Professional Documents
Culture Documents
Technical Publications
P.O. Box 597
Sturtevant, Wisconsin 53177 United States
www.evinrude.com or www.johnson.com
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude ® Twist Grip™
IMPORTANT: For complete outboard rigging and control installation information, refer to the Predeliv-
ery and Installation Guide included with the service manual set.
All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526.
2
REFERENCE INFORMATION
REFERENCE INFORMATION
1
TABLE OF CONTENTS
SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LIST OF ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EMISSION-RELATED INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3
REFERENCE INFORMATION
SAFETY NOTICE
SAFETY NOTICE
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This pu blication is written fo r qualified, facto ry- DO NOT perform any work unt il yo u have read
trained technicia ns who ar e alrea dy familiar with and understood these instructions completely.
the use of Evinrude/Johnson Special Tools. The
included in formation is not a substitu te for wo rk Torque wre nch tig htening specifications must
experience. It is an organized guide for reference, strictly be adhered to.
repair, and/or maintenance. Should removal of any locking fastener (lock tabs,
The following symbols and/or signal words locknuts, or p atch screws) be requ ired, a lways
may be used in this document: replace with a new one.
Indicates a hazardous situation which, if Unless otherwise specified, engine must be OFF
not avoided, could result in death or seri- when performing this work.
ous injury
Always be aware of p arts that can move, such as
flywheels, propellers, etc.
A CAUTION Some components may be HOT. Always wait for
Indicates a hazardous situation which, if engine to cool down before performing work.
not avoided, could result in minor or mod-
If you use procedures or service tools that are not
erate personal injury.
recommended in th is manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.
NOTICE Indicates an instruction which, if
not followed, could severely damage engine This document ma y be tra nslated into othe r la n-
components or other property. guages. In the event of any discrepancy, the Eng-
lish version shall prevail.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1
A DANGER
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and prop area is clear of people and objects before starting engine or operating boat.
Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
A 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.
REFERENCE INFORMATION
ABBREVIATIONS USED IN THIS MANUAL
6
REFERENCE INFORMATION
EMISSION-RELATED INSTALLATION INSTRUCTIONS
7
REFERENCE INFORMATION
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
HORSEPOWER or SUFFIX
Z = 30” XX-long
B E 200 DP X IN E
PREFIX: DESIGN FEATURES: MODEL YR:
B = Bodensee model B = Blue Paint I =1
D = ICON model C = Counter Rotation N=2
D = Evinrude E-TEC® T =3
E = Electric Start w/Remote Steering R=4
F = Direct-Injection O=5
G = Graphite Paint D=6
H = High Output U=7
J = Jet Drive C=8
M = Military E=9
P = Power Trim and Tilt S=0
R = Rope Start w/Tiller Steering Ex: IN = 2012
S = Saltwater Approved
T = Tiller Steering
TE = Tiller Electric
V = White Paint
W = Commercial Model
Model and serial numbers are located on the swivel bracket and on the powerhead.
8
REFERENCE INFORMATION
MODELS COVERED IN THIS MANUAL
9
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
40 – 65 HP E-TEC Models
40 HP – 5000 to 6000 RPM
Full Throttle 50 HP – 5500 to 6000 RPM
Operating Range RPM 60 HP – 5500 to 6000 RPM
65 HP – 5500 to 6000 RPM
40 HP (29.4 kw) @ 5500 RPM
50 HP (36.8 kw) @ 5750 RPM
Power
60 HP (44.1 kw) @ 5750 RPM
65 HP (47.8 kw) @ 5750 RPM
Idle RPM in Gear 800 ± 50 EMM Controlled
Idle RPM in Neutral 750 ± 50 EMM Controlled
Test Propeller P/N 382861
Weight (RL) Models: 232 lbs. (105 kg)
(may vary depending
(HL, PL, SL, TL) Models: 240 lbs. (109 kg)
ENGINE
on model)
10
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
40 – 65 HP E-TEC Models
1
Minimum Battery
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
ELECTRICAL
Requirements
25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
11
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
75 – 90 HP E-TEC Models
Full Throttle
4500 to 5500 RPM
Operating Range RPM
75 HP (56 kw) @ 5000 RPM
Power
90 HP (67.1 kw) @ 5000 RPM
Idle RPM in Gear 700 ± 50 EMM Controlled
Idle RPM in Neutral 600 ± 50 EMM Controlled
(L) Models: P/N 386246
Test Propeller
(X) Models: P/N 387388
Weight (L) Models: 320 lbs. (145 kg)
(may vary depending
on model)
(X) Models: 335 lbs. (152 kg)
Lubrication
NMMA TC-W3 certified
Engine Type In-line, 3 Cylinder, Two-Cycle
Displacement 79.1 cu. in. (1296 cc)
Bore 3.601 in (91.47 mm)
Stroke 2.588 in. (65.74 mm)
3.6005 to 3.6015 in. (91.45 to 91.48 mm)
Standard Bore
To bore oversize, add piston oversize dimension to standard bore
Top Crankshaft Journal 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Center Crankshaft Journals 2.1870 to 2.1875 in. (55.55 to 55.56 mm)
Bottom Crankshaft Journal 1.5747 to 1.5752 in. (40.0 to 40.01 mm)
Rod Crankpin 1.3757 to 1.3762 in. (34.94 to 34.96 mm)
Piston Ring End Gap, Both 0.011 to 0.023 in. (0.28 to 0.58 mm)
Fuel/Oil Control EMM Controlled
Starting Enrichment EMM Controlled
Minimum (High) Fuel Pressure 24 to 28 psi (165 to 193 kPa)
Minimum Fuel Lift
3 psi (21 kPa)
Pump Pressure
FUEL
12
REFERENCE INFORMATION
SERVICE SPECIFICATIONS
1
75 – 90 HP E-TEC Models
Minimum Battery
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
ELECTRICAL
Requirements
25-Amp fully regulated. Refer to Predelivery and Installation Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
13
REFERENCE INFORMATION
STANDARD TORQUE SPECIFICATIONS
A WARNING
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become
Nautical Orientation 006411
weak, use only authorized Evinrude/John-
son Genuine Parts.
14
ROUTINE SERVICE
ROUTINE SERVICE
TABLE OF CONTENTS
2
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STEERING FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
THROTTLE FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TILT LIMIT SWITCH ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRIM SENDING UNIT ADJUSTMENT (40 – 60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRIM SENDING UNIT ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
15
ROUTINE SERVICE
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
Emergency stop circuit and lanyard, check operation
Controls, steering and tilting; check operation
Engine mounting hardware, re-tighten (40 ft. lbs.)
Fasteners, tighten any loosened components
Water intake screens, check condition
Cooling system; check water pump indicator / water pressure
Anticorrosion anodes, check condition
Gearcase, check condition
Propeller, check condition
Fuel and oil systems, inspect and repair leaks (2)
Check battery connections and condition
Access EMM information, resolve any service codes
Electrical and ignition wires, inspect for wear or chafing
Fuel filter, replace
Oil filters, replace
Gearcase lubricant, replace A
Spark plugs, inspect or replace (2)
(2)
Thermostats, inspect and check operation
(3) C
Grease fittings, lubricate
Power trim/tilt and fluid level, inspect B
(3) C
Propeller shaft splines, inspect and lubricate
(3) D
Starter pinion shaft, inspect and lubricate
Control cables, inspect and adjust
Steering cable, inspect and lubricate C
Water pump, inspect / replace (more often if water pressure loss or overheating occurs)
(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
16
ROUTINE SERVICE
LIFTING THE OUTBOARD
1 2
2
1. Shift cable casing guide extended to midpoint DP0811
2. Throttle cable casing guide retracted
17
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
1 3
1
2 4
2 5
1. Straight section DP0818
2. Angled section DP0817
001998
• Push th e clip toward s t he h ole while li fting on 1.
2.
Throttle cable
Shift cable
the curved end with the pliers. 3. Main wiring harness
• Be sure retainer clip fully engages the pin. 4.
5.
Battery cable
Fuel line
• Lock the retainer by moving the an gled section
behind the straight section.
Place the g rommet int o position in the lower
engine cover.
002104
18
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
NOTICE After installation, make sure there If there are not enough threads on the shift cable
is enough clearance for all cables to avoid for the adjustment, or if the gea rcase does not
binding or chafing through all engine steering shift fully into FOR WARD or REVERSE, refer to
and tilting angles. SHIFT ROD ADJUSTMENT on p. 300, or SHIFT
ROD ADJUSTMENT on p. 323.
Control Cable Installation With remote control lever in NEUTRAL, pull firmly 2
Refer to Control Cable Identification on p. 17. on throttle cable casing to remove slack.
Remove cable ret ainer from an chor b lock. Apply With engine throttle lever against stop, place the
Triple-Guard grease to both anchor block pockets. cable trunnion into the up per a nchor po cket an d
adjust the trunn ion nut so the ca sing fits onto the
throttle lever pin.
1
1. Cable retainer 002099
1
2 1
19
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
IMPORTANT: Move control handle to FOR- the seal only. DO NOT fill connectors with Electri-
WARD and pull back slowly t o NEUT RAL. Make cal Grease.
sure the engine throttle lever is against the stop. If
not, remove slack by adjusting cable trunnion.
002103
001999
SystemCheck Harness
Connections Install electrical cover and secure with screws.
Place th e wirin g harne ss through notch in lower
motor cover a nd ro ute t o the recess in th e fly-
wheel cover. Secure the cable with a tie strap as
shown:
2
1
002102
20
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
I-Command Network Connections Connect the I-Command Engine Inte rface Cable
If the outbo ard will be used with I-Command, or to the EMM CANbus connector.
other NMEA 2000 compliant CANbus instruments, 1
use the following connections to su pply informa- 2
tion to the network:
1 2 CYLINDER MODELS
To prevent interference with engine cover latch,
2 bundle excess wiring b ehind EMM cooling water
hose. Secure I-Command connectors to back side
3 of engine harness with tie strap.
1
2
2
1
1. Engine harness 006738
2 2. EMM cooling water hose
3
21
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
22
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
Route I-Command Ignit ion Harness throu gh wire Water Pressure Gauge
channel in flywheel cover . Inst all electrical cover.
To display engine water pre ssure, inst all a wa ter
Make sure bo th harnesses are in front o f the t ab
pressure hose fitting in th e cylind er block as
and tighten with tie strap.
shown.
1
Use Pipe Sealant with Teflon on the threads of the 2
hose fitting. Refer to inst allation instructions sup-
plied with gauge.
3
2
1
4
1. Electrical cover 006737
2. Wire channel
3. Tab
4. Tie strap
Use Evinrude Diagnostics software to adjust net- 1. Water pressure hose fitting 002461
work settings in th e EMM. From the Settings
screen, select Engine Options. For an I-Command water pressure display , sev-
eral water p ressure senso r kit s are a vailable.
Refer to the Evinrude/Johnson Genuine Parts
and Accessories catalog.
23
ROUTINE SERVICE
BATTERY AND BATTERY CONNECTIONS
A WARNING
Keep the battery connections clean, tight, 3
and insulated to prevent their shorting or
arcing and causing an explosion. If the bat-
tery mounting system does not cover the 2
connections, install protective covers.
Check often to see that connections stay
clean and tight. 1
Marine Style Battery Post DR5103
Check battery connections frequently. Periodically 1. Starwasher
2. Hex nut
remove battery to clean and service connections. 3. Terminal Insulator
• Confirm that battery meets the minimum engine
requirements. NOTICE Do not use wing nuts to fasten ANY
• Connections must be clean and tight. battery cables. Wing nuts can loosen and
• Observe a ll wiring connections prio r to d isas- cause electrical system damage not covered
sembly. under warranty.
Disconnect battery negative (–) cable first and the Tighten all conn ections securely . Apply Triple-
battery positive (+) cable last. Guard grease to prevent corrosion.
Clean all terminals, bat tery posts, and connectors A WARNING
with a solu tion of b aking soda and wate r. Use a
wire brush o r battery terminal tool to remove cor- Battery electrolyte is acidic—handle with
rosion buildup. Rinse and clean all surfaces. care. If electrolyte contacts any part of the
body, immediately flush with water and
IMPORTANT: Connect the battery p ositive (+) seek medical attention.
cable to the battery positive (+ ) post FIRST. Con-
nect the b attery negative (–) cable to the batte ry
negative (–) post LAST.
24
ROUTINE SERVICE
OETIKER CLAMP SERVICING
OETIKER CLAMP 1
SERVICING
Clamp Identification
Use Oetiker clamps for making hose connections. 2
These clamps provide co rrosion resistance, mini-
mize the potential for abrasion of rigging compo-
nents, and provide solid, permanent connections.
A WARNING
DO NOT re-use Oetiker clamps. Fuel leak-
age could contribute to a fire or explosion.
Clamp Selection
To select the c orrect size Oetiker clamp, measure Chose a clamp so that the outside diameter of the
the outside diameter of the hose when installed on hose is appro ximately in the middle of the clamp-
the fitting. ing range of the clamp.
Hose mm 0 5 10 15 20 25 30 35 40 45
Diameter inch 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 1-3/4
008458
25
ROUTINE SERVICE
OETIKER CLAMP SERVICING
000108
DP0886
000090
1 2
1. Open clamp 000092
2. Closed clamp
000091
26
ROUTINE SERVICE
ADJUSTMENTS
002191
1. Steering friction adjustment—Manual tilt models 001256
27
ROUTINE SERVICE
ADJUSTMENTS
Tilt Limit Switch Adjustment Place the outboard in normal operating position.
(75 – 90 HP) Rotate the LOWER adjustment tab UP to reduce
the maximum tilt. Rot ate the UPPER adjustment
A WARNING tab DOWN to increase the maximum tilt position.
If the outboard does not clear all boat parts
when tilted fully or turned side to side,
safety related parts could be damaged in
the course of such outboard movement.
Injuries could result from loss of boat con-
trol.
2
Adjust th e tilt limit switch o n all new outbo ard
installations.
1
Check the clearance between outboard(s) and the
boat’s motor we ll and transo m area. T ilt out-
1. Lower adjustment tab DR4268
board(s) to highest point of clearance and turn the 2. Upper adjustment tab
steering system lock to lock.
Check the adjustment by tilting the outboard fully.
If the outb oard cont acts the boat's mo tor well
when fully tilted, adjust the tilt limit cam t o reduce Repeat this procedure until the tilt limit switch
full-tilt position. stops the outboa rd's u pward travel before it co n-
tacts the motor well.
NOTICE The tilt limit cam will not prevent
the outboard from overriding the adjustment if To pre vent da mage to equipment, provide addi-
the outboard is tilted manually. tional motor we ll clea rance when n eeded. Co n-
sider eith er chan ging the outboard mo unting
position or modifying the boat if the possib ility for
interference and damage exists.
A 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
28
ROUTINE SERVICE
ADJUSTMENTS
4
1
1. Lever DR5090
2. Eccentric cam
1. Trailering lock 18954 3. Contact point
4. Cam screw
29
ROUTINE SERVICE
ADJUSTMENTS
Trim Sending Unit Adjustment Observe the trim gau ge. If the needle does not
show cen ter position, tilt the outboard up a nd
(75 – 90 HP) adjust the sending unit by pivoting it up or down.
Tilt the outboard and engage the tilt support.
A WARNING
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.
30
ROUTINE SERVICE
ADJUSTMENTS
IMPORTANT: A single trim t ab 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 loa d condit ions. No sing le
adjustment ca n relieve steering effort und er all Outboards with High Transom Heights
conditions. The trim tab may be ab ove the surface o f th e
water when the out board is trimmed out. Steering
If the boat pulls to the left or right when its load is effort might increase. Lower the trim setting to
evenly distributed, adjust the trim tab as follows: submerge the trim t ab and t o reduce steerin g
• With the remo te co ntrol in NEUTRAL and the effort.
engine OFF, loosen the trim tab screw.
• If the boa t pulled to the right, move rear of the Dual Standard Rotation Outboards
trim tab slightly to the right. Move both trim t abs equa lly and in the same
• If the bo at pulled to the left, move rear of the direction.
trim tab slightly to the left.
Dual Outboards, One Counter and One
Tighten the trim tab screw as follows: Standard Rotation
• 40 – 90 HP: 35 to 40 ft. lbs. (47 to 54 N·m). Set both trim tabs to the center position.
31
ROUTINE SERVICE
ADJUSTMENTS
6340
32
ROUTINE SERVICE
OPERATIONAL CHECKS
Fuel System
Perform running checks o f the fuel system by fo l-
lowing these steps:
33
ROUTINE SERVICE
COOLING SYSTEM
2
1
1
1. Water pump overboard indicator 008469
Idle Speed
Make sure the outboard idles within the specified
idle RPM ra nge. If th e outboard is run on a flush-
ing device, the idle speed and qu ality may no t be
representative of actual in water use.
34
ROUTINE SERVICE
COOLING SYSTEM
002024
35
ROUTINE SERVICE
COOLING SYSTEM
Running the Outboard Using a Install flushin g adapter onto gearcase water inlet
screens.
Hose and Flushing Adapter
A WARNING
To prevent injury from contact with rotat-
ing propeller, remove the propeller before
running engine with a flushing adapter. 1
36
ROUTINE SERVICE
LUBRICATION
A WARNING
Failure to regrease as recommended
2
could result in steering system corrosion.
Corrosion can affect steering effort, mak-
ing operator control difficult.
1 1
Grease the stainless steel output end of the steer-
ing cable with Triple-Guard grease.
1 1
2
1
1. Tiller handle fittings – Long handle 008197
37
ROUTINE SERVICE
LUBRICATION
1
1 1
2 1. Tilt tube fittings DR38798
1 2
38
ROUTINE SERVICE
LUBRICATION
2
1. Lubricant level plug 001993
2. Lubricant drain/fill plug
39
ROUTINE SERVICE
LUBRICATION
40
ROUTINE SERVICE
LUBRICATION
41
ROUTINE SERVICE
SPARK PLUGS
Removal 1 2
Remove ignition coil abo ve spark plug to ga in
access. When reinstalling coils, tighten screws to
a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
006521
If the mark does not rea ch the unsh aded ar ea
before the torque of 30 ft. lbs. (41 N·m) is reached,
the spark plug cannot be indexed for that cylinder.
Indexing Try another sp ark plug an d repe at th e ste ps
Spark p lug indexing position s the groun d ele c- above.
trode of the sp ark plug opp osite the fuel injector
nozzle.
42
ROUTINE SERVICE
FUEL AND OIL SYSTEMS
Fuel Filter
Evinrude E-TEC 40–9 0 HP ou tboards are
equipped with an in-line fuel filter. Refer to FUEL
COMPONENT SERVICING on p. 142.
40 - 65 HP 002227
A WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
43
ROUTINE SERVICE
ANTI-CORROSION PROTECTION
44
ROUTINE SERVICE
STORAGE
45
ROUTINE SERVICE
PRE-SEASON SERVICE
A WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
46
ROUTINE SERVICE
SUBMERGED ENGINES
47
ROUTINE SERVICE
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
48
ENGINE COVER SERVICE
49
ENGINE COVER SERVICE
UPPER COVER SERVICE
1
1
1
1. Bracket 006468
006469
1. Trim/tilt switch connector 002169
50
ENGINE COVER SERVICE
LOWER COVER SERVICE
Lower Cover Installation Start the top fron t scr ew n ext and draw cover
halves together.
Installation of lower mot or covers will be easier if
the following steps are performed in order:
• Install air silencer on throttle body.
• Place st arboard cover o n out board and ro ute
fuel h ose and battery cable throu gh g rommet
notch. 1
• Insert trim cable grommet into port side cover.
• Connect trim/tilt switch connector. 3
• Place port side cover into position on outboard.
1
1. Trim cable grommet 002216
2. Trim/tilt switch connector
1
1
1. Lower cover screws 002168
51
ENGINE COVER SERVICE
LOWER COVER SERVICE
006746
1. Triple-Guard grease 006470
Install nut on switch. Tighten nut to a torque of 10
Apply Ultra-Lock to sc rew threa ds. Pl ace spring to 16 in. lbs. (1 to 2 N·m).
washer and ho ok in to positio n and tig hten screw
to a torque of 180 in. lbs. (20 N·m).
3
1
006747
006748
52
ENGINE MANAGEMENT MODULE (EMM)
53
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
DESCRIPTION
1
The Engine Manage ment Mo dule (EMM) is a
water-cooled e ngine controller . It contro ls many
outboard systems in cluding alternato r ou tput for
2
the 12 V and 55 V circuit s. Operating vo ltage is
supplied to the EMM by the stator.
EMM Connections
When the ignition key is turned ON, LEDs 3 and 4
IMPORTANT: EMM connections an d wiring should light, indicating that sensor circuits and the
must be clean and tigh t. Impro per ele ctrical con- stop circuit are working.
nections can damage the EMM. DO NOT r un the
As the outbo ard is being started, all four LEDs
outboard with loose or disconnected wiring. should light and then go off in sequence. If any of
Make sure EMM connections are clean and tight. the LEDs d oes NOT light during st arting, refer to
• Engine wire harness to EMM connectors; J1-A, EMM LED INDICATORS on p. 77.
J1-B, J2 When the outboard is running, all LEDs should be
• Stator to EMM connections; one 6-pin AMP and off. If any LED is lighted while the outboard is run-
J2 connector. ning, refer to EMM LED INDICATORS on p. 77.
54
ENGINE MANAGEMENT MODULE (EMM)
EMM INPUTS AND OUTPUTS DIAGRAM
3
A B 12
ABC
A B
1 2
1 2
4
INPUTS
J1-A
J1-B
+ 1
2
3
2 4
17
J2
1
OUTPUTS
2 1
30 40
20
A
C
B
50
10
60
0
x 100
RPM
70 11
3550
IT
EX
U
P
DO G ES
WN PA TE R
EN
MENU
18 10
14 15 13 12 16
008026
1. Engine Management Module (EMM) 7. Low Oil Switch 13. Fuel Injector
2. Battery (12 volt) 8. Air Temperature Sensor (AT) 14. Tachometer/SystemCheck Gauge
3. Stator 9. Engine Temperature Sensor 15. I-Command (CANbus) Display
4. Crankshaft Position Sensor (CPS) 10. Fuel Pump (high pressure) 16. Diagnostic Connector
5. Throttle Position Sensor (TPS) 11. Oil Injection Pump and Manifold 17. LED Indicators
6. Neutral Switch 12. Ignition Coil 18. Exhaust Water Valve (60–65 HP)
55
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL SENSORS
56
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
75 - 90 HP MODELS
If cylinder he ad temperature exceeds 212° F
(100° C) below 3500 RPM, the EMM:
Activates S.A.F.E.
Stores service code 40
EMM LED 4: ON (Running)
Engine Monitor TEMP display: ON
57
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If cylinder h ead temperatu re exceeds 212° F If cylinder head does not rea ch operating temper-
(100° C) above 35 00 RPM, or 23 0° F (1 10° C) ature (104°F / 40°C belo w 2300 RPM) in 1 0 min-
below 3500 RPM, the EMM: utes, the EMM:
Activates SHUTDOWN Stores service code 58
Stores service code 31 EMM LED 3: OFF (Cranking)
EMM LED 4: FLASHING EMM LED 3: ON (Running)
Engine Monitor TEMP display: FLASHING
Low Oil Switch
40 - 65 HP MODELS The low oil switch monit ors the oil level in the oil
If cylinder h ead temperatu re exceeds 212° F tank.
(100° C), the EMM:
If the oil level falls below one-quarter capacity, the
Activates S.A.F.E. EMM signals:
Stores service code 43
Engine Monitor LOW OIL display: ON
EMM LED 4: ON (Running)
Engine Monitor TEMP display: ON
When the oil le vel falls b elow o ne-quarter, t he
EMM b egins counting oil pump pulse cycles.
If cylinder h ead temperatu re exceeds 248°F When it reaches:
(120°C), the EMM:
• 40 – 65 HP: 4800 pulses
Activates SHUTDOWN • 75 – 90 HP: 6000 pulses
Stores service code 31 the EMM:
EMM LED 4: FLASHING
Activates S.A.F.E.
Engine Monitor TEMP display: FLASHING
Stores service code 117
EMM LED 4: ON (Running)
ALL MODELS Engine Monitor NO OIL display: ON
The o utboard will not restart a fter a te mperature
related SHUTDOWN until the engine temperature
To recover from S.A.F.E. mode, the oil pump must
returns to normal. Refer to SHUTDOWN MODE
cycle for a minimum of th ree pulses with the oil
on p. 62.
level above one-quarter.
If sensor valu es a re le ss than -15°F (-2 6.1°C) or
If ou tboard h as bee n run for more tha n 3 hours
greater than 332°F (166.5°C), the EMM:
with NO OIL faults (codes 34 & 117), the EMM
Stores service code 41
Activates SHUTDOWN
EMM LED 3: OFF (Cranking)
Stores service code 33
EMM LED 3: ON (Running)
EMM LED 4: FLASHING
Engine Monitor NO OIL display: FLASHING
If sensor values are below -4°F (-20°C), the EMM:
Stores service code 42
EMM LED 3: OFF (Cranking)
EMM LED 3: ON (Running)
58
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If TPS voltage is greater than 0.78 volts when the If the sensor is da maged or the signal is intermit-
key is turned to ON, or the recoil starter is pulled, tent (10 occurrences), the EMM:
the EMM:
Stores service code 16
Creates service code 11 EMM LED 2: OFF (Cranking)
EMM LED 3: ON (Running)
4
If the outboard starts, the code is saved.
If code 11 is present as both a Active Fault and a Approximate air g ap b etween CPS a nd flywhee l
Occurred Fa ult, re fer to Control Cable Installa- encoder ribs is 0.073 inch (1.85 mm).
tion on p. 19. Fo r tiller models, re fer to Throttle Use the Evinrude Diagnostics so ftware Monitor
Cable Adjustment on p. 276, or Throttle Cable screen to check CPS opera tion. The software
Adjustment on p. 287. should show an RPM re ading while the outboard
If the TPS or TPS circuit fails (below 0.14 volts or is cranking. If the CPS or its circuit fails, no RPM
above 4.92 volts), the EMM: reading will appear and the outboard cannot run.
59
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL EMM FUNCTIONS
60
ENGINE MANAGEMENT MODULE (EMM)
ENGINE MONITOR SYSTEM
Engine Running
All warning circuits are active wh en the eng ine is
running. Th e horn circu it is active when engin e
Typical I-Command and SystemCheck gauges 007988
speed exceeds 500 RPM.
61
ENGINE MANAGEMENT MODULE (EMM)
S.A.F.E. WARNING SYSTEM
62
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication
Locate the diag nostic connector on th e engine. 1
Remove the cover and install the Diagnostic Inter-
face Cable (P/N 437955).
63
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
If Diagnostic Power Supply Tool, P/N 587005, is The serial number and cylinder location displayed
not ava ilable, a Bat tery Cab le, P/N 584348, can on the Injector Coefficients screen must match the
be con nected to th e engine mounte d so lenoid. actual cylinder placement for each injector.
Use acc essory Key Switc h As sembly,
P/N 176408, to control power to the EMM.
1 2
64
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Active Faults
An a ctive fau lt is a service code t hat currently Static Tests Screen 008569A
exists. Active faults become occurred faults only if
the outboard is running. Ignition Test
Use the diagnostics software to test each ig nition
circuit. Refer to Static Ignition Test on p. 81.
Fuel Test
Use the diagnostics sof tware t o te st each fue l
injector circuit. Refer to Fuel Injector Static Test
on p. 84.
Oil Injector
Use the diagnostics software to test the oil injec-
tion pu mp circuit. Refer to OILING SYSTEM
TESTS on p. 166.
Fuel Pump
Active Faults Review Screen 008585
Use the diagnostics software to test the fuel pump
circuit. Refer to Fuel Pump Static Test on p. 84.
Water Injector
This test activat es the exhaust water valve sole-
noid (60 - 65 HP). Refer to Exhaust Water Valve
Static Test on p. 86.
65
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Ignition Test
This test momen tarily disab les the ig nition a nd
fuel injection circuits to one cylinder. By dropping 1. Oil control setting 008580
one cylind er, RPM and ru nning quality change s
can be observe d. Re fer to DYNAMIC TESTS on
A CAUTION
p. 76.
Running an Evinrude E-TEC outboard on
Fuel Test other grades of oil while set to the XD100
This te st momen tarily disables one f uel injector oil ratio will result in increased engine
circuit. By dropp ing o ne cylinder , RPM and run- wear and shortened outboard life.
ning q uality chang es can b e observed. Refe r to
DYNAMIC TESTS on p. 76.
66
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
67
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
68
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
1
Engine Report data files 008593
1. Exports button
2. Data files
69
ENGINE MANAGEMENT MODULE (EMM)
EMM SERVICING
Removal
Disconnect cooling hoses from EMM.
002383
1
EMM Transfer
EMM Transfer is used to save engine history data
when the EMM must be replaced.
70
ENGINE MANAGEMENT MODULE (EMM)
EMM SERVICING
Installation
Installation is the revers e of removal. Pay close
attention when performing the following tasks.
1 1
71
ENGINE MANAGEMENT MODULE (EMM)
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
72
SYSTEM ANALYSIS
SYSTEM ANALYSIS
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
VISUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
CYLINDER DROP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
EMM LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
KEY ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5
IGNITION OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REQUIRED IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SYSTEM VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STATIC IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
IGNITION CONTROL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
FUEL DELIVERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FUEL PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FUEL INJECTOR STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
RUNNING FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
EXHAUST WATER VALVE (60–65 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXHAUST WATER VALVE STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
EXHAUST WATER VALVE DYNAMIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
73
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
1. Main engine harness ground 002292 Occurred Faults Review Screen 008584
2. Ground stud (battery)
Check the diag nostics software Profiles,
Inspect spark plugs for wea r, oil fowling, or dam- Occurred, and Historical Faults screens for evi-
age. A rich or lean running condition or evidence dence of abnormal operation.
of internal eng ine da mage could be identified b y
the appearance of the spark plugs.
74
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
75
SYSTEM ANALYSIS
DYNAMIC TESTS
76
SYSTEM ANALYSIS
EMM LED INDICATORS
When the EMM is ON (engine not run ning), the LED 4 – LANYARD/STOP OKAY. For NO LIGHT,
following LEDs should light: check for:
• Grounded stop circuit.
LED 3 – Sensor Circuit s working . FLASHING
LIGHT indicates Code 57 – engine will not start. For FLASHING LIGHT, check for:
• Code 29 – EMM temp. OVER range (flashing)
LED 4 – S top Circuit not g rounded–okay to start. • Code 31 – Engine temp. OVER range (flashing)
FLASHING LIGHT indicates severe overheat or • Code 33 – Engine shut down, excessive no oil
no oil – engine in SHUTDOWN mode. condition
77
SYSTEM ANALYSIS
EMM LED INDICATORS
78
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
EMM
• Controls ignition grounds, injector grounds, and
002292
engine timing. 1. Main engine harness ground
79
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
Results:
• EMM ON (not running) - approximately 1 V less
Engine RPM and CPS Sync displays 008566A
than battery voltage, system voltage is GOOD.
• EMM ON (not running) - no voltage, check 12 V
If the Monitor screen says “Check CPS Sync,” power to EMM. Repair connection or wiring.
refer to Crankshaft Position Sensor (CPS) Test • RUNNING - 55 V ± 2, system voltage is GOOD.
on p. 95. • RUNNING - less tha n 55 V ± 2, check st ator
output to EMM. Rep air connection o r wirin g.
Possible faulty stator or EMM. Refer to STATOR
TESTS on p. 97.
80
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
81
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
82
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector
and test th e continuity of each ignition control cir-
Use a digital multimeter to test the following:
cuit (orange). Check resistance bet ween J1-B
• System voltage supply to ignition coil. connector an d ig nition coil connector. Refer to
• Ignition control signal from EMM. engine wiring diagram.
• Engine harness resistance.
If circuits test good, replace EMM.
Disconnect ignition coil connector.
Ignition Coil Tests
Supply voltage test:
There are no simple ignition coil test s available.
Use an ap propriate adapter to connect the red
Before replacing an ignition coil, be sure:
meter lead to pin 3 (wh ite/red) of the engine har-
ness connector and the black lead to ground. With • 55 V is supplied to the white/red wire of the igni-
EMM ON, voltage should be appro ximately 1 V tion coil connector
less than battery voltage. • A control signal is present on the orange wire of
the ignition coil conn ector. Re fer to Ignition
Control signal test: Control Circuit Tests on p. 83.
Set meter to the Hz scale to check ignition control • The black wire of the ignition coil connector pro- 5
signal. vides continuity to ground.
• The secondary spark plug lea d provides conti-
Use an ap propriate adapter to connect the red nuity.
meter lead to pin 2 (orange) of the engine harness
connector and the black le ad to ground. Activate If all of the ab ove tests a re g ood, and a cylinder
diagnostics sof tware Static Ignition test and does not have spark, replace the ignition coil with
observe me ter for consist ent read ing (a pproxi- a known good coil.
mately 2 Hz).
Capacitor Test
If control signal is pre sent, connect black meter
lead to p in 1 (black) and re peat te st to confirm IMPORTANT: Make sure the ca pacitor is dis -
harness ground. charged before testing. Ma ke a mo mentary co n-
nection between the two terminals to ground any
stored energy.
83
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Inspect all fuel hoses, filte rs, and co nnections. 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 for an a udible click from each injector when it is
Use the Evinrude Diagnostics software Fuel Pump actuated. If the injector activates, the EMM an d
test to activate the electric fuel pump. If the pump injector circuits are not at fault.
runs, the EMM a nd fu el pump circuit are not at
fault. IMPORTANT: Do NOT perform static tests using
Diagnostic Power Supply T ool, P/N 587005, with
IMPORTANT: Do NOT perform static tests using internal 9 volt batteries only . This will p roduce
Diagnostic Power Supply T ool, P/N 587005, with false results. Refer to Communication on p. 63.
internal 9 volt batt eries only . This will produce
false results. Refer to Communication on p. 63.
Static Tests Screen 008569A IMPORTANT: This test is operating the injectors
with 12 V ba ttery power on the system voltage
If the pump does not run: (55 V) circuit. Bat tery must be f ully charge d a nd
• Check voltage at pin 1 of fuel pu mp connector. connections must be clean and tight. Injector acti-
Voltage sho uld be slightly less than 12 V with vation should be carefully confirmed.
KEY ON, or when fuel pump test is activated.
84
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Results: Results:
No injectors actuate: No light activation on any injector wires (outboa rd
• Use the Monitor screen of the diagnostics soft- cranks and starter turns flywheel):
ware to make su re volt age 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 p. 85. • Eliminate all other possibilities to isolate a faulty
EMM.
Some injectors actuate; some do not:
• For non-working injectors, test the resistance of Irregular or n o lig ht activa tion o n some in jector
injector circuit between the injector connector wires:
and injector control wire at the EMM. • Test the resist ance of individual injector circuits
• See Fuel Injector Resistance Test on p. 139. between the injector connector and injector con-
trol wire at the EMM.
All injectors actuate: • Check battery cable connections.
• Refer to Running Fuel System Tests on p. 85. • Make sure all grounds are clean and tight.
• See Fuel Injector Resistance Test on p. 139.
Running Fuel System Tests 5
Run or crank the outboard. Steady light activation o n all in jector wire s an d
consistent voltage readings, EMM injector contro l
Use the Evinrude Diagnostics sof tware Monitor function is good:
screen to check syste m voltage. If vo ltage is low, • Use the diagnostics software Dynamic Fuel Test
or drops as RPM increases, refe r to Stator Volt- to isolate a faulty cylinde r. See DYNAMIC
age Output Test on p. 97. TESTS on p. 76.
Use an inductive timing light to monit or the injec-
tor control wire (connector pin 2) for each injector.
Make sure the pickup is attached to only one wire.
Flashes on th e timing light indicate current in the
circuit is being switche d by the EMM. The
Dynamic Tests screen allows the contr ol signal to
be turned off to a particular injector.
85
SYSTEM ANALYSIS
EXHAUST WATER VALVE (60–65HP)
If the valve is stuck open , the outbo ard may be Start the outboard. No water should flo w from the
low on top speed power (above 4600 RPM). hose. If wate r ap pears, check f or de bris in valve
assembly.
Exhaust Water Valve Static Test
Use Evinrude Diagnostics sof tware to test the With the outb oard id ling, activate the dyna mic
water valve solenoid ele ctrical circuit. The water water va lve test and check for wa ter flow . A
valve is a 55 volt co il. The static test, which oper- steady stream of water should flow from the hose
ates on 12 VDC, will not activate the water valve. while the test is running.
Monitor the voltage at pin 2 (blue/red wire) of the Water should flow at a rate of 18 to 25 oun ces /
the water valve connector. V oltage shou ld d rop minute (550 to 750cc / minute).
while the static test is active.
1
1
86
ELECTRICAL AND IGNITION
87
ELECTRICAL AND IGNITION
SERVICE CHART
SERVICE CHART
5 to 8 in lbs.
(.6 to .9 N·m)
84 to 106 in lbs. F
(9.5 to 12 N·m) 60 to 84 in lbs.
(7 to 9.5 N·m)
T
F
60 to 84 in lbs.
(7 to 9.5 N·m)
IMPORTANT:
DO NOT lubricate TPS
to throttle shaft surface
24 to 36 in lbs.
(2.7 to 4 N·m)
F
24 to 36 in lbs.
(2.7 to 4 N·m)
F
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
24 to 36 in lbs. D Moly Lube
(2.7 to 4 N·m) E Red Ultra Lock
F Blue Nut Lock
N Starter Bendix Lube
008029 T Liquid Neoprene
88
ELECTRICAL AND IGNITION
SERVICE CHART
24 to 36 in lbs.
(2.7 to 4 N·m)
B
J
15 to 30 ft. lbs.
(20 to 41 N·m)
60 to 84 in lbs.
(7 to 9.5 N ·m)
6
30 to 42 in lbs.
(3.4 to 4.8 N·m)
24 to 36 in lbs.
(2.7 to 4 N·m)
7 to 10 in. lbs.
(0.8 to 1.1 N·m)
60 to 84 in. lbs.
(7 to 9.5 N ·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
J Thermal Grease
T Liquid Neoprene
X See Service Manual Text 002249
89
ELECTRICAL AND IGNITION
IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 65 HP
1
3 1
321
1 1
2 2
2
1 23
8 + 2
123
26 18 10
10 1
27 19 11
11 2
28 20 12
12 3
29 4
30
31
21
22
13
13
14
14 5 J1-A
23 15
15 6
32 7
24 16
16
33
34 25 17
17
8
9
4
1
20 14 8 2
21 15 9 3
22
6 543 21 23
16
17
10
11
4
5
J1-B 321
24 18
25 12 6
26 19 13 7
6 5 4 3 2 1
9
1
10
2
11
3
12
13
4
5
J2
14
6
15
7
16
8
6
90
ELECTRICAL AND IGNITION
IGNITION SYSTEM CIRCUIT DIAGRAM, 75 – 90 HP
1
3 1
321
1 1
2 2
2
1 23
8 + 2
123 6
26 18 10
10 1
27 19 11
11 2
28 20 12
12 3
29 4
30
31
21
22
13
13
14
14 5 J1-A
23 15
15 6
32 7
24 16
16
33
34 25 17
17
8
9
4
1
20 14 8 2
21 15 9 3
22
6 543 21 23
16
17
10
11
4
5
J1-B 321
24 18
25 12 6
26 19 13 7
6 5 4 3 2 1
7
9
1
10
2
11
3
12
13
4
5
J2
14
6
15
7
16
8
6
321
91
ELECTRICAL AND IGNITION
ELECTRICAL HARNESS CONNECTIONS
92
ELECTRICAL AND IGNITION
ELECTRICAL HARNESS CONNECTIONS
001876 001877
Pin Pin
Description of Circuit Wire Color Description of Circuit Wire Color
No. No.
1 Injector, cylinder 2, 75–90 HP Purple 1 Stator winding, 1S Yellow
1 Injector, cylinder 2, 40–65 HP Green 2 Stator winding, 2S Brown
2 Injector, cylinder 3, 75–90 HP Green 3 Stator winding, 3S Orange
2 Exhaust water valve, 60–65 HP Blue/Red 4 Fuel pump control Brown
6
3 vacant 5 System Ground Black
4 vacant 6 +12 V out Red
5 vacant 7 System Ground Black
6 NO OIL signal, SystemCheck Tan/Yellow 8 System Ground Black
7 Ignition, cylinder 3, 75–90 HP Orange/Green 9 Stator winding, 1F Yellow/White
7 vacant, 40–65 HP 10 Stator winding, 2F Brown/White
8 Injector, cylinder 1 Blue 11 Stator winding, 3F Orange/White
9 vacant 12 Fuel pump (flyback) White/Red
10 vacant 13 +55 V, out White/Red
11 vacant 14 +12 V out Red
12 vacant 15 vacant
13 vacant 16 vacant
14 Injector ground Black
15 vacant
16 vacant
17 vacant
18 vacant
19 Ignition, cylinder 2, 75–90 HP Orange/Purple
19 Ignition, cylinder 2, 40–65 HP Orange/Green
20 Injector ground Black
21 Injector ground Black
22 vacant
23 Oil solenoid Blue
24 vacant
25 vacant
26 Ignition, cylinder 1 Orange/Blue
93
ELECTRICAL AND IGNITION
GROUND CIRCUITS
94
ELECTRICAL AND IGNITION
SENSOR TESTS
1
1
95
ELECTRICAL AND IGNITION
SENSOR TESTS
Connect red meter lea d to terminal “A” and black Air Temperature Sensor (AT) Test
meter lead to terminal “C.” Rotate the sensor lever
Remove the electrical connector from the air tem-
through it s range of trave l. Resistance reading
perature sensor.
must change evenly as the sensor lever is moved.
Use a digital multimeter to measure sensor re sis-
Connect red meter lead on terminal “B” and black
tance.
meter lea d to terminal “C.” Ro tate the sensor
lever. Resistance reading must chang e 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 ele ctrical connector from the engine
temperature sensor.
1. AT sensor 006613
1
96
ELECTRICAL AND IGNITION
STATOR TESTS
97
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
98
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
Following the manufa cturer’s dire ctions, conne ct Start and run th e outboard at appr oximately 5000
the variable lo ad teste r (carbon pile) across the RPM. Use the variable load tester to draw the bat-
battery terminals. Stevens mo del LB-85 a nd tery down at a rate equivalent to the stator’s full
Snap-On model MT54 0D are examples o f testers output.
available. • The ammeter should indicate nearly full output,
approximately 25 A @ 5000 RPM.
A WARNING
Decrease the battery load toward 0 A.
Excessive battery discharge rates might
• Ammeter should show a reduced output. As the
overheat battery causing electrolyte gas-
current draw decreases, th e battery volt age
sing. This might create an explosive atmo-
should stabilize at approximately 14.5 V.
sphere. Always work in a well ventilated
• If results vary, check stator BEFORE replacing
area.
the EMM. Refer to STATOR TESTS on p. 97.
4
55 V Alternator Circuit
2 Check battery ground cable for continuity.
1. J2 connector 007261
2. Test probe
99
ELECTRICAL AND IGNITION
ELECTRIC START CIRCUIT
1
2
3
4
5
6 7
13
11
9
B M 1 2
M C S
A 8
4 5
FUSE
1 2
12
A B
A B 9
26 18 10
10 1
6 27
28
19 11
11 2
3
20 12
12
29 4
30 21 13
13
5 J1-A
31 22
23
14
14
15
15 6 10
32 7
15 NEG 33
34
24
25
16
16
17
17
8
9
–
J1-B
14
9
1
10
2
11
3
12
3 2 13
4
J2
5
14
6
15
7
16
8
+
1
008049
100
ELECTRICAL AND IGNITION
ELECTRIC START CIRCUIT
C C C
main ground stud on the starter housing. A S A S A S
to instrument harness.
S
A
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)
101
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
+
3 2 1
2 3
1. Ignition switch, START position – Continuity 000691R AB
between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V
3. Neutral safety switch
3 4
1. Battery positive cable (B+) terminal 002073
2. Starter positive (+) cable terminal
3. “A” terminal (yellow/red)
4. “B” terminal (yellow/green)
102
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
Use a digit al voltme ter to me asure the volt age No Load Current Draw Test
drop on each section of the start circuit. Securely fasten starter in a vise or suitable fixture
before proceeding with this check.
If an y vo ltage read ing is greate r than 0.5 VDC
check that connections are clean, tight and free of Use a batte ry rated at 500 CCA (60 amp-hr) or
corrosion. Clean or replace an y corroded or dam- higher that is in good condition and fully charged.
aged cables or connections.
Use an inductive ammeter or connect a 0 to 10 0
STEP 1: Con nect voltmet er positive (+) lead to amp amme ter in series with a heavy jump er
the terminal for the ne gative (–) batter y cab le at between the b attery positive (+) terminal and th e
powerhead. Conn ect vo ltmeter negat ive (–) le ad starter positive (+) terminal.
to negative (–) battery post.
Fluke model 33 4 or 336, Snap-On model MT110
• Activate st arter motor and ob serve volt age
or EETA501, and various other ammeters should
6
reading.
be available through local tool suppliers.
V–
NEG V Attach or hold a vibration t achometer, such as a
1
Frahm † Reed tachometer, to the starter.
3 –
2 4
+
103
ELECTRICAL AND IGNITION
REMOTE CONTROL SWITCH TESTS
104
ELECTRICAL AND IGNITION
REMOTE CONTROL SWITCH TESTS
1
6
2
3
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 th e clip on the emergency stop switch or
2. Neutral start switch
key switch. S tart the outb oard. Pull the clip from
the switch. The outboard must stop running.
Replace switch if results are incorrect.
105
ELECTRICAL AND IGNITION
TILT/TRIM RELAY TEST
1
1
Test Procedure
Make sure r ed and black wire s are connected to
12 V battery power supply.
Use a wire jumper to alternately connect B+ to ter- Water Valve Solenoid Resistance
minals “1” and “2” of tilt and trim switch connector.
295 Ω ± 20 @ 77°F (25°C)
106
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
If the gauge lig hts do not turn on, turn the key
switch OFF. Disconnect the gauge 8-pin connec-
tor from the back of the gauge an d turn the ke y
switch ON. T est for b attery volt age be tween
107
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
the two conn ectors, replace SystemCheck WATER TEMP/ HOT Circuit Test
gauge.
The tan wire of engine harness and the MWS har-
ness receives a signal f rom the EMM. The EMM
receives information from th e temperature sensor
on the cylinder head.
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 se lf-test
sequence, t he ga uge WATER TEMP / HOT indi-
CHECK ENGINE Circuit Test cator should stay on.
Separate th e 6 -pin SystemCheck connector of • If L ED is n ot on, test circuit for continuity . Test
MWS instrument harness from engine harness. for con tinuity of both the engine harness (t an
Black wire (pin 3) must be grounded. wire) and th e MW S instrument harn ess (t an
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 temp erature sensor
on. itself, refer to Engine Temperature Sensor Test
• If the CHECK ENGINE light is not on, test circuit on p. 96.
for continuity. Check continuity of the MWS
instrument harness (tan/orange wire).
• Check cont inuity of the engine wire harness
between terminal 2 (tan/orange wire) of the Sys-
temCheck connector and pin 17 of the EMM J1-
A connector.
108
ELECTRICAL AND IGNITION
TACHOMETER CIRCUIT TESTS
2
1
3
002079
If the LOW OIL ligh t does not turn on af ter con- 006551
necting the terminal to ground, test circuit for con-
1. Purple lead
2. Black lead 6
3. Gray lead
tinuity.
Turn the key switch OFF and reconnect all discon- Connect the red meter lead to the tachometer pur-
nected circuits. ple wire and the black meter lead to the tachome-
ter black wire (key ON, outboard NOT running).
NO OIL Circuit • If meter shows battery voltage, go to next step.
• If meter shows less than battery voltage, check
Separate th e 6 -pin SystemCheck connector of
the purple, red/purple, and black wiring circuit s;
MWS instrument harness from engine harness.
fuse, key switch, and battery connections.
Black wire (pin 3) must be grounded.
Disconnect g ray a nd black wires at t achometer.
Using a jumper wire, connect tan/yellow wire (p in
Set Fluke 29 Serie s II mete r, or equivalent, to Hz
5) to a clean engine ground.
scale. Co nnect mete r between gra y wire an d
Turn the key switch ON. After the normal self-test black wire. With outboa rd running at 100 0 RPM,
sequence, the NO OIL light should stay on. meter should indicate 90 to 105 Hz.
• If the NO OIL light is not on, test circuit for conti- • If meter read s 90 to 1 05 Hz, replace tachome-
nuity. Test for continuity of the MWS instrument ter.
harness (tan/yellow wire). • If meter reads low or no signal, confirm outp ut
• Test for continuity of the eng ine wire harness on gray wire at pin 16 of EMM J1-A connector.
between terminal 5 (tan/yellow wire) of the Sys- – Reading OK – Check condition of tachometer
temCheck connector and pin 24 of the EMM J1- circuit (gray wire). Repair as needed.
A connector. – Reading not OK – Check connection at EMM;
replace faulty EMM.
Turn the key switch OFF and reconnect all discon-
nected circuits.
109
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
1
Lift flywheel cover to remove.
002087
110
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
002088
1. Stator screws 006486
Apply Moly Lube grease to the th reads of the
puller pressing screw, P/N 307637, and the center To install stator, p osition stator on cylin der block.
hole of the crankshaft. Apply Nut Lock to screw threads. Inst all scre ws
Assemble the following components from Univer-
and tighten in crossing pattern to a torque of 84 to 6
106 in. lbs. (9.5 to 12 N·m).
sal Puller Set, P/N 378103:
• Body, P/N 307636 Flywheel Installation
• Screw, P/N 307637
• Handle, P/N 307638 A WARNING
• Three screws P/N 309492
To avoid injury, keep hands and fingers
• Three washers, P/N 307640
clear from underside of flywheel. Flywheel
Put the puller on flywheel with body flat side up. can snap toward stator with great magnetic
Attach the pu ller body with the three shoulder force.
screws and wash ers. Hold puller bo dy with h an-
dle, and tighten pressing scre w u ntil flywheel Install the outer edge of flywheel key parallel with
releases. T urn the center scre w a nd lif t the fly- centerline of crankshaft.
wheel off of the crankshaft.
1
1
111
ELECTRICAL AND IGNITION
IGNITION COIL SERVICING
1. Screws 008187
112
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
113
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
location to align with the cast-in TDC boss on the Check ignit ion timing a fter any of t he following
flywheel. Tighten retaining screw. procedures:
• Powerhead replacement
• Crankshaft replacement
• Flywheel removal or replacement
• CPS replacement
• EMM replacement
• EMM software replacement (reprogramming)
IMPORTANT: Make sur e the timing pointer is
set and the outboard reaches operating tempera-
ture before making any timing adjustments.
TPS Calibration
2 3 4 1
Use Evinrude Diagnostics sof tware to te ll t he
1. Mark “A’” 002092
2. Mark “B” EMM what throttle position sensor voltage is when
3. Mark “C” the throttle plates begin to open.
4. TDC boss
Set TPS Calibration af ter replacing or adju sting
Repeat the entire ad justment process to make any throttle body or throttle linkage parts.
sure pointer is aligned correctly.
Remove the lower engine covers and air silencer.
Install spark plugs. Refer to S park Plug Indexing
on p. 42. Do NOT start the outboard.
114
ELECTRICAL AND IGNITION
ELECTRIC STARTER SERVICING
Disconnect the battery cables at the battery. Install the battery negative cable (–) to the double-
ended stud.
Remove lower motor cove rs an d air silencer .
Refer to Lower Cover Removal on p. 50. Coat connections with Black Neoprene Dip.
1 1
1. Screws 008189
115
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
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
116
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
AMP Connectors
IMPORTANT: Always use the appropriate meter
test probe s and ada pters when testing compo-
nents 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 conn ectors Terminal Installation
together until latched.
Align terminal with co nnector housing. Push con-
1 nector and seal into housing until seated.
6
2
1. Latch 002448
2. Seal
1
2
2
1
1. Terminal 002452
2. Seal
1. Anti backout device, plug 002449
2. Anti backout device, receptacle 002450
117
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
Disconnect Disconnect
Depress BOT H latches and pull con nector from Use a screw driver to open latch. Pull co nnector
plug. from plug.
Connect Connect
Push connector into plug until latches engage. Push connector until seate d 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.
118
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
1. Latch 002456
2. Terminal with seal
1
Packard Connectors
IMPORTANT: Always use the appropriate meter 6
test probe s and ada pters when testing compo- 1. Tab DRC5940a
nents fitted with these terminals.
Terminal Installation
Disconnect
Install wire gasket o n wires and fe ed wires
Lift latch(s). Remove connector.
through the corr ect terminal position of the co n-
Connect nector housing. Terminal is crimped onto wire and
then pulled back into connector housing until lock-
Confirm the seal is in place. Push connector o nto
ing tab engages and terminal is seated.
housing until latched.
002304
Crimping Terminals
DSC02124
Strip insulation back 3/16 in. (5 mm). Position end
of wire strands in terminal past the wire crimp area
and the end o f insulation in the insula tion crimp
area of the terminal.
119
ELECTRICAL AND IGNITION
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
120
FUEL SYSTEM
FUEL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
FUEL SYSTEM CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
REGULATIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
PORTABLE FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUEL FLOW REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
VENT LINE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
VAPOR SEPARATOR VENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL INJECTOR PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
CIRCULATION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
LIFT PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
LIFT PUMP VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
LIFT PUMP DIAPHRAGM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ANTI-SIPHON VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FUEL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
FUEL LIFT PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
VAPOR SEPARATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
FUEL MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INTAKE MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
121
FUEL SYSTEM
SERVICE CHART
SERVICE CHART
2-CYLINDER MODELS: INJECTORS, VAPOR SEPARATOR, FUEL PUMP
S
Tighten in 3 stages
5 ft. lbs.
1 (7 N·m)
A
10 ft. lbs.
2 (14 N·m)
24-36 in. lbs.
(2.7-4 N·m) A 24-26 Ft. lbs.
3
(33-35 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound 002154a
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant
S STP † Oil Treatment
122
FUEL SYSTEM
SERVICE CHART
A Triple-Guard Grease
002474
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
123
FUEL SYSTEM
SERVICE CHART
S
Tighten in 3 stages
5 ft. lbs.
1 (7 N·m)
A
10 ft. lbs.
2 (14 N·m)
24-36 in. lbs.
(2.7-4 N·m) A 3 24-26 Ft. lbs.
(33-35 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant 002154b
S STP † Oil Treatment
124
FUEL SYSTEM
SERVICE CHART
F
25-35 in. lbs
(2.8-3.5 n·m)
F
60-120 in. lbs
(7-14 n·m)
IMPORTANT:
DO NOT lubricate TPS
to throttle shaft surface
7
10-14 in. lbs
(1.1-1.6 n·m)
10-14 in. lbs
(1.1-1.6 n·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock 002155a
G Needle Bearing Grease
125
FUEL SYSTEM
FUEL SYSTEM HOSE ROUTING
9
4
9 10 11 2
3
8
7 6
Fuel Supply
12
Fuel Return
1
002148
126
FUEL SYSTEM
3-CYLINDER MODELS
9
4
9 10 11 2
3
8
7 6
Fuel Supply
Fuel Return
12 7
1
5
002148a
127
FUEL SYSTEM
FUEL SYSTEM CIRCUIT DIAGRAMS
4 3 3
1 1
2 2
1 1
10 2 2
1
9
8
7
J1-A
2
20 14 8 1
21 15 2
9 3
22 16
6 543 21 23 17
10
11
4
5
J1-B
24 18
25 12 6
19 13 7
26
5 6 5 4 3 2 1
9
1
10
2
11
3
12
13
4
5
J2
14
6
15
7
16
8
6
006479
128
FUEL SYSTEM
3-CYLINDER MODELS
4 3 3 3
1
2
1 1 1 1
2 2 2
9 10
8
11
+
J1-A
2
7
1
20 14 8 2
21 15 9 3
22
6 543 21 23
16
17
10
11
4
5
J1-B
24 18
25 12 6
26 19 13 7
7
5 6 5 4 3 2 1
9
1
10
2
11
3
12
13
4
J2 J2
5
14
6
15
7
16
8
6 006756
129
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
130
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
131
FUEL SYSTEM
COMPONENTS
Vacuum from the fuel lift pump pulls fuel fro m the
COMPONENTS fuel t ank. Once fu el reaches the pump, interna l
The fuel syste m includes the following compo- pump pressure force s the fuel from the pump
nents: through the fuel filter and into the vapor separator.
• Fuel Lift Pump
• Fuel Filter Fuel Filter
• Vapor Separator The fuel filter protects the vapor separator and the
• Fuel Circulation Pump high-pressure components of the fuel system from
• Fuel Supply Manifolds contaminants. Refer to INSPECTION AND MAIN-
• Fuel Injectors TENANCE SCHEDULE on p. 16 for service fre-
• Fuel Return Manifolds quency.
1. Filter 002145
Vapor Separator
1
The vapor separator:
• Serves as a water-cooled fuel reservoir to accu-
mulate incoming fuel from the fuel lift pump and
2
from the fuel return manifold.
• Contains a flo at con trolling the venting of fue l
vapors.
• Contains a fu el pressu re regulator for t he hig h
2-Cylinder models
1. Fuel lift pump
006558 pressure fuel system.
2. Pulse hose fitting
132
FUEL SYSTEM
COMPONENTS
Vapor Separator Assembly 006555 The vapor separator vent is opened and closed by
1. Circulation pump
a float valve. The float valve move s with the fuel
level in the fu el chamb er. Hot fuel causes an
Fuel Reservoir increase in vapor pressure. This results in a lower
The vapor separator accumulates fuel in an inter- fuel le vel in th e va por sep arator. The float valve
nal fuel reservoir and supplies fuel to the electric drops and the vent opens. This allows fuel vapor
circulation p ump. It is water-cooled to e nhance to flow t o the int ake manifold through the ve nt
vapor separating capabilities. hose.
Cooling As the vapor pressu re in the va por sep arator
Water is use d to cool the f uel as it flo ws through decreases, the fuel level begins to in crease. An 7
the vapor sep arator. Th e cooling p assage of the increase in the fuel level raises the float valve and
separator self-drains when the ou tboard is sto red the vent closes.
vertically. Refer to HOSE ROUTING AND WATER
FLOW DIAGRAMS on p. 174. Pressure Regulator
The fuel pressure regulator helps maintain consis-
Venting tent fuel pressure in the fuel system.
The fuel vapor vent regulates fuel vapor pressure
in the reservoir. Fuel returning from the injecto rs ente rs the fue l
chamber o f t he vapor sep arator th rough a pres-
sure regu lator. The p ressure reg ulator ma intains
1 approximately 20 to 30 psi (138 to 207 kPa) of fuel
pressure in the high pressure side of the fuel sys-
tem.
1. Vent 005007
133
FUEL SYSTEM
COMPONENTS
Fuel Injectors
Fuel injectors are fuel metering, electric solenoids
(55 V) bolted directly to the cylinder head. T he
1. Fuel pump electrical connector 006557 EMM controls t he activatio n of each in jector by
rapidly connecting and disconnecting the injec-
tor’s internal coil to ground.
134
FUEL SYSTEM
COMPONENTS
006619
135
FUEL SYSTEM
FUEL SYSTEM PRIMING
REMOTE MODELS
Insert the fuel supply hose from the fuel tank into a
suitable container. Squeeze the fuel primer bulb or
activate the boat-mounted electric fuel primer until
fuel flows from the fuel hose.
002552
TILLER MODELS
Connect the fuel hose connector to the quick con-
IMPORTANT: Failure to remove the clamp may nect fitting on the outboard.
cause fuel starvation and poor running qualities. ALL MODELS
Use the primer to fill the vapor separator.
A WARNING
Failure to check for fuel leaks could allow
a leak to go undetected, resulting in fire or
explosion and may cause personal injury
or property damage.
136
FUEL SYSTEM
FUEL SYSTEM TESTS
137
FUEL SYSTEM
FUEL SYSTEM TESTS
Make su re filter is no t clogg ed. Clean or r eplace Disconnect the battery cables at the battery.
as needed.
Loosen oil tank assembly to provide access to fuel
Apply oil to valve and connect pressure pump and manifolds. Refer to Oil Tank Assembly on p. 169.
hose to the fuel return fitting of vapor separator.
Relieve fuel system pressu re. Refer to Relieving
Apply pressure to ch eck regulator ope ration. The Fuel System Pressure on p. 142.
pressure sh ould open check valve at a pproxi-
mately 15 psi (103 kPa). A WARNING
Protect against hazardous fuel spray.
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 inje ctor to 30 psi
(207 kPa). Pressure must h old f or at least five
minutes.
1
2 2
3 1
1. Filter 000249r
2. Fuel return fitting
3. Pressure regulator
138
FUEL SYSTEM
FUEL SYSTEM TESTS
Use a digital multimeter to measure the injector Use a digital multimeter with app ropriate adapter
coil resistance. leads to measure the fue l pump circuit an d coil
resistance.
Fuel Injector Coil Resistance
2 to 3 Ω @ 72°F (22°C) Fuel Pump Resistance
3 Ω @ 77°F (25°C)
006620
006633
Use a dig ital multimeter with ap propriate adapter
leads to measure resistance of the complete injec- Lift Pump Pressure Test 7
tor circuit, including injector and associated wiring.
Install a 0 to 15 p si (0 to 103 kPa) Fue l Pressure
Measure resist ance betwee n pin 1 (wh ite/red) of Gauge, P/N 5006397 or equ ivalent, to the lower
injector con nector (connected) and the approp ri- fuel pressure test fitting.
ate pin lo cation o f EMM J1-B co nnector (discon-
nected). Refer to engin e wiring diag ram for
1
specific EMM J1-B connector pin location for the
injector circuit being tested (blue, purple or green).
139
FUEL SYSTEM
FUEL SYSTEM TESTS
140
FUEL SYSTEM
FUEL SYSTEM TESTS
141
FUEL SYSTEM
FUEL COMPONENT SERVICING
142
FUEL SYSTEM
FUEL COMPONENT SERVICING
2
1
1. Screws 002194
143
FUEL SYSTEM
FUEL COMPONENT SERVICING
007860
144
FUEL SYSTEM
FUEL COMPONENT SERVICING
1 2
1. Retainer 005342
2. Manifold fitting groove
2 7
Install the fuel manifolds to the fu el pump assem-
bly and secure with clamps:
006555
1. Fuel supply manifold
2. Fuel return manifold
• Fuel supply manifold to circulation pump.
• Fuel return manifold to vapor separator.
Remove fuel manifold retainer screws and remove
Install oil tank asse mbly. Refer to Oil Tank
retainers from fuel injectors.
Assembly on p. 169.
1. Screw 006559
145
FUEL SYSTEM
FUEL COMPONENT SERVICING
Removal
Disconnect the battery cables at the battery.
Disconnect the fuel injector electrical connector. Remove adaptor from injector. Remove crush ring
and O-rings from injector. Inspect and clean injec-
146
FUEL SYSTEM
FUEL COMPONENT SERVICING
tor filter. Install new crush ring and O-rings. Lubri- Installation
cate O-rings with STP † Oil Treatment.
NOTICE All injectors must be installed in the
correct cylinder by serial number. Improper
injector installation can result in powerhead
failure.
Install injector into mount housing. Press on injec- Use t he Evinrude Diagnostics so ftware Settings
tor face until injector seats in mount housing. screen to upload the coefficient file to the EMM.
002318
147
FUEL SYSTEM
FUEL COMPONENT SERVICING
Use the drop down menu to navigate to the saved Install Injector
coefficient file location. The following ite ms and their ma ting surfaces
must be cleaned prior to reassembly:
The coefficient file name must ma tch the serial
• Injector
number of the injector.
• Cylinder head
Select the correct file for the injector. • Adapter
• Screws
Select the Replace Injector button. • Threaded areas.
1
A CAUTION
All injector components must be clean to
ensure correct torque tightening specifi-
cations. To prevent fuel leakage, carefully
follow these installation instructions.
2
3 Place injector and insulator in th e proper cylinder
location.
002316
148
FUEL SYSTEM
FUEL COMPONENT SERVICING
Tighten scre ws in stages, st arting wit h the lower Intake Manifold Service
screw.
• First torque is 5 ft. lbs. (7 N·m). Removal
• Second torque is 10 ft. lbs. (14 N·m). Disconnect vapor separator vent hose, main bear-
• Final torque is 24 to 26 ft. lbs. (33 to 35 N·m). ing vent hose, a ir temperature sensor, crankshaft
position sensor, and throttle position sensor.
Use Ball So cket Remover To ol, P/N 342226, to
remove throttle link arm.
1 2
1. Screws 002503
149
FUEL SYSTEM
FUEL COMPONENT SERVICING
Disassembly Inspection
All reed pla te assemb ly an d reed va lve assem- Inspect the leaf plate a ssemblies for da mage or
blies must be clea ned prior to rea ssembly. DO contamination:
NOT use strong ca rburetor cleane r or the hot • Leaf plates must not be distorted.
soaking tank method for cleaning. • Leaf valve must not be cracked or chipped.
• Leaf plate stops must not be distorted or loose.
Remove the re ed valve ret ainer screws a nd
remove the assembly. • Leaf plate assemblies must be clean.
Inspect t he intake manifold. All gasket surfaces
must be cleaned, smooth, and free of nicks. Use a
machinist’s stra ight-edge and a feeler gauge to
check flatness in all directions. Surface must be
flat, ± 0.004 in. (0.10 mm).
002496
1. Straight-edge 002324
Assembly
Remove old adhe sive from reed valve ret aining
screws.
002504
002333
150
FUEL SYSTEM
FUEL COMPONENT SERVICING
Prime screw th reads with Locquic Primer and let Tighten the center screws first and exp and o ut-
dry. Apply Nut Lock to threads. Position reed valve ward. Tighten in st ages to a final to rque of 60 to
on reed plate an d inst all screws. T ighten screws 120 in. lbs. (7 to 13.5 N·m).
to a torque of 25 to 35 in. lbs. (2.8 to 4.0 N·m).
002501
002326
Install vapor separator vent hose and main bear-
Installation ing vent hose. Secure with tie straps.
Place reed plate assembly on cylinder/crankcase.
Install air temp erature sensor, crankshaft position
Apply Nut Lock to two re ed plate screws. Inst all sensor, and throttle position sensor electrical con-
and tighten screws to a torque of 60 to 120 in. lbs. nectors.
(7 to 13.5 N·m).
Connect throttle linkage. 7
IMPORTANT: DO NOT lubricate th rottle link-
ages.
002505
151
FUEL SYSTEM
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
152
OILING SYSTEM
OILING SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
OIL SUPPLY DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
OIL RECIRCULATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
OILING SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
OIL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
NO OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
OIL INJECTION PUMP VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
OIL INJECTION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8
LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
153
OILING SYSTEM
SERVICE CHART
SERVICE CHART
40 – 65 HP
30 to 42 in lbs.
(3.5 - 5 N·m) F
F
30 to 42 in lbs.
30 tp 42 in lbs. (3.5 to 5 N·m)
(3.5 - 5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant
008058
X See Service Manual instructions
154
OILING SYSTEM
75 – 90 HP
30 to 42 in lbs.
(3.5 to 5 N·m)
F
F 30 to 42 in lbs.
(3.5 to 5 N·m)
30 to 42 in lbs.
(3.5 to 5 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
E Red Ultra Lock
F Blue Nut Lock
H Outboard Engine Lubricant
008059
X See Service Manual instructions
155
OILING SYSTEM
OIL SUPPLY DIAGRAMS
3 1
1 6
008060
156
OILING SYSTEM
75 – 90 HP
5
3
5 1
5
2
4
8
1 6
008061
157
OILING SYSTEM
OIL RECIRCULATION DIAGRAMS
002483a
75 – 90 HP
158
OILING SYSTEM
OILING SYSTEM CIRCUIT DIAGRAM
5 3 4
10
BA
11 12 9
2 26 18 10
10 1
BA
27 19 11
11 2
28 20 12
12 3
29 4
30
31
21
22
13
13
14
14 5 J1-A
23 15
15 6
32 7
33 24 16
16
17 8
34 25 17 9
7 1
6
20
21
14
15
8
9
2 8
22 3
16
6 543 21 23 17
10
11
4
5
J1-B
24 18
25 12 6
26 19 13 7
6 5 4 3 2 1
9
1
10
2
11
8
3
12
13
4
5
J2
14
6
15
7
16
8
008050
1. Stator
2. Main harness ground (BLACK)
3. Alternator grounds (BLACK)
4. Alternator output, WHITE / RED wires (55 V)
5. Capacitor (55 V)
6. EMM injector control (BLUE)
7. 55 V to injection pump (WHITE / RED)
8. Oil injection pump
9. Low oil switch
10. Low oil switch to EMM (TAN/BLACK)
11. Low oil signal to SystemCheck gauge (TAN/BLACK)
12. No oil signal to SystemCheck gauge (TAN/YELLOW)
159
OILING SYSTEM
OIL SYSTEM REQUIREMENTS
008062
160
OILING SYSTEM
COMPONENTS
2-CYLINDER MODELS The oil manifold distributes the oil supplied by the
Oil Tank Components: pump.
• Tank, 2 quart. (1.87 liter) capacity
• Oil pickup and filter assembly 2
• Oil injection pump and manifold assembly
• LOW OIL switch
• Oil distribution hoses
008063
3
Oil Injection Pump
1. Oil injector pump 008064
The oil injection pump is an electric (55 V) actua- 2. Oil distribution manifold
tor st yle pump. It d raws o il from the oil tank a nd 3. Pickup tube and filter
supplies pressurized oil to th e oil manifo ld. The
EMM supplies 55 V and controls activation of the Electrical Circuit (55 V)
pump. The oil injector is powere d by t he 5 5 V elect rical 8
circuit. The EMM controls pump operation by rap-
idly connecting a nd disconnectin g the pump’s
internal coil to ground.
161
OILING SYSTEM
COMPONENTS
NO OIL Warning 1
When the oil le vel falls below one-quarter, the
EMM