten
screws to a torque of 30 to 42 in. lbs. (3.5 to 4.7 Tighten the center screws first and expand out-
N·m). ward. Final torque is 60 to 84 in. lbs. (7 to 9.5
N·m).
004194
004257
186
FUEL SYSTEM
FUEL COMPONENT SERVICING
Connect throttle linkage and throttle position sen- Position clamps as shown.
sor connector.
4
1
187
FUEL SYSTEM
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
188
OILING SYSTEM
OILING SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
OILING SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
OIL SUPPLY DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
OIL RECIRCULATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
NO OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OIL PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OILING RATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
OIL INJECTION PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
OIL INJECTION PUMP VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
OIL INJECTION PUMP CIRCUIT RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
OIL SUPPLY VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
9
OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
189
OILING SYSTEM
SERVICE CHART
SERVICE CHART
XD 30
This outboard has
been programmed
for use of ®
This outboard has
been programmed
for use of
XD 100
Evinrude®/Johnson Evinrude®/Johnson®
XD 50 TCW3RL OIL
See your Dealer if
you decide to
XD100™ oil.
See your Dealer if
you decide to
(Blue)
discontinue using discontinue using
(Yellow) Evinrude/Johnson
TCW3RL OIL
Refer to the
Operator’s Guide for
Evinrude/Johnson
XD100 oil.
Refer to the
Operator’s Guide for
Oil Requirements. Oil Requirements.
P/N 351520 P/N 351520
*IMPORTANT*
This outboard has been programmed
for the use of Evinrude®/Johnson® XD 100
XD100™ outboard oil ONLY.
Failure to use Evinrude/Johnson Boat Label
XD100 outboard oil may harm engine
performance and shorten engine life.
EVINRUDE.COM P/N 352369
This outboard has been programmed
XD100 outboard oil may harm engine
performance and shorten engine life.
WWW.EVINRUDE.COM
*IMPORTANT*
XD 100
Tank Label
(Accessory)
004097a
190
OILING SYSTEM
OILING SYSTEM CIRCUIT DIAGRAM
1 2 4
11 12 13
20 21 22 23
1 2 3 4
8
14 15
J2
24 25 26 27 28 29
5 6 7 8 9 10
16 17
12345
18 19
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
4
12345 J1-A
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
4
J1-B
5 6
9
3 3
004110
191
OILING SYSTEM
OIL SUPPLY DIAGRAMS
4
3
192
OILING SYSTEM
OIL SUPPLY DIAGRAMS
3.3 L models
Rear View
3
4
5
6
Top View
2 1
006870
193
OILING SYSTEM
OIL SUPPLY DIAGRAMS
3.4 L models
Port View
Starboard View
007256
194
OILING SYSTEM
OIL RECIRCULATION DIAGRAMS
1
2
3
4
5
6
004111a
195
OILING SYSTEM
COMPONENTS
196
OILING SYSTEM
COMPONENTS
197
OILING SYSTEM
COMPONENTS
On 3.3 L models, one oil distribution hose is cylinders into the incoming air stream in front of
routed to a tee fitting at the top of the block, above the top reed valve.
#2 cylinder.
1
1
2 1
Cylinder Recirculation
Internal powerhead oil drain passages connect
the lowest point of the intake port area of the cylin-
der block to external check valves. External hoses
connect these check valves to a hose fitting
pressed into the top of the intake manifold / throt-
tle body. Intake manifold vacuum draws any accu-
mulation of oil from the intake port area of the
198
OILING SYSTEM
OIL CONTROL SETTINGS
Oiling Rates
EMM programming controls the rate of oil injection
based on engine RPM. This rate can be adjusted
for the grade of oil being used, and also for power-
1. Lower to upper main bearing oiling circuit 005043
2. Idle oil circuit head break-in. Use Evinrude Diagnostics software
3. Tee fitting to access these features.
4. Cylinder recirculation circuit
Refer to Oil Injection Rate on p. 60.
Crankcase / Main Bearing Recirculation
The movement of oil through the main bearings is Break-in Oiling
controlled by internal passages, external fittings The EMM automatically supplies extra oil to the
and hoses, and an in-line check valve. engine during the first two hours of operation,
above 2000 RPM.
Both center main bearings receive oil through
• Use Evinrude Diagnostics software to make
grooved passages in the crankcase. Oil migrates
sure the break-in program has been started on
to the bearings from the crankcase areas of the a new outboard.
higher cylinders. • Use the diagnostics software to start break-in
The lower main bearing receives oil through a oiling after a powerhead rebuild.
grooved passage in the crankcase.
9
1
Lower to upper main bearing oil flow
Lower main bearing cavity through internal crank-
case passage to external fitting, external hoses
with in-line check valve to external fitting at upper
main bearing, and into upper main bearing
through internal crankcase passage.
199
OILING SYSTEM
OILING SYSTEM TESTS
200
OILING SYSTEM
OILING SYSTEM TESTS
1
2
1
3
201
OILING SYSTEM
OILING SYSTEM TESTS
Place a new seal on oil tank and reinstall pickup LOW OIL Sending Unit Test
with filter into oil tank. Install and tighten screws. Remove oil from the oil tank
Oil Injection Pump Function Test Turn the key switch ON. The dash mounted
Remove oil distribution hose from fitting at crank- Engine Monitor system should show a LOW OIL
case. Squeeze oil supply primer bulb to provide oil warning.
to injection pump.
Once the warning has been confirmed, refill the oil
tank. The LOW OIL warning should stop when the
oil level exceeds one-quarter of oil tank’s capacity.
1
202
OILING SYSTEM
OIL COMPONENT SERVICING
203
OILING SYSTEM
OIL COMPONENT SERVICING
204
OILING SYSTEM
OIL COMPONENT SERVICING
Install oil pump on bracket with clamp and retain- Reconnect oil supply hose to the inlet fitting of oil
ing screw. Tighten to a torque of 24 to 36 in. lbs. (3 pump. Fasten with Oetiker clamp.
to 4 N·m).
1 1
Reconnect the electrical connector. Make sure oiling system is primed. Check oil flow
through oil distribution hoses. Check oil system
IMPORTANT: Use oil primer bulb to purge air operation and routing of oil hoses. Refer to Oil
from oil supply hose before reconnecting hose to Supply Priming on p. 61.
oil pump.
Run the outboard and check for leaks.
205
OILING SYSTEM
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
206
COOLING SYSTEM
COOLING SYSTEM
TABLE OF CONTENTS
HOSE ROUTING AND WATER FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
ADAPTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
EMM AND VAPOR SEPARATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
IDLE OPERATING TEMPERATURE TROUBLESHOOTING (BELOW RANGE) . . . . . . . . . . . . . . . . . . . . . . . 213
TEMPERATURE SENDER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
10
207
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAM
6 9 11
7
7
8
5
8
5
5 4
PORT
Port REAR
Rear
Outgoing
Outgoing water
water (warm/hot)
(warm/hot)
1
Incoming water (cool)
Incoming Water (cool)
004109
208
COOLING SYSTEM
COMPONENTS
1
2
3
10
1
5
209
COOLING SYSTEM
COMPONENTS
Overheating: A restricted or faulty valve typically Overcooling: Debris may prevent the thermostat
results in HIGH SPEED overheating. from closing completely.
Thermostat DSC02335
Pressure Relief Valve Components DRC8113
Block Venting
A fitting and hose from the top of the block allows
the constant movement of water and/or air from
the block. Circulated water flows through the EMM
and Vapor Separator before exiting through the
overboard indicator.
210
COOLING SYSTEM
OPERATION
Additional Cooling
Two external water supply hoses direct water flow
into the exhaust (plenum) area of the cylinder
1. Thermostats 004269
block. The water reduces exhaust runner temper-
2. Pressure valve assembly
atures and circulates through the cylinder block.
10
The thermostats and pressure valve control the
The base gasket limits water flow to the base of
flow of water entering the vertical water passages
the block and diverts water flow to the rear port
of the cylinder heads.
and rear starboard fittings of the adapter housing.
211
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
EMM and Vapor Separator Reduce speed to IDLE for five minutes. Check
Cooling IDLE operating temperature.
Cooling water is routed from the top of the cylinder Increase speed to 5000 RPM and check tempera-
block to the inlet fitting of the EMM water cavity. ture.
Cooling of the EMM helps to stabilize the temper-
atures of internal components. Check temperature on both sides of powerhead.
IMPORTANT: Improper EMM cooling will acti- If engine temperature is not within range, trouble-
vate service codes 25 and 29 and the Engine shoot cooling system.
Monitor warning system. Refer to the EMM Ser-
vice Code Chart at the back of this manual for If engine temperature tests within range, but the
specific service code information. SystemCheck gauge indicates a “WATER TEMP”
warning, refer to WATER TEMP/ HOT Circuit
Cooling water from the EMM is routed to the water Test on p. 146.
inlet fitting of the vapor separator water cavity.
Cooling the vapor separator fuel chamber mini-
mizes fuel vaporization.
212
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
Pyrometer Method
Use a Temperature Gun, P/N 772018, or a digital Seal
pyrometer to measure the outboard’s operating
temperature.
Pressure Relief Valve DRC8113
Measure temperature at the top of cylinder block,
next to the thermostat housing and cylinder head. If IDLE temperature increases to specific operat-
Check temperature on both sides of powerhead. ing range, pressure relief valve and thermostats
are functioning properly. 10
213
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
If IDLE temperature is below specific operating Start the outboard and check IDLE operating tem-
range, pinch off the water outlet hoses from pres- perature using Evinrude Diagnostics software pro-
sure relief valve to cylinder heads. gram.
Thermostats
1. Outlet hoses DSC00827 Remove thermostat cover(s) and inspect thermo-
2. Pliers stat(s).
004338
214
COOLING SYSTEM
TEMPERATURE SENDER SERVICING
007209 004338
Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Installation Inspection
Fill bottom of sensor cavity with 0.7 cc of Thermal Inspect all parts for cracks, heat damage, or signs
Joint Compound, P/N 322170. Sensor cavity of corrosion. Replace damaged parts. Clean
should be filled to 1 inch (25 mm) below the top debris from housing and parts.
edge of the cavity.
1 in. 1
(25 mm)
000757
10
Assembly
Assembly is the reverse of disassembly. Pay
close attention when performing the following
additional tasks.
3 2 Coat threads of each cylinder head thermostat
cover with Gasket Sealing Compound. Install and
1. Temperature sensor 007049 tighten the cover to a torque of 120 to 144 in. lbs.
2. Sensor cavity (13.5 to 16.5 N·m).
3. Thermal joint compound
215
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
1. Hoses 004269
1. Bracket DRC8113
2. Cap
216
POWERHEAD
POWERHEAD
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
TAPER PIN TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
POWERHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
POWERHEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
THROTTLE LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
SHIFT LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
POWERHEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CRANKSHAFT AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
SHIFT LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
THROTTLE LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
FINAL POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
POWERHEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
PORT HOSE ROUTINGS – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
STARBOARD HOSE ROUTINGS – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
PORT HOSE ROUTINGS – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
11
STARBOARD HOSE ROUTINGS – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
PORT – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
STARBOARD – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
PORT – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
STARBOARD – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
FRONT – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
FRONT – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
REAR – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
REAR – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
217
POWERHEAD
SERVICE CHART
SERVICE CHART
A Triple-Guard Grease
60-84 In. lbs. B Gasket Sealing Compound
(7-9.5 N·m)
D Moly Lube
B
L B
X
H
A
Q
P, X
J
E
38-42 Ft. lbs.
(52-57 N·m)
17-19 Ft. lbs. H
(23-26 N·m)
H
H
218
POWERHEAD
SERVICE CHART
B
60-65 Ft. lbs.
(81-88 N·m)
X
F
96-120 In. lbs.
(11-13.5 N·m)
F
96-120 In. lbs.
11
(11-13.5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
Y Extreme Pressure Grease
004108 X See Service Manual Text
219
POWERHEAD
TAPER PIN TOOL
COMPRESSION TESTING
Start and run outboard until it achieves operating If engine shows a variation greater than 15 psi
temperature, then shut OFF. (100 kPa) between cylinders, check for:
• damaged cylinder head
Disconnect crankshaft position sensor (CPS) con-
• damaged pistons
nector. Remove all spark plugs.
• broken or stuck piston rings
Advance throttle linkage to WOT. • scored cylinder walls
Install compression tester’s hose attachment into Return throttle to idle position and reconnect CPS
spark plug hole (14 mm threads). connector. Replace spark plugs. Refer to Spark
Plug Indexing on p. 84.
While cranking outboard with starter, note maxi-
mum pressure reading on gauge. Repeat proce-
dure for each cylinder.
220
POWERHEAD
POWERHEAD REMOVAL
WARNING
Protect against hazardous fuel spray.
Before starting any fuel system service,
carefully relieve fuel system pressure.
Refer to Relieving Fuel System Pressure
on p. 178. 2 1
To prevent accidental starting while ser-
vicing, disconnect the battery cables at
the battery.
2
1. Cooling hose (to exhaust plenum) 005042
2. Exhaust back pressure hose (to EMM)
3. Cooling hose (from block) – 3.3 L models
11
1
221
POWERHEAD
POWERHEAD REMOVAL
1 1
1
1
48758
222
POWERHEAD
POWERHEAD DISASSEMBLY
Remove shift linkage. Refer to Shift Linkage Slide entire shift linkage assembly from crank-
Removal on p. 223. case.
223
POWERHEAD
POWERHEAD DISASSEMBLY
004140
2
Remove the lower crankcase head screws.
1. Tool 49428
2. Taper pin
004146
004139
004136
224
POWERHEAD
POWERHEAD DISASSEMBLY
Separate crankcase and cylinder block. It may be Connecting Rods and Pistons
necessary to tap on crankshaft with a rawhide or
Use a permanent marker to identify each connect-
rubber mallet to loosen.
ing rod cap, connecting rod, and piston by cylinder
number. Number 1 is closest to the flywheel.
49429
000825
Carefully remove the crankcase from the cylinder
block to avoid damaging the crankshaft seal rings.
Use Torquing Socket, P/N 346187, to loosen in
stages the rod cap retaining screws. DO NOT
remove the screws.
004137
11
49431
225
POWERHEAD
POWERHEAD DISASSEMBLY
Use one hand to support the piston, and remove Remove wrist pin retaining rings. Discard retaining
the rod cap screws with your other hand. Remove rings.
each piston and rod assembly.
000689
46519 31809
226
POWERHEAD
POWERHEAD DISASSEMBLY
Use a drift punch to remove the upper crankshaft Remove the O-ring from crankshaft sleeve and
seal. Remove and discard two crankcase head inspect it. Replace the O-ring if it is not in good
O-rings. condition.
0865 30057
If the lower crankcase head is to be resealed or Inspect the crankshaft sleeve and replace, if nec-
the lower main bearing replaced, remove the four essary. To remove the sleeve, use Slide Hammer,
bearing retainer screws. While rotating the crank- P/N 432128, and Large Puller Jaws, P/N 432129.
case head, gently tap on the flange and remove
the head.
30056
30069
227
POWERHEAD
POWERHEAD DISASSEMBLY
IMPORTANT: If the lower main bearing is Remove center main bearings and split sleeves
removed from the crankshaft, it must be dis- for inspection. DO NOT mix parts. Note location of
carded. DO NOT reuse it. bearings for reassembly.
5195
30291
5198
228
POWERHEAD
CYLINDER BLOCK CLEANING
WARNING
IMPORTANT: Before inspecting or assembling
powerhead, all internal components must be com- To avoid personal injury, wear eye protec-
pletely clean and free of contaminants. tion and rubber gloves when using Gel
Seal and Gasket Remover.
Remove any carbon accumulation from exhaust
port areas.
229
POWERHEAD
POWERHEAD INSPECTION
POWERHEAD Crankshaft
Measure the diameter of each crankpin and main
INSPECTION bearing journal. The lower main bearing journal
For dimensions, refer to SERVICE SPECIFICA- would only be measured if the bearing was
TIONS on p. 10. removed for another reason.
49425
1936
230
POWERHEAD
POWERHEAD INSPECTION
The dimensional difference between the two Ring end gap should be:
areas is cylinder taper. • 0.022 to 0.028 in. (0.56 to 0.71 mm)
• The cylinder taper must not exceed 0.002 in.
(0.05 mm). IMPORTANT: Ring end gap increases approxi-
mately 0.003 in. (0.076 mm) for each 0.001 in.
(0.025 mm) increase in cylinder bore diameter.
DO NOT exceed cylinder oversize dimension.
1 Use a machinist’s straightedge to check for proper
ring clearance. Position piston rings on piston.
Push rings into groove and hold straightedge
against the side of the piston. Rings must be even
or just below the surface of piston. Rings must
move freely in piston ring groove.
11
1. Cylinder taper DR1119
231
POWERHEAD
POWERHEAD ASSEMBLY
Bearings POWERHEAD
Inspect center main bearing and split sleeves for
excess wear, nicks, or scratches. Replace if nec- ASSEMBLY
essary.
IMPORTANT: Proceed slowly. Make no forced
assemblies unless a pressing operation is called
for. All internal components must be perfectly
clean and lightly coated with outboard lubricant.
Crankshaft
Place bearing retainer plate, flat side down, on
lower end of crankshaft.
24381
232
POWERHEAD
POWERHEAD ASSEMBLY
new sleeve onto the crankshaft until the installer Use retaining ring pliers to install bearing retaining
contacts the lower main bearing. ring with sharp edge facing away from bearing.
30061
30071
000829
233
POWERHEAD
POWERHEAD ASSEMBLY
Lightly coat the outside diameter of a new crank- Install new seals on the four bearing retainer
shaft seal with Gasket Sealing Compound. Use screws. Apply Nut Lock to the threads of the
Seal Installation Tool, P/N 325453, to install seal screws and tighen to a torque of 96 to 120 in. lbs.
in lower crankcase head with extended lip of seal (11 to 13.5 N·m).
facing down. Coat seal lips with Triple-Guard
grease.
1
1. Seal, extended lip DRC5798
000827
Lightly coat two new O-rings with Gasket Sealing
Compound and install on lower crankcase head. Lightly coat the outside diameter of a new upper
Keep sealer away from oil passage. seal with Gasket Sealing Compound. Use the flat
end of Seal Installation Tool, P/N 325453, to install
seal flush in upper crankcase head with the lip
facing down. Coat the seal lip with Triple-Guard
1 grease.
000826
234
POWERHEAD
POWERHEAD ASSEMBLY
Lightly coat two new O-rings with Gasket Sealing Apply outboard lubricant to the wrist pin bearings.
Compound, and install on upper crankcase head. Install the bearings in the wrist pin bore.
Keep sealer away from oil passage.
Oil the wrist pin bore and wrist pin. Place connect-
ing rod with bearing into the piston with the align-
ment dots facing the top of the piston.
1
002057
11
1
1. Stamped markings 004305
Use Wrist Pin Cone, P/N 331913, and Driver,
P/N 396747, to install new wrist pin retaining rings
IMPORTANT: It is also very important that the
connecting rods are installed with the alignment
dots facing up, toward the flywheel.
235
POWERHEAD
POWERHEAD ASSEMBLY
in each wrist pin hole. Gap of retaining ring faces IMPORTANT: Before continuing, make sure that
away from notch in piston. all Gel-Seal II has been removed from the cylinder
block and crankcase mating flanges. If traces of
hardened Gel-Seal II are left, main bearings could
be misaligned. Refer to CYLINDER BLOCK
CLEANING on p. 229.
DR1641
Slide piston and rod assembly into the correct cyl-
inder, as marked during disassembly. Guide con-
necting rod through cylinder block to avoid
scratching cylinder wall.
1
1. Gap in retaining ring 000756
2. Notch in piston
49435
Installing Pistons
When all pistons and connecting rods are assem- Cylinder Head Installation
bled, install piston ring sets. Be sure rings are Lightly coat both sides of a new cylinder head
installed in the cylinder used to test ring end gap. gasket with Gasket Sealing Compound. Place
Refer to POWERHEAD INSPECTION on p. 230. gasket on cylinder block following instructions
printed on gasket.
IMPORTANT: Be sure gap of ring fits squarely
around dowel pin. Apply soapy water to water dam and insert into
block.
002048
236
POWERHEAD
POWERHEAD ASSEMBLY
Install cylinder head with the thermostat toward Gently lower crankshaft into place.
the top. Apply Triple-Guard grease to threads and • Turn all crankcase seal ring gaps to face up.
install the cylinder head screws. DO NOT use any • Locate each main bearing on its dowel pin. A
sealant on threads mark placed on the bearing race opposite the
dowel pin hole will help in the alignment pro-
Following sequence on cylinder head, tighten all cess.
screws in stages to a torque of 17 to 19 ft. lbs. (23 • Tap the crankshaft upward with a rawhide mallet
to 26 N·m). to seat crankshaft and lower crankcase head.
• Loosely secure upper and lower crankcase
heads with two screws.
004133
31828
31827
11
004130
237
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate rod cap screw threads and under screw Install Rod Cap Alignment Fixture, P/N 396749,
head mating surface with a light coat of Triple- before tightening rod cap screws. Align the flat
Guard grease. Apply outboard lubricant to screw marked “SET” on the rod adjustment stop with the
hole threads in rod, and to screw head mating sur- arrow on the frame. Position the stop at the high-
face on cap. est setting (two lines showing). Rotate adjustment
knob 180° to lock the stop in position.
Align dot on rod cap with dot on the connecting
rod.
238
POWERHEAD
POWERHEAD ASSEMBLY
Apply a light coat of outboard lubricant to the cor- Loosen both rod cap screws one-quarter turn.
ners of the connecting rod and rod cap. Place
frame on connecting rod using the following pro- Use Torquing Socket, P/N 346187, to tighten rod
cedure: cap screws in three stages:
• Position frame onto the connecting rod so the • Apply first torque of 40 to 60 in. lbs. (5 to 7 N·m)
contact area of the jaw is centered on the side to both rod cap screws.
of the rod. • Tighten screws to a torque of 20 to 22 ft. lbs. (27
• Tighten forcing screw until jaws contact con- to 30 N·m).
necting rod. • Apply final torque of 60 to 65 ft. lbs. (81 to 88
• Slide frame down until adjustment stop contacts N·m).
the rod cap. The groove lines on the jaws must
be centered on the rod/crankpin diameter.
21605
11
21587
239
POWERHEAD
POWERHEAD ASSEMBLY
004135
004134
240
POWERHEAD
POWERHEAD ASSEMBLY
004142
241
POWERHEAD
POWERHEAD ASSEMBLY
242
POWERHEAD
POWERHEAD INSTALLATION
11
1
48758
243
POWERHEAD
POWERHEAD INSTALLATION
1 2
1
2
2 1
1. Trim/tilt connectors 004251
3
Install flywheel. Refer to Flywheel Installation on
p. 149.
1. Cooling hose (from exhaust plenum) 004239
2. Cooling hose (from vapor separator)
3. Speedometer hose
244
POWERHEAD
POWERHEAD INSTALLATION
Install air temperature sensor, air silencer, and fly- IMPORTANT: Perform the following procedures
wheel cover. Tighten flywheel cover screws to a before returning outboard to service:
torque of 30 to 42 in. lbs. (3.5 to 5 N·m). • Index all spark plugs. Refer to Spark Plug
Indexing on p. 84.
• Adjust timing pointer and check engine timing.
Refer to TIMING ADJUSTMENTS on p. 151.
• Use Evinrude Diagnostics software to start pow-
erhead break-in oiling. Refer to Powerhead
1 Break-In on p. 106.
• Prime oiling system. Refer to Oiling System Oil
Supply Priming on p. 61.
• Run outboard and check for water, fuel, or oil
leaks.
• Make sure engine reaches correct operating
1. Air temperature sensor 004219 temperature and does not overheat.
11
245
POWERHEAD
POWERHEAD VIEWS
POWERHEAD VIEWS
Port Hose Routings – 3.3 L models
006951
246
POWERHEAD
POWERHEAD VIEWS
11
006952
247
POWERHEAD
POWERHEAD VIEWS
007153
248
POWERHEAD
POWERHEAD VIEWS
11
007154
249
POWERHEAD
POWERHEAD VIEWS
007139
250
POWERHEAD
POWERHEAD VIEWS
11
007138
251
POWERHEAD
POWERHEAD VIEWS
007143
252
POWERHEAD
POWERHEAD VIEWS
11
007144
253
POWERHEAD
POWERHEAD VIEWS
007140
254
POWERHEAD
POWERHEAD VIEWS
11
007145
255
POWERHEAD
POWERHEAD VIEWS
007141
256
POWERHEAD
POWERHEAD VIEWS
11
007142
257
POWERHEAD
POWERHEAD VIEWS
Top
007146
258
MIDSECTION
MIDSECTION
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
STERN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
EXHAUST HOUSING – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
EXHAUST HOUSING – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
EXHAUST HOUSING DISASSEMBLY – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
EXHAUST HOUSING DISASSEMBLY – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
EXHAUST HOUSING ASSEMBLY – 3.3 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
EXHAUST HOUSING ASSEMBLY – 3.4 L MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
STERN BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
EXHAUST RELIEF MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
12
259
MIDSECTION
SERVICE CHART
SERVICE CHART
Stern Bracket
40-50 In. lbs.
(4.5-5.5 N·m)
IMPORTANT
Use Triple-Guard grease
on all pivot points
40-50 In. lbs.
(4.5-5.7 N·m)
004105
U Instant Bonding Adhesive
260
MIDSECTION
SERVICE CHART
B
F 60-84 In. lbs.
120-144 In. lbs. (7-9.5 N·m)
(14-16 N·m)
L
B B
60-84 In. lbs. 144-168 In. lbs.
(7-9.5 N·m) (16-19 N·m)
Q
9-12 Ft. lbs.
(12-16 N·m)
B
60-84 In. lbs. C
(7-9.5 N·m)
Q
C
B See Assembly
60-84 In. lbs. Instructions
(7-9.5 N·m)
B
60-84 In. lbs.
(7-9.5 N·m)
B
B
C
A A
156-180 In. lbs.
A Triple-Guard Grease C
B Gasket Sealing Compound
(18-20 N·m)
12
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
L Pipe Thread Sealing Compound C
P Permatex #2
A 004107
Q Gel Seal II
261
MIDSECTION
SERVICE CHART
P
144-168 In. lbs.
(16.5-19 N·m)
B
144-168 In. lbs.
Q (16.5-19 N·m)
9-12 Ft. lbs.
(12-16 N·m)
B C
60-84 In. lbs.
(7-9.5 N·m)
C F
60-84 In. lbs.
(7-9.5 N·m
A
Q
A
156-180 In. lbs.
A Triple-Guard Grease (18-20 N·m)
C
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
L Pipe Thread Sealing Compound C
P Permatex #2
Q Gel Seal II A 004107BT
262
MIDSECTION
SERVICE CHART
Muffler
12
263
MIDSECTION
TILT TUBE
Removal
WARNING
Support the outboard with a suitable hoist.
Pull the locking tabs on the tilt limit cam loose from
30747
the collar.
Thread the spacer from Tilt Tube Service Kit,
P/N 434523, onto the starboard end of the tilt
tube.
30748
30745
264
MIDSECTION
TILT TUBE
Thread Slide Hammer, P/N 432128, into the Install the starboard locknut.
adapter until at least 2 in. (51 mm) of thread are
engaged. WARNING
Replace locknut if definite resistance is
not felt.
30744
Pull tilt tube from stern bracket with the slide ham-
mer. When tilt tube clears the port stern bracket,
remove tilt tube from the spacer.
Installation
Thread starboard end of tilt tube into the spacer.
Thread the adapter onto port end of tilt tube.
30741
Use a wood or leather mallet to tap the tilt tube
into position. Replace steering cable wiper nut on port end of tilt
tube.
30743
12
1
30750
265
MIDSECTION
EXHAUST HOUSING
006979
32590
1 TYPICAL 23033
32578
266
MIDSECTION
EXHAUST HOUSING
Exhaust Housing Disassembly – Mark the water tube for correct reassembly loca-
tion. Remove six inner exhaust housing screws.
3.3 L models Remove the inner exhaust housing.
Remove two front adapter to outer exhaust hous-
ing screws. Remove three nuts at rear of the
adapter.
13638
1. Cover 13641
2. Water plate
32588
12
267
MIDSECTION
EXHAUST HOUSING
Exhaust Housing Disassembly – Loosen and remove the upper mount plate screws
and remove the mount plate.
3.4 L models
Remove two front adapter to outer exhaust hous-
ing screws.
32588
Remove three nuts at rear of the adapter. Lift the adapter/inner exhaust housing out of the
.
exhaust housing.
.
006978
006981
268
MIDSECTION
EXHAUST HOUSING
Cleaning and Inspection Inspect the water tube for obstructions or kinks,
which may restrict water flow.
WARNING
Exhaust Housing Assembly –
Wear safety glasses to avoid personal
injury, and set compressed air to less than
3.3 L models
25 psi (172 kPa). Lightly coat both sides of a new gasket with Gas-
ket Sealing Compound and install the gasket and
water plate.
Clean all parts with parts cleaning solvent and dry
with compressed air. All nut and screw threads Apply Gasket Sealing Compound to threads of the
coated with thread locking material must be thor- water plate retaining screws. Install with washers
oughly cleaned before assembly. When using a and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
thread locking product, be sure to prime the N·m).
threads with Locquic Primer.
12
13642
DR2223
269
MIDSECTION
EXHAUST HOUSING
Coat the outside diameter of a new water tube Install a new inner exhaust housing seal. Apply
grommet with Adhesive 847. Install grommet in Adhesive 847 to the seal groove.
the inner exhaust housing. Install the water tube.
7715
13640
Lightly coat both sides of a new inner exhaust
housing gasket with Gasket Sealing Compound Clean and degrease the adapter housing and
and install it. outer exhaust housing mating surfaces with
Cleaning Solvent. Apply Gel-Seal II sealant to the
Install the inner exhaust housing. Coat inner adapter flange of the exhaust housing.
exhaust housing screws with Gasket Sealing
Compound and tighten to a torque of 60 to 84 in.
lbs. (7 to 9.5 N·m).
13692
7713
32580
270
MIDSECTION
EXHAUST HOUSING
Lubricate the upper mount with soapy water and Tighten the small adapter to exhaust housing
push into place in the adapter housing. The mount screws and nuts to a torque of 60 to 84 in. lbs. (7
radius must face aft with the “TOP” mark facing to 9.5 N·m).
up.
13691
32579
13690
12
271
MIDSECTION
EXHAUST HOUSING
13692
006981
32580
272
MIDSECTION
EXHAUST HOUSING
Lubricate the upper mount with soapy water and Tighten the small adapter to exhaust housing
push into place in the adapter housing. The mount screws and nuts to a torque of 60 to 84 in. lbs. (7
radius must face aft with the “TOP” mark facing to 9.5 N·m).
up.
13691
23033
006986
12
32579
273
MIDSECTION
EXHAUST HOUSING
Exhaust Housing Installation Attach the ground lead and star washer to the
steering arm’s starboard side.
Bring the exhaust housing into position with the
stern bracket.
1 32586
32585
274
MIDSECTION
STERN BRACKET
Remove and discard steering shaft locknut. Pry out upper and lower steering shaft seals and
discard. Remove the upper and lower steering
shaft bushings.
30738
30765 / 30764
Remove the lower mount bracket and keeper.
Remove the tilt tube. Refer to TILT TUBE on
p. 264.
12
30736
30763
275
MIDSECTION
STERN BRACKET
Remove the anode. Remove the tilt limit switch and retainer from the
swivel bracket.
2
1. Anode 30762
1. Tilt limit switch 30758
Remove the swivel bracket. Inspect and, if neces- 2. Retainer
2
1
1. Tilt tube bushing 30761
Remove the trim sender unit from the port stern 1. Trail lock spring 30756
2. Trail arm retainer
bracket and pull its wires through the braided
tube. Remove the trail lock arm and bushings from the
swivel bracket.
30760
276
MIDSECTION
STERN BRACKET
Remove the two trim rod rollers from the swivel Stern Bracket Assembly
bracket.
IMPORTANT: Before proceeding, make sure all
components have been thoroughly cleaned.
Replace any seals that have been removed.
Inspect all thrust washers and bushings for evi-
dence of deterioration.
Install the detent roller and spring and the tilt sup-
1 port with bushing in the swivel bracket. Tighten
bushing to a torque of 28 to 30 ft. lbs. (38 to 41
N·m).
1
30752
12
277
MIDSECTION
STERN BRACKET
Install the two trim rod rollers on the swivel Install the tilt limit switch and retainer on the swivel
bracket. Tighten to a torque of 216 to 240 in. lbs. bracket. Tighten screws to a torque of 40 to 50 in.
(25 to 27 N·m). lbs. (4.5 to 5.5 N·m).
2
1
278
MIDSECTION
STERN BRACKET
• Coat the bushings and seal lips with Triple- Install the steering shaft keeper. Apply Locquic
Guard grease. Primer and Nut Lock to the splines of the steering
shaft and lower mount bracket.
30765 / 30764
30736
30761
Install the tilt tube and tilt limit cam. Refer to TILT
TUBE on p. 264.
30735
279
MIDSECTION
EXHAUST RELIEF MUFFLER ASSEMBLY
1
1
1. Overboard indicator and flush port 004225
280
GEARCASE
GEARCASE
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
GEARCASE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
PROPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
GEARCASE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
PROPELLER SHAFT BEARING HOUSING REMOVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
SHIFTER, BEARING AND SEAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PINION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
DRIVESHAFT BEARING HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
PROPELLER SHAFT BEARING HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
SHIFT ROD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
GEARCASE – COUNTER ROTATION
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
PINION GEAR REMOVAL AND DRIVESHAFT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
SHIFTER, BEARING AND SEAL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
SHIFT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
PINION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
PROPELLER SHAFT BEARING HOUSING AND FORWARD GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
SHIFT ROD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
13
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
281
GEARCASE
SERVICE CHART
SERVICE CHART
V6 PERFORMANCE MODELS “L2”-TYPE GEARCASE
C
B B
A
A
A 45-50 Ft. lbs.
B (61-68 N·m)
C A
A 18-20 Ft. lbs. B
X (24-27 N·m)
26-28 Ft. lbs.
(35-38 N·m) 60-84 in. lbs.
(6.8-9.5 N·m)
G B
B
B 26-28 Ft. lbs.
60-84 In. lbs. 14-18 In. lbs. (35-38 N·m)
(7-9.5 N·m) (1.5-2 N·m)
100-110 Ft. lbs.
J (136-149 N·m)
A A
35-40 Ft. lbs.
(47-54 N·m)
282
GEARCASE
SERVICE CHART
C
B
C
A
A 26-28 Ft. lbs.
(35-38 N·m)
A B B 45-50 Ft. lbs.
(61-68 N·m)
C
A X A
18-20 Ft. lbs.
(24-27 N·m) 60-84 in. lbs.
G (6.8-9.5 N·m)
B B
14-18 In. lbs. 26-28 Ft. lbs.
(1.5-2 N·m) (35-38 N·m)
J B
60-84 In. lbs.
100-110 Ft. lbs.
(7-9.5 N·m)
A (136-149 N·m)
A
35-40 Ft. lbs. 60-84 In. lbs.
(47-54 N·m) (7-9.5 N·m)
A A (41-46 N·m)
J
A
A Triple-Guard Grease
A B Gasket Sealing Compound
C Adhesive 847
D
E
Moly Lube
Red Ultra Lock
13
F Blue Nut Lock
G Needle Bearing Grease
J Gearcase Lubricant
006830 X See Service Manual Text
283
GEARCASE
SERVICE CHART
C A
60-84 In. lbs.
24-36 In. lbs. (7-9.5 N·m)
(3-4 N·m) B B A
A
120-144 In. lbs.
B (13.5-16.5 N·m)
A D
B 60-84 In. lbs.
(7-9.5 N·m)
B
A
C
B
C
A
A
26-28 Ft. lbs.
A (35-38 N·m)
B 45-50 Ft. lbs.
C B (61-68 N·m)
A
X A
18-20 Ft. lbs. 60-84 in. lbs.
(6.8-9.5 N·m)
B G (24-27 N·m)
B
26-28 Ft. lbs.
14-18 In. lbs.
(35-38 N·m)
(1.5-2 N·m)
100-110 Ft. lbs. B
100 Ft. lbs. J (136-149 N·m) 60-84 In. lbs.
(136 N·m) J (7-9.5 N·m)
A G
A
A A
A Triple-Guard Grease
B Gasket Sealing Compound
A C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
J Gearcase Lubricant
006831 X See Service Manual Text
284
GEARCASE
GEARCASE TYPES
GEARCASE TYPES
Housing
Outboard Model Description of Features Gear Ratio
Type
high speed profile, external water screens, pressed in 14:26 (.538)
90°V6 20 in.
“L2” propeller bearing housing, performance gearset (V6). and
90°V6 25 in.
.583 ratio is original equipment on 225HO/250/300 HP. 14:24 (.583)
90°V6 20 in. front water inlets and straight leading edge, pressed in
90°V6 25 in. propeller shaft bearing housing with retaining flange, 13:24 (.542)
90°V6 30 in. heavy duty standard gearset (V6)
“M2”
front water inlets and straight leading edge, pressed in
90°V6 25 in. / 30 in.
propeller shaft bearing housing with retaining flange“ 13:24 (.542)
Counter Rotation
CR” shafts, bearings and heavy duty gearset (V6)
Housing Identification
Remove the trim tab retaining screw, gasket and Make note of identification markings. Refer to
trim tab from the gearcase. Housing Profiles on p. 285.
1
1
Housing Profiles
V6 “L2” Type V6 “M2” Type
19.20 19.20
13
006976 4.918
5.082
285
GEARCASE
PROPELLER SERVICE
002388
286
GEARCASE
SHIFT INTERRUPT SWITCH
1
13
1. Index mark COA3663
2. Trim tab retaining screw
287
GEARCASE
GEARCASE REMOVAL AND INSTALLATION
Remove the forward screw with the washer, and Gearcase Installation
remove middle screw.
WARNING
2 During service, the outboard may drop
unexpectedly. Avoid personal injury;
always support the outboard’s weight with
a suitable hoist or the tilt support bracket
during service.
288
GEARCASE
GEARCASE REMOVAL AND INSTALLATION
Apply Gel-Seal II to gearcase mating surface pads Apply Gasket Sealing Compound to threads of the
on exhaust housing. Slide the gearcase into gearcase retaining screws. Tighten the screws to
place, making sure that: a torque of:
• Driveshaft engages the crankshaft. • 3/8 in. screws – 26 to 28 ft. lbs. (35 to 38 N·m)
• Water tube enters the water pump. • 7/16 in. screws – 45 to 50 ft. lbs. (61 to 68 N·m)
• Lower inner exhaust housing installs correctly.
• Shift rod does not turn and is positioned prop-
erly in shift shaft connection area.
289
GEARCASE
WATER PUMP SERVICE
2 1
1. Trim tab screw COA3663
2. Index mark
1
IMPORTANT: Standard rotation and counter
rotation trim tabs must not be interchanged. This
would result in inadequate cooling water supply to 1. Screws 31998
the propeller hub.
Slide the water pump off the driveshaft. Remove
Place the shift rod in the shift rod lever. Install the the impeller key, O-ring, impeller plate, and gas-
retaining pin and washer. Tighten pin to a torque ket. Discard the gasket.
of 60 to 84 in. lbs. (7 to 9.5 N·m).
Make sure gasket surface is clean and smooth.
1 1
To prevent loss of operator control, check Remove all the parts from the housing.
for proper shifting operation and adjust, if
necessary. Inspection
Check impeller for overheating, hub separation,
IMPORTANT: During break-in period of a reas- and other wear or damage.
sembled gearcase, change the gearcase lubricant
between 10 to 20 hours of operation. Check liner and wear plate for scoring, distortion,
and impeller material transfer.
290
GEARCASE
WATER PUMP SERVICE
1 1
1. Chamfer 32000
1. O-ring 34814
On outboard models with 5/8 in. diameter water
tube, remove water tube from exhaust housing
Lightly coat the exterior of the impeller cup with
and replace o-rings. Apply a light coat of Triple-
Gasket Sealing Compound. Install the cup in the
impeller housing.
Make sure vent hole in impeller cup is open.
13
291
GEARCASE
WATER PUMP SERVICE
Guard grease to the o-rings and reinstall water Apply a thin bead of Adhesive 847 in the seal
tube in exhaust housing. groove, and install the special shaped O-ring seal.
1
1 1
Apply Triple-Guard grease to screw threads and Apply Gasket Sealing Compound to both sides of
install the impeller housing cover. Tighten screws a new impeller plate gasket. Install the gasket and
to a torque of 24 to 36 in. lbs. (3 to 4 N·m). impeller plate.
Apply Adhesive 847 to flat side of the impeller Apply Triple-Guard grease to a new impeller O-
housing grommet. Install the grommet, flat side ring. Slide the O-ring down the driveshaft and half
down. way over installed impeller key to temporarily hold
key in place.
1
2
3
1
2
4
292
GEARCASE
WATER PUMP SERVICE
slide water pump down over key. Be sure impeller On 25 in. and 30 in. outboard models, place the
key does not fall out of position. appropriate water tube spacer and grommet on
the impeller housing cover.
2
2
1 1
Align the impeller housing with the gearcase. After water pump is assembled completely, rotate
Apply Gasket Sealing Compound to threads of the driveshaft counter clockwise 1/4 turn to unlock
four impeller housing screws. Tighten the screws and release impeller and key from driveshaft.
to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
Next, pull up on driveshaft and turn clockwise to
On 20 in. outboard models, place Grommet, lock impeller to shaft. This process increases
P/N 349354, on housing cover. pump efficiency by locking the impeller in a slightly
lower position on the driveshaft.
1. Grommet 007150
007078
13
293
GEARCASE
SHIFT ROD ADJUSTMENT
COA6166
294
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY
13
295
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY
Propeller Shaft Bearing Housing Remove the propeller shaft bearing housing from
the gearcase using:
Removal – “L2” and “M2” Type • Propeller Shaft Bearing Housing Puller Kit,
IMPORTANT: Identify gearcase type before dis- P/N 354060.
assembly. For counter rotation gearcases, refer to DO NOT use tools designed to push on the pro-
GEARCASE DISASSEMBLY on p. 317. peller shaft. Pushing force against the propeller
The propeller shaft bearing housing on “L2” and shaft could damage the forward gear thrust bear-
“M2” models is PRESSED into gearcase housing. ing or thrust washer.
296
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY
Pull propeller shaft and bearing housing far Pinion Gear and Driveshaft
enough to loosen the PRESSED bearing housing
from the gearcase housing.
Removal
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
1
“L2” Type Gearcase 006836
1
1
297
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY
Remove driveshaft from the gearcase. The bear- Locked Driveshaft Removal
ing housing, shims, thrust bearing, and thrust The driveshaft to pinion taper is a locking taper. If
washer will come out with the driveshaft. necessary, use Driveshaft Puller, P/N 390706, and
Backing Plate, P/N 325867, to break the lock.
Install the tools as shown by clamping them
around the driveshaft. Alternately tighten the two
1
vertical screws against the backing plate inserted
between the puller and the gearcase until the
driveshaft pops loose from the pinion.
2
4
1
3
2
1. Bearing housing COA3558
2. Shims
3. Thrust bearing 3
4. Thrust washer
Remove the pinion gear and pinion nut from the 1. Drive shaft 006879
gearcase. 2. Puller
3. Backing plate
006878
006880
298
GEARCASE – STANDARD ROTATION
GEARCASE DISASSEMBLY
0.125 in.
1 (3.2 mm)
1. Roll pin DR4610
006882
13
006883
299
GEARCASE – STANDARD ROTATION
GEARCASE HOUSING INSPECTION
006787
300
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Insert a suitable tool under one end of the clutch 1. Gear 006889
2. Thrust bearing
dog spring and remove it from its groove by 3. Thrust washer
unwrapping it from around the clutch dog. Dis-
card the spring. Remove the shift lever pin from the housing.
Remove shift shaft, cradle and shift lever. Move
shifter detent as needed to help ease removal of
parts.
1
5 4
3
1
2
1. Clutch dog spring 006887
WARNING
Wear safety glasses to avoid personal
injury. The detent ball and spring and
come out with great force.
1
1. Pin 006888
13
301
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Wrap the housing with a shop cloth to catch ball the ball, remove the tool and position detent to
and spring. Rotate the shifter detent 90° in either engage NEUTRAL position.
direction, then pull the detent out of the housing.
006900
3
006899
302
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Rest the cradle on the shift shaft. IMPORTANT: Bearing and washer must be
installed in the correct order.
2
1
1
1. Cradle 004512
1. Thrust bearing 006905
2. Shift shaft
2. Thrust washer
Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro-
shift cradle. Pull shifter detent back up to NEU- peller shaft. Install the clutch dog on the shaft with
TRAL position to hold the cradle and shaft in “PROP END” facing rear of the shaft.
place.
IMPORTANT: The clutch dog is not symmetri-
cal. If installed backward, it will not fully engage
and will immediately damage itself and the gears.
001219
13
303
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
of the pin, MAKING SURE NONE OF THE COILS Use a 7/8 in. wrench to hold the remover in place.
OVERLAP OR ARE LOOSE. Use a 3/4 in. wrench to turn flange nut clockwise.
Draw the bearing up from the housing.
1
2
1
2
3
3 4
7
1. 1/4-20 X 1/2 in. Hex head screw 824182
2. 1 in. O.D. Flat washer
3. Spacer; P/N 350932 “M” and “M2”
P/N 326584 “L” and “L2”
4. Plate and Bearing P/N 391260
5. Rod P/N 326582
6. Installer/Remover, P/N 350958
7. 1/4-20 X 1 1/4 in. Hex head screw
304
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Apply Needle Bearing grease to the needle bear- Driveshaft Bearing Housing
ings and insert them into the bearing case.
Service
Place the bearing on the installer tool with the let- The driveshaft bearing is not serviceable. Replace
tered side of the bearing facing the top of the the bearing housing assembly if the bearing is
gearcase. Use Needle Bearing grease to hold the worn or damaged. Also, inspect the driveshaft
bearing on the tool. bearing surface if the bearing is damaged.
IMPORTANT: The pinion bearing is tapered so Seal Removal
that, when installed correctly, its shape compen- Remove the driveshaft bearing housing seals
sates for stresses in the gearcase and allows full using Puller Bridge, P/N 432127, and Large Puller
bearing contact. Whenever a gearcase is disas- Jaws, P/N 432129. Discard the seals.
sembled, the pinion bearing should be checked to
ensure that it has been installed with the lettering
facing up.
Seal Installation
Lightly apply Gasket Sealing Compound to a new
O-ring. Install the O-ring in top groove of the bear-
ing housing. Do not allow sealant in oil passage.
13
305
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
groove is an oil passage. Gearcase damage could Propeller Shaft Bearing Housing
result.
Service
Rear Seal Removal
1 Remove seals using Puller Bridge, P/N 432127,
and Small Puller Jaws, P/N 432131. Position the
plate on top of the housing to support the bridge,
2 and tighten jaws securely behind the inner seal.
306
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
1
1. Anode 006897
13
307
GEARCASE – STANDARD ROTATION
SHIFTER, BEARING AND SEAL SERVICING
1 1
308
GEARCASE – STANDARD ROTATION
DRIVESHAFT SHIMMING
2 4 1
309
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
1. Pin 006885
005417
310
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
1
1
2
1. Cover seal 006918
ALL GEARCASES
1. Grommet 006917
Thread the shift rod into the shifter detent about
2. Shift rod spacer four turns.
Apply Triple-Guard grease to the threaded end of Move shift rod from side to side while pushing on
the shift rod and insert it through the cover. Turn the propeller shaft to ensure proper alignment of
the shift rod while pushing it through the cover to the bearing housing locator pin into the locator pin
avoid damaging the O-ring. hole in the gearcase.
13
311
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
Apply Gasket Sealing Compound to the threads of Using Driveshaft Seal Protector, P/N 318674,
the shift rod cover screws. Tighten the screws to a slide the driveshaft bearing housing onto the
torque of 60 to 84 in. lbs. (7 to 9.5 N·m). driveshaft and into position in the gearcase.
312
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
the driveshaft by hand to thread the nut on to Pad handle of holder to prevent damage to gear-
shaft. case.
006923 2
13
313
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
Slide the gear assembly onto the propeller shaft gearcase. Align and level gearcase assembly in
until it engages the pinion gear. fixture as shown. Secure fixture to floor press.
Lightly apply Triple Guard Grease to a new bear- Housing must be completely seated in gearcase
ing housing O-ring. Install O-ring in groove in the to install retainer tabs. Depth to retainer tab sur-
housing. Grease the machined side surfaces of face on bearing housing is approximately
bearing housing. 1 in. (25.4 mm).
006845
314
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
2 006846
006924
13
315
GEARCASE – STANDARD ROTATION
GEARCASE ASSEMBLY
gearcase. Align and level gearcase assembly in Apply Ultra Lock to threads and install two retain-
fixture as shown. Secure fixture to floor press. ing screws. Tighten screws to a torque of 18 to 20
ft. lbs. (24 to 27 N·m).
2
3 1
1
1. Retainer screws 006835
006928
316
GEARCASE – COUNTER ROTATION
GEARCASE DISASSEMBLY
1
2
006834
317
GEARCASE – COUNTER ROTATION
GEARCASE HOUSING INSPECTION
Remove propeller shaft, forward gear and bearing shaft assembly. Remove propeller shaft assembly
housing assembly from gearcase. from the gearcase.
006850
GEARCASE HOUSING
1
INSPECTION
Refer to GEARCASE HOUSING INSPECTION on
1. Cover gasket 006884 p. 300.
318
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Insert a suitable tool under one end of the clutch 1. Gear 006931
2. Thrust bearing
dog spring and remove it from its groove by 3. Thrust washer
unwrapping it from around the clutch dog. Dis-
card the spring. IMPORTANT: The shift housing supports the
reverse gear on counter rotation gearcases.
1. Pin 006861
WARNING
Wear safety glasses to avoid personal
injury. The detent ball and spring and
come out with great force.
1
1. Pin 006930
13
319
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Wrap the housing with a shop cloth to catch ball able tool. Once the detent is past the ball, remove
and spring. Pull the shifter detent straight out of the tool and position detent to engage NEUTRAL.
the housing.
1
2
1
1. Punch 006934
1. Ball and spring 006932
2. Shifter detent Thoroughly grease 25 needle bearings with Nee-
dle Bearing grease and place in the bearing case.
Remove the detent ball and spring.
006933
1
Insert shifter detent into the housing as shown,
while depressing the ball and spring with a suit-
1. Cradle 006860
2. Shift lever
320
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Install arms of shift lever into detent slots. Align Coat thrust bearing and thrust washer with Needle
the pivot holes and insert the retaining pin. Push Bearing grease. Place the bearing on the back of
shifter detent down. the gear. Set the washer on top of the thrust bear-
ing. Insert the gear, bearing, and washer into the
1 bearing housing.
2 1
1
1. Clutch Shaft Retainer Kit 0000
2. Clutch Shaft 1. “PROP END” 006906
13
321
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
006937
1
1. Retaining spring 006935
Pinion Bearing
Refer to Pinion Bearing Installation on p. 304.
006853
006936
322
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Push propeller shaft out of the bearing housing. used.) Use depth gauge to measure distance from
flange of housing to flat surface as shown.
1
006939
1. Flange 006855
Remove the thrust washer and thrust bearing.
Add the appropriate shims to create a dimension
of 0.140 in. (3.556 mm).
1
To determine thickness of shims; use the following
example:
1.389 in. reading on the gauge
2 + 0.011 in. shims required
= 1.400 in. required dimension
Assembly
Position the forward gear bearing housing assem-
bly on a flat, level surface. (Mirror or glass can be
1
13
323
GEARCASE – COUNTER ROTATION
SHIFTER, BEARING AND SEAL SERVICING
Coat bearing surfaces of propeller shaft with gear- Use Spanner Wrench, P/N 432400, to tighten the
case lubricant. Slide the propeller housing onto gear assembly to a torque of 100 ft. lbs. (136
the propeller shaft. N·m).
006942 006943
IMPORTANT: Use caution when assembling the Inspect the bearing housing anode. Replace
propeller shaft in the bearing housing. Thrust anode if it is reduced to two-thirds of original size.
bearing must remain around shoulder on the pro- Tighten screws to a torque of 108 to 132 in. lbs.
peller shaft. (12 to 15 N·m).
1. Anode 006897
1. Shim(s) 006937
324
GEARCASE – COUNTER ROTATION
DRIVESHAFT SHIMMING
2 4
13
1. Driveshaft bearing housing 006911
2. Thrust washer
3. Thrust bearing
4. Pinion gear
325
GEARCASE – COUNTER ROTATION
DRIVESHAFT SHIMMING
Check squareness of the bearing housing mount- Remove the driveshaft from the tool and add the
ing surface by holding the shim gauge bar against required shims between the bearing housing and
the pinion while rotating just the bearing hous- the thrust washer.
ing. Use a feeler gauge to measure clearance
between the gauge bar and the bearing housing IMPORTANT: Use extreme care when removing
between each pair of screw holes. Replace the bearing housing to avoid damaging the seals. Use
bearing housing and repeat check if variance is Driveshaft Seal Protector, P/N 318674.
greater than 0.004 in. (0.010 mm).
Check clearance again. The measurement
Check squareness of the pinion to the driveshaft. between the gauge bar and pinion should be
Hold the shim gauge bar against the bearing 0.020 in. (0.508 mm).
housing (between the screw holes) while rotating
just the driveshaft and pinion assembly. Mea-
sure clearance between the gauge bar and the
pinion at several locations. If variance is greater
than 0.002 in. (0.050 mm) replace the pinion or
driveshaft, as necessary, and repeat check.
Subtract the average clearance measurement
from 0.020 in. (0.508 mm) to determine the cor-
rect shim thickness required. Select the fewest
number of shims to achieve the correct thickness.
005417
326
GEARCASE – COUNTER ROTATION
GEARCASE ASSEMBLY
1. Water intake screen 006886 Lightly apply Triple Guard Grease to new bearing
housing O-rings. Install O-rings in grooves in the
Shift Housing, Gear, and housing. Grease the machined side surfaces of
bearing housing.
Propeller Shaft Installation
Push shifter detent into farthest downward posi- Place bearing housing in gearcase.
tion. Tip the rear of the gearcase slightly down-
ward to assist in the installation of the shaft
assembly.
Be sure the thrust bearing and the thrust washer
are in the proper position. Insert the shaft assem-
bly fully into the gearcase while aligning shift
housing pin with hole in forward end of gearcase
housing.
006846
13
1. Pin 006929
327
GEARCASE – COUNTER ROTATION
GEARCASE ASSEMBLY
Align retaining holes in bearing housing with Housing must be completely seated in gearcase
screw holes in gearcase. Thread Alignment Pins, to install retainer screws. Bearing housing is
P/N 354140, into gearcase. approximately level with gearcase.
1 1
2
3
1. Retainer screws 006835
4
Final Assembly and Adjustment
To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 286
1 • WATER PUMP SERVICE on p. 290
• SHIFT ROD ADJUSTMENT on p. 294
• GEARCASE REMOVAL AND INSTALLA-
TION on p. 287
• Gearcase Lubricant on p. 79
• Propeller Hardware Installation on p. 67
• Trim Tab Adjustment on p. 70
During break-in period of a reassembled gear-
1. Gearcase fixture, P/N 354059 006927
case, change the gearcase lubricant between 10
2. Vertical alignment screws to 20 hours of operation.
3. Handle P/N 345822
4. M2 Adapter P/N 353057
328
TRIM AND TILT
14
329
TRIM AND TILT
SERVICE CHART
SERVICE CHART
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
004106 G Needle Bearing Grease
330
TRIM AND TILT
SYSTEM DESCRIPTION
A tilt relief valve limits the propeller thrust load that 1. Trailering Bracket 001987
will be supported by the unit in tilt range. As pres-
sure increases, the outboard will tilt down to the For mooring or storing the boat with the outboard
top of the trim range. tilted, a tilt support is provided to support the out-
board.
IMPORTANT: When in tilt range, make sure
water is available to gearcase water pickups.
Manual Adjustment
The outboard can be manually raised or lowered 1
through the entire trim and tilt range by opening
the manual release valve a minimum of three
turns. The manual release valve must be closed
and torqued 45 to 55 in. lbs. (5 to 6 N·m) to hold
the outboard in position and before normal opera-
tion can be resumed.
1. Tilt support 002279
331
TRIM AND TILT
MODES OF OPERATION
MODES OF OPERATION
The trim/tilt hydraulic assembly achieves trim and
tilt movement through the following modes of
operation.
2
Trim-OUT / Tilt-UP Mode 1
When the UP switch is pressed, the trim/tilt motor 3
rotates clockwise (as viewed from pump end) and
turns the pump gears. 7
Fluid pressure pushes the UP check valve off its
seat, and fluid passes through the valve to the
bottom of all cylinders, pushing the pistons UP. 4
Fluid is pushed from the top of the tilt cylinder by
the piston and returns to the pump through the
open DOWN check valve.
332
TRIM AND TILT
MODES OF OPERATION
14
333
TRIM AND TILT
MODES OF OPERATION
Impact Relief
Should the gearcase hit an underwater object and
the outboard suddenly tilts up, the tilt cylinder
extends. The fluid above the piston is com-
pressed, producing high pressure.
1 1
334
TRIM AND TILT
MODES OF OPERATION
14
335
TRIM AND TILT
MODES OF OPERATION
Manual Release – UP
The outboard can be positioned manually by first 2
opening (loosening) the manual release valve.
Open the manual release valve only enough to let Do not attempt to hold the outboard up by
the outboard trim in to desired position. closing the manual release valve. The out-
board must be held manually, and lowered
to the trim range manually, after it has
been tilted up manually. The outboard can
drop to the trim range if the support is
removed.
336
TRIM AND TILT
MODES OF OPERATION
14
337
TRIM AND TILT
ROUTINE INSPECTIONS
2
1. Grooves (V4 Models) 30959
2. No grooves (V6 Models)
338
TRIM AND TILT
TROUBLESHOOTING
14
339
TRIM AND TILT
TROUBLESHOOTING
• The “B” adapter, P/N 336659, checks operation bypass the reservoir cap. These steps will relieve
of the DOWN circuit. the pressure in the unit.
1 2 1
This kit does not include a gauge and collar Remove the manual release valve retaining ring
assembly. Gauge and collar assembly shipped using retaining ring pliers.
with Power Trim/Tilt Service Kit, P/N 390010, will
work. Gauge and Collar Assembly, P/N 983975, is
also available.
41754
340
TRIM AND TILT
TROUBLESHOOTING
all rods must be completely extended to check Remove the manual release valve. Install pres-
fluid level. sure gauge and adapter “B” to check problems in
the DOWN circuit. Cycle the unit down and up
several times to purge air. With all rods fully
extended, run the unit down momentarily to
reduce pressure. Check fluid level again, and add
fluid if necessary. Remember that all rods must be
completely extended to check fluid level.
41754
14
341
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
Use a battery rated at 360 CCA (50 Ah) or higher Test results include three basic possibilities:
that is in good condition and fully charged to per-
form this test. A. Low current draw – Check for:
• Valves leaking
IMPORTANT: Specifications are for static • Relief valve springs weak
hydraulic tests. DO NOT attempt to perform the • Pump damaged
following tests while the boat is moving.
• O-rings leaking
• Check valves fouled or damaged
• Manual release valve damaged
342
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
B. High current draw – Check for: The motor shaft must rotate clockwise, as viewed
• Pump binding from the pump end, when positive (+) is applied to
• Motor binding the blue lead, and negative (–) is connected to
• Valves sticking green lead.
• Relief valve springs damaged (stall up only) The motor shaft must rotate counterclockwise, as
C. Normal current draw, slow operating viewed from the pump end, when positive (+) is
speed – Check for: applied to the green lead, and negative (–) is
• Impact valves damaged applied to the blue lead.
• Check valve or shuttle valve malfunctioning
• Manual release valve damaged Blue lead (+)
Green lead (-)
Green lead (+)
Blue lead (-)
30957
14
343
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
DRC6245
STEP 2
Remove the white/tan lead from the trim gauge
“S” terminal. With key switch ON, gauge should
indicate full-trim DOWN position. Now connect a
jumper wire between terminals “S” and “G.” Gauge
should indicate full-trim UP position.
• If results are different, replace the trim gauge.
• If results agree, refer to Trim Sender Test.
DRC6247
DRC6246A
344
TRIM AND TILT
TRIM AND TILT SERVICE
25078
000686
27381
000687 1
14
345
TRIM AND TILT
TRIM AND TILT SERVICE
Remove the external snap rings from the upper Use a punch to remove the lower pin and remove
pin. the trim/tilt unit from the stern brackets.
25064 25076
25065
25077
25077
346
TRIM AND TILT
TRIM AND TILT SERVICE
Install external snap rings onto upper pin with Attach the ground wire to the trim/tilt unit.
sharp edge facing out.
25079 27381
14
347
TRIM AND TILT
TRIM AND TILT SERVICE
348
TRIM AND TILT
TRIM AND TILT SERVICE
Remove the three Pozidriv screws securing the Remove the four screws securing motor to pump
reservoir to cylinder body. Remove reservoir. manifold assembly.
41753 41760
Remove the reservoir O-ring from the cylinder Remove the wire shield from the pump manifold.
body. Check the machined surfaces for nicks and Remove the motor and inspect the motor O-ring
scratches. and the O-ring on the cable connector.
1. O-ring 41759
41787
14
349
TRIM AND TILT
TRIM AND TILT SERVICE
solvent and inspect it for tears, clogging, or other Remove the manifold. Remove five O-rings from
damage. cylinder body. Check machined surfaces for nicks
and scratches.
1. Coupler 41763
2. Filter screen
41799
41798
41789
350
TRIM AND TILT
TRIM AND TILT SERVICE
Slowly pull the piston out with a rag wrapped Remove the washer. Slide the tilt piston off the
around the rod and the top of the cylinder. Drain rod. Be careful not to lose the springs, plungers,
the remaining fluid from the cylinder. or small check valves in the piston assembly.
41784
41765
Remove and discard the small inner O-ring and
Inspect the bore of the tilt cylinder for excessive large outer O-ring.
scoring. If the bore of the tilt cylinder is scored or
damaged, the hydraulic assembly must be
replaced. 1
351
TRIM AND TILT
TRIM AND TILT SERVICE
Two of the piston relief holes are small, the other Use a screwdriver to carefully pry the scraper out
two holes are larger. Two of the springs have five of the end cap. Discard the scraper. Remove and
coils and the other two have nine coils. On assem- discard the large outer O-ring.
bly, the two five-coil springs go in the large relief
holes, and the two nine-coil springs go in the small
relief holes.
41791
2 1
Remove and discard inner O-ring of the end cap.
1 2
3 1 3
1. Five-coil spring 41817
2. Nine-coil spring 1. Inner O-ring 41795
3. Piston check ball 2. Lip
4. Plunger 3. Outer O-ring
352
TRIM AND TILT
TRIM AND TILT SERVICE
Use a wire brush to clean all thread-locking mate- Clean any thread-locking material from the
rial from the threads on the tilt rod. threads on the inside of the nut. Spray threads of
with Locquic Primer and let dry. Apply a small
amount of Nut Lock to the threads. Slide the
washer over the threads and install the nut.
Tighten to a torque of 58 to 87 ft. lbs. (79 to 118
N·m).
41821
1. O-ring 41816
14
353
TRIM AND TILT
TRIM AND TILT SERVICE
Trim Rod Removal Drain the remaining fluid from the cylinders.
Inspect both bores of the trim cylinders for exces-
Unscrew trim cylinder end caps using Trim Cylin-
sive scoring. If one or both trim bores are scored
der End Cap Remover/Installer, P/N 436710, or
or damaged, the hydraulic assembly must be
Universal Spanner Wrench, P/N 912084, and a
replaced.
breaker bar. Small pins must be used in the span-
ner wrench.
41840
41829
Remove and discard both back-up rings and the
O-ring from each trim rod piston.
Slide the caps to the end of the rods. Drain the
fluid from the top of the pistons.
41841
41842
41838
354
TRIM AND TILT
TRIM AND TILT SERVICE
Remove the rod from the vise. Use a small screw- Lubricate and install a new O-ring and two new
driver to carefully pry the scraper out of the end back-up rings on the trim rod piston. Place one
cap. Discard the scraper. back-up ring on each side of the O-ring. Position
the open end of the back-up rings 180° apart.
41843
41844
1
Trim Rod Assembly
Lubricate and install a new quad-ring and scraper
in the end cap. Install a new scraper with the bevel
facing out. Lubricate and install a new O-ring on
the outside of the end cap.
1. Bevel 41845
2. O-ring
14
355
TRIM AND TILT
TRIM AND TILT SERVICE
Manifold and Reservoir removed later for the Pressure Leakdown Test
on p. 339.
Installation
Lubricate five new manifold body O-rings. Place
them in the cylinder body.
41851
41863
1. O-ring 41865
356
TRIM AND TILT
TRIM AND TILT SERVICE
Attach the reservoir to the cylinder body with three P/N 912084. Tighten caps to a torque of 60 to 70
Pozidriv screws. Tighten the screws to a torque of ft. lbs. (81 to 95 N·m).
35 to 52 in. lbs. (4.0 to 5.9 N·m).
41868
41866
Tilt Rod Installation
Trim Rod Installation Lubricate the tilt rod piston. Slide the end cap all
Lubricate the trim rod pistons. Place the rod the way up on the rod assembly. Place the piston
assemblies into the body. Push them in until the end of the rod assembly into the cylinder body.
end caps just clear the tops of the cylinders. Fill Push it in until the end cap just clears the cylinder
the cylinders with Power Trim/Tilt & Steering Fluid. top. Leave enough room to pour fluid into the cyl-
Failure to fill the cylinders could cause difficulty in inder. Fill the cylinder with Power Trim/Tilt & Steer-
purging air from the unit. ing Fluid. Failure to fill the cylinder could cause
difficulty purging air from the unit.
41867
41869
Screw the trim rod end caps into the cylinder body.
Use Trim Cylinder End Cap Remover/Installer, Screw tilt cylinder end cap into cylinder body. Use
P/N 436710, or Universal Spanner Wrench, Tilt Cylinder End Cap Remover/Installer,
P/N 326485, or Universal Spanner Wrench,
14
357
TRIM AND TILT
TRIM AND TILT SERVICE
P/N 912084. Tighten cap to a torque of 58 to 87 ft. Install the filter screen.
lbs. (79 to 118 N·m).
1
2
1. O-ring 41857
1. Coupler 41852 2. Cable
Fill the pump cavity with Power Trim/Tilt & Steer- Install the four motor screws. Tighten the screws
ing Fluid up to the top of the two bosses. Rotate to a torque of 35 to 52 in. lbs. (4.0 to 5.9 N·m).
the coupler clockwise and then counterclockwise
until no more air bubbles come out of the pump.
41858
1. Bosses 41854
358
TRIM AND TILT
ADJUSTMENTS
Fill the reservoir to the bottom of the fill hole with Check the tilt rod bushings. Replace them if they
Power Trim/Tilt & Steering Fluid. Install and are worn excessively.
tighten the reservoir cap. Turn the manual release
valve in until it seats. Cycle the unit up and down
several times to purge air.
41888
41878
ADJUSTMENTS
Refer to Trim Sending Unit Adjustment on
p. 69.
14
359
TRIM AND TILT
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
360
SAFETY
SAFETY
TABLE OF CONTENTS
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM . . . . . . . . . . . . . . . . . . . . . S–3
OUTBOARD SHIFT SYSTEMS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–4
OUTBOARD SPEED CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–5
OUTBOARD STEERING CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–6
OUTBOARD FUEL, ELECTRICAL SYSTEM, AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–8
OUTBOARD MOUNTING SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–11
OUTBOARD HYDRAULIC TILT/TRIM SHOCK ABSORPTION SYSTEM AND SAFETY . . . . . . . . . . . . . . . . S–13
OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–14
SUMMING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–16
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM . . . . . . . . . . . . . . . . . . . . . S–17
HANDLING OUTBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–17
HANDLING LEAD/ACID BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–21
GASOLINE – HANDLE WITH CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–22
HAZARDOUS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–23
SAFETY AWARENESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
S–1
S–2
SAFETY
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manu-
facturers are careful to make sure:
• Product user is informed; and
• Products are safe and reliable.
It is up to you, the people who...
• Rig boats;
• Fix machinery; and
• Maintain equipment
...to keep the products safe and reliable.
This section talks about safe boating and how you can help make it safe. Some of these safety issues
you will know, others you may not.
First!
A word about parts... Plain parts; special parts; all parts!
Second!
• Special locking bolts and nuts are often used to hold steering, shift, and throttle remote control
cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with other
parts. Store them on the outboard, then they are there when you need them.
• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steer-
ing, shift, and throttle cables to the outboard.
S–3
SAFETY
IF... IF...
NEUTRAL FORWARD
S–4
SAFETY
If Operator cannot slow down the outboard or shift into NEUTRAL gear (stop propeller), Operator
could panic and lose control of boat.
S–5
SAFETY
• If steering system comes apart, boat might turn suddenly and circle. Persons thrown into the water
could be hit.
S–6
SAFETY
Replace damaged parts. If weakened, parts could fail later on the water when least expected.
S–7
SAFETY
• When not boating, fuel leaking in car trunk or van, or place where portable tank is stored (base-
ment or cottage), could be ignited by any open flame or spark (furnace pilot light, etc.).
• When boating, fuel leaking under the engine cover could be ignited by a damaged or deteriorated
electrical part or loose wire connection making stray sparks.
GA
S
Remember:
S–8
SAFETY
If electrical parts are replaced or even removed from the outboard, check the following:
Wire and high voltage lead routing
• As shown in service manual
• Away from moving parts which could cut wires or wire insulation
• Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads
Sleeves, boots, shields
• In position (to avoid shock hazard)
• Not torn or cracked
Spark Plugs
• Avoid rough handling that
could crack ceramic part of
plug. (Sparks may jump
across outside of plug.)
In transom area:
All Connections
• Clean Electric Cable
• Tight • Not rubbing on sharp objects
(Prevents sparks) • Enough slack to allow full turn-
ing without pull loads on cable
(prevents sparks)
Batteries
• Secure in approved battery
box or battery tray
• Battery terminals insulated
• No strain on cables
S–9
SAFETY
After repair on any part of the fuel system, pressure test engine portion of fuel system as shown:
When Storing:
Squeeze until
bulb feels hard
GASOLINE
When Running:
• Make sure silencer and its gaskets are on engine and drain hose is in place.
• Air silencer mounting screws are special lock screws. Use only the special screws.
S–10
SAFETY
• outboard parts
S–11
SAFETY
If weakened, parts could fail later on the water, when not expected
If boat plate
shows...
Use only
or smaller
S–12
SAFETY
S–13
SAFETY
• The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled
from the emergency stop / key switch.
If switch fails...
If lanyard is caught...
S–14
SAFETY
S–15
SAFETY
Summing up
Now you know some things that can take the joy out of boating.
S–16
SAFETY
Handling Outboards
When lifting outboards
Some outboards have a fixed lift bracket bolted to the powerhead.
Because outboard will want to hang like this when off the floor...
Center of gravity
Stand Clear!
It might hit you
If engine does not have fixed lifting bracket as it swings.
and you use Universal Puller, P/N 378103,
and Lifting Eye, P/N 321537, or Lifting Eye
and Adapter Assembly, P/N 396748...
• Make sure shop aids have extra capacity, and keep them in good repair.
S–17
SAFETY
• Two people working together on a live outboard must look out for each other. Never, ever, use the key
to start the outboard before signaling your partner. He may be leaning over the outboard with hands on
the flywheel, handling a “hot” electrical part, or near the propeller.
Outboard starting at the wrong time
When you do things that turn the flywheel like:
• Off-season storage fogging (oiling) of outboard;
• Removing propeller with a powered tool;
• Electrical system checks;
• Servicing the flywheel; or
• Any other actions ALWAYS...
1) Turn key
switch OFF
3) Shift to
2) Twist and remove NEUTRAL
ALL spark plug leads
Check prop shaft. Is outboard really in NEUTRAL?
S–18
SAFETY
DANGER
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
• Whenever running the engine, assure there is proper ventilation to avoid the accumulation of carbon
monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain
damage, or death if inhaled in sufficient concentrations. CO accumulation can occur while docked,
anchored, or underway, and in many confined areas such as the boat cabin, cockpit, swim platform,
and heads. It can be worsened or caused by weather, mooring and operating conditions, and other
boats. Avoid exhaust fumes from the engine or other boats, provide proper ventilation, shut off the
engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accu-
mulation. In high concentrations, CO can be fatal within minutes. Lower concentrations are just as
lethal over long periods of time.
S–19
SAFETY
DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Always shut off the engine
when near people in the water.
Eye protection
Eyes need protection when:
• Chiseling
Tip: When steel on steel,
use plastic- or brass-type
hammers. They don’t chip
off as easily as steel
hammers.
Wear
Safety
Glasses
Protect • Acid • Ends of cables
eyes
from:
S–20
SAFETY
If spilled or
Strong acid solution splashed on any
(sulfuric acid) part of body...
After charging:
DO NOT check battery charge by • Shut off charger
placing metal objects across • Pull charger plug out of 110 V
posts. You will make sparks and outlet
serious burns are possible. • Take charger cables off battery
posts
S–21
SAFETY
20
Parts By
Air Volume
• Always store gasoline outside in a safe can (flame arrester and pressure relief valve in pour spout).
• Fill portable tanks outside of boat. Spillage will collect in bottom of boat.
• Use fuel as fuel ONLY, not for a cleaner or degreaser.
• If fumes are smelled in shop, basement, or garage, immediately:
– Put out open flames, cigarettes, sparking devices;
– Wipe up spill or leak;
– Get towels and rags outside fast;
– Open doors and windows; and
– Check lowest area for fumes.
Be aware of items in and around repair area which can ignite fumes. Control them if fumes are smelled.
• Matches, cigarettes, blow torches, welders
• Electric motors (with unsealed cases)
• Electric generators (with unsealed cases)
• Light switches
• Appliance pilot lights or electric ignitors (furnace, dryer, water heaters)
• Loose wires on running outboards
• Other variables which may ignite fumes
S–22
SAFETY
Hazardous Products
READ
• “How and where to use”
• “How to give First Aid.” Have recommended First Aid materials on hand should an
emergency arise
• “How to dispose of can”
And remember: Little children are very curious and will try to taste
everything so keep containers away from children!
S–23
SAFETY
2) Are you ready to take responsibility for the safe maintenance practices and proce-
dures of your repair shop, co-workers, and technicians?
3) Do you understand all the safety precautions and instructions contained in this entire
service manual?
4) Will you follow all safety warnings, precautions, instructions and recommendations
outlined in this service manual?
5) Do you understand that the service manual as a whole and this Safety section, in par-
ticular, contain essential information to help prevent personal injury and damage to
equipment and your customers?
6) Have you received training related to common shop safety practices to protect your-
self and others around you?
7) When replacement parts are required, will you use Evinrude ®/Johnson ® Genuine
Parts or parts with equivalent characteristics, including type, strength and material?
8) Are you ready to follow the recommendations in this service manual before you ser-
vice any boat or outboard?
S–24
INDEX
INDEX
A nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn Batteries
Abbreviations 6 Battery Charge Isolator 32
Accessories Battery Switches 30
Accessory Charge Kit, P/N 5006253 32 Cable Routing 41
CANbus Water Pressure Transducer Kit, Cables 30
P/N 5006214 57 Charging System Tests 136
Drag Link, P/N 175125 50 Connections 30, 82
Fuel Filter Assembly, P/N 174176 36 Installation 29
Remote Oil Fill Kit, P/N 176461 39 Multiple Batteries 30
Rigging 40 Requirements 11, 13, 29
XD100 Outboard Oil Decal, P/N 352369 60 Storage 87
Adapter Housing 209 Wiring Diagrams 33
Service 266 Bearing
Adjustments Connecting Rod 237
Control Cable 53, 54 Crankshaft 232, 233
Shift Rod 294 Pinion Gear 304
Tilt Limit Switch 68 Break-In
Timing 151 EMM Programming 61, 65, 199, 245
Timing Pointer 151 Gearcase 290, 328
TPS Calibration 107, 152 Oiling 61
Trim Sending Unit 69 Procedure 65, 106
Trim Tab 70
Air Silencer C nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
I–1
INDEX
I–2
INDEX
I–3
INDEX
I–4
INDEX
I–5
INDEX
I–6
INDEX
I–7
INDEX
I–8
INDEX
I–9
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
T–1
TROUBLE CHECK CHART
OUTBOARD WILL NOT START
T–2
TROUBLE CHECK CHART
OUTBOARD HARD TO START
T–3
TROUBLE CHECK CHART
OUTBOARD WILL NOT SHUT OFF
T–4
TROUBLE CHECK CHART
OUTBOARD STARTS, LOW MAXIMUM RPM
EXCESSIVE SMOKING
OBSERVATION POSSIBLE CAUSE PROCEDURE
Contaminated or poor fuel Check or replace fuel supply
Excessive fuel or oil Check fuel system for fuel supply air leaks or
May coincide with consumption leaking fuel injectors
increased oil Outboard in break-in mode Use diagnostic program to confirm
consumption Outboard mounted too low Check installation height of outboard
(normal if occurs after Check vapor separator assembly for proper
winterization) Vapor separator vent
venting/float valve operation
Faulty/leaking fuel injector(s) Check injectors, refer to FUEL SYSTEM
Damaged fuel lift pump Check for internal leaks
T–5
TROUBLE CHECK CHART
OUTBOARD SURGES, RUNS ROUGH
T–6
MWS Instrument Wiring Harness
A A
B B
C C
5 5
1 1
2 2
3 3
6 6
4 4
6 6
4 5
5 4
7 2
1
2 3
3 1
8
1
2
DRC6165R
Lanyard Switch / Emergency Stop Circuits
M
A
Single Outboard
C
B S
M
3
4
2
5
6
1
M
A
M
A
Dual Outboards
C C S
B S B
M M
3
4
2
5
6
1
3
4
2
5
6
1
000705
CANbus Keyswitch/TNT Wiring Harness
A A A. Trim down
B B B. Trim up
C C C. Trim sender
47 ohm 1/4 watt resistor
5 5
5. Battery + (12V)
1 1 1. Stop circuit
2 2 2. Start solenoid
3 3 3. Ground (B-)
4 4 6. Choke
4. Switched B+ (12V)
Switched B+ (12V)
10 Amp Fused
B+ (12V)
Ground (B-)
004839
MWS DASHBOARD
TM
SYSTEM CHECK TACHOMETER SPEEDOMETER
6 5
4 6
2 4
5
PUL / 3
7 REV
1
2
3
8
PUL +12V
GND
+
+
S I S I S I LIGHT SWITCH
G G
G G
WARNING
HORN
TO OUTBOARD
DRC6278R
Evinrude E-TEC
EMM LED Diagnostic Indicators
1
2 Exception: ALL LED’s ON / FLASHING indicates
3 Winterization Mode
4
FUSE
1 3
ABC
90°V6 / 200-300HP E-TEC 7 9 10
5
4
B A
1 2
4
B A
2
5
3
C A B
6
123
12345
8
12345
16
A B
+
2 1
1 2
11 12 13
1 2 3 4
20 21 22 23
17
14 15
J2
5 6 7 8 9 10
24 25 26 27 28 29
15
16 17
12 18
13
18 19
321
11
26 27 28 29 30 31 32 33 34
1 2 3 4 5 6 7 8 9
18 19 20 21 22 23 24 25
10 11 12 13 14 15 16 17
12 3 4
14
4
3
J1-A
5
1. Oil Injector
2
6
1
2. Electric Starter 19
3. Air Temperature Sensor
20 21 22 23 24 25 26
1 2 3 4 5 6 7
14 15 16 17 18 19
8 9 10 11 12 13
4. Throttle Position Sensor
1
J1-B
6
5. Crankshaft Position Sensor
2
5
3
6. Stator
4
20
7. Diagnostic Connector
8. Main Harness Ground
9. Capacitor
CBA
10. Fuse (10 Amp)
21
11. Water-in-Fuel Sensor
12. High Pressure Fuel Pump
13. Water Pressure Sensor (CANbus) 22
14. CANbus Connector
3 2 1
15. EMM
16. Starter Solenoid
17. Accessory Charge Connector 23
18. Trim/Tilt Relay Module
2 1
19. Key Switch
1 2
12
2
1
2 26 25
21. Trim/Tilt Connector 27 27 26 1
22. Trim/Tilt Switch
1 2
23. Shift Interrupt Switch
321
321
1 2
B A
12
2 1
12
321
INTERNAL
SENSOR
DASHBOARD
S.A.F.E
DOWN
CODE
SHUT
TIME TO
EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION
ACTIVATE
DISPLAY
Code number indicates affected cylinder. 20 knock events in 100 combustion cycles with maximum correction applied.
1-6 Excessive knock detected 3 LED 3: ON (Running) CHECK ENGINE Immediate Make sure sensor is securely fastened to the cylinder head.
Check timing adjustments. Test fuel and cooling systems. Check fuel quality.
7 Knock Sensor circuit OPEN – Port LED 3: ON (Running) CHECK ENGINE 5 seconds Integrated sensor output in EMM less < 0.15 V. Check sensor connection.
8 Knock Sensor circuit OPEN – Stbd LED 3: ON (Running) CHECK ENGINE 5 seconds Integrated sensor output in EMM less < 0.15 V. Check sensor connection.
TPS Voltage > 0.65 V with key ON (or cranking). Becomes stored fault when outboard starts.
Throttle Position Sensor
11 - - 2 seconds When both hard and stored faults are present, check for improperly adjusted throttle cable.
(TPS) out of idle range
If voltage is > .78 V, engine speed is limited to idle.
Throttle Position Sensor TPS Voltage: < 0.14 V, or > 4.92 V. Engine limited to idle speed.
12 LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 2 seconds
(TPS) circuit fault Check sensor resistance—3000 Ω (between pins A and B) & 4000 Ω (between pins A and C)
13 TPS below range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds TPS Voltage < 0.2 V. Check linkage and IDLE stop.
14 TPS above range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds TPS Voltage > 4.85 V. Check linkage and WOT stop.
15 ROM (EMM program) 3 - - 15 seconds ROM “CHECKSUM” failure. Check software program number in EMM. Reload or replace with proper program.
Crankshaft Position Sensor (CPS) LED 2: OFF (Cranking) 5 losses, rpm<2000 EMM counts losses of synchronization with crankshaft sensor. Check CPS mounting and resistance. Air gap range: 00.036 to
16 -
Intermittent loss of SYNC LED 3: ON (Running) 1 loss, rpm >2000 0.110 in. (1 to 2.8 mm), nominal 0.073 in. (1.85 mm) Resistance: 560 Ω ± 10% @ 77°F (25°C)
1 min: V4–3.3L V6 55 V alternator output < 45 V at 500 to 1000 RPM, or < 52 V above 1000 RPM.
17 55 V circuit BELOW range 3 3 LED 1: ON (Running) CHECK ENGINE
10 sec: 3.4L V6 Engine limited to 1200 RPM. Perform stator/charging tests.
System Voltage > 57 V. Engine limited to 1200 RPM. Perform stator/charging tests.
18 55 V circuit ABOVE range 3 3 LED 1: ON (Running) CHECK ENGINE 1 minute
Check for loose connections in 55 V circuit. Check capacitor.
19 Start-in-gear LED 3: OFF (Cranking) CHECK ENGINE - Attempted engine start while in gear (EMM in tiller mode). Engine will not start.
21 Winterization activated All LEDs FLASHING All Lights FLASHING - Engine is speed limited, and stops after 360 oil pulses. Refer to Maintenance or Operator’s Guide.
23 EMM Temperature Sensor circuit fault 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds EMM Temperature < -67° F (-55° C), or > 311° F (155° C).
24 EMM Temperature BELOW range 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds EMM Temperature < -22 ° F (-30° C).
25 EMM Temperature ABOVE range 3 3 LED 4: ON (Running) WATER TEMP/HOT 10 seconds EMM Temperature > 176°F (80°C). Engine limited to 1200 RPM. See Code 29.
26 12 V circuit BELOW range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage <12 V below 2000 RPM or < 12.5 V above 2000 RPM. Perform stator/charging tests.
27 12 V circuit ABOVE range 3 LED 1: ON (Running) LOW BATTERY 5 minutes Battery voltage > 15.5 V. Check battery connections and wiring.
Check shift switch linkage and switch activation. Check continuity of switch: normally open / continuity depressed.
28 Shift switch malfunction LED 3: ON (Running) - 10 seconds
90°V6 models only.
WATER TEMP/HOT EMM Temperature > 212° F (100° C). Engine SHUTDOWN. Will NOT restart until EMM temperature
29 EMM Temperature OVER range 3 3 LED 4: FLASHING 5 seconds
(FLASHING) returns to operating range. Check outboard and EMM cooling systems.
WATER TEMP/HOT Engine Temperature > 248° F (120° C). Engine SHUTDOWN. Check cooling system.
31 Engine temperature OVER range 3 LED 4: FLASHING 3 seconds
(FLASHING) Check temperature sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
33 Critical NO OIL detected 3 3 LED 4: FLASHING NO OIL (FLASHING) 5 hours Outboard has run five hours with code 34 or 38. Engine SHUTDOWN. Will restart and run for 1 minute intervals.
34 Oil injection pump circuit OPEN 3 LED 4: ON (Running) NO OIL 4 seconds Engine limited to 1200 RPM. Check oil injection pump circuit resistance—2-3 Ω.
37 Water in fuel LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 10 seconds Check fuel supply, 5 V circuit, and ground (NEG). Resistance between probes should be infinite (no continuity).
V4 100 oiler cycles Loss of oil manifold pressure. Engine limited to 1200 RPM. Check oil supply.
38 Oil pressure feedback NOT detected 3 LED 4: ON (Running) NO OIL
V6 150 oiler cycles Test injection pump. Monitor oil flow to distribution hoses.
Engine Temperature ABOVE range (port)–low 60° V4 & V6 Models: Engine Temperature > 230° F (110° C) below 3000 RPM
40 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
speed 90° V6 Models: Engine Temperature > 212° F (100° C) below 2000 RPM
Engine Temperature < -13° F (-25° C), or > 329° F (165° C).
41 Engine Temperature Sensor circuit fault (port) LED 3: OFF (Cranking) / ON (Running) - 10 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
42 Engine Temperature BELOW range (port) LED 3: OFF (Cranking) / ON (Running) - 10 seconds Engine Temperature < -4° F (-20° C). Check engine temperature and sensor resistance.
60° V4 & V6 Models: Engine Temperature > 194°F (90°C) above 3000 RPM activates S.A.F.E.
90° V6 Models: Engine Temperature > 185° F (85° C) above 2000 RPM for 60 seconds activates warning light and horn;
43 Engine Temperature ABOVE range (port) 3 LED 4: ON (Running) WATER TEMP/HOT 3 seconds
90° V6 Models: Engine Temperature > 194°F (90°C) above 2000 RPM for 3 seconds activates S.A.F.E.
Engine limited to 1200 RPM. Check cooling system.
Pressure < 3.8 in. Hg (13 kPa), or > 35.1 in. Hg (119.0 kPa). Make sure EMM BP sensor tube is NOT plugged.
44 Barometric Pressure (BP) Sensor circuit fault 3 - - 10 seconds
Check atmospheric condition for comparison. Clear code and retest.
45 BP Sensor BELOW range 3 - - 10 seconds Pressure < 20.7 in. Hg (70 kPa).
46 BP Sensor ABOVE range 3 - - 10 seconds Pressure > 31 in. Hg (105 kPa).
Air temperature < -67° F (-55° C), or > 212° F (100° C).
47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) - 10 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
48 Air Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 10 seconds Air temperature below -22°F (-30°C)
49 Air Temperature ABOVE range LED 3: OFF (Cranking) / ON (Running) - 10 seconds Air temperature above 158°F (70°C)
S.A.F.E
DOWN
CODE
SHUT
TIME TO
EMM CIRCUIT/SENSOR EMM LED DISPLAY GAUGE WARNING SENSOR: CIRCUIT VOLTAGE / RESISTANCE (Ω) / INFORMATION
ACTIVATE
DISPLAY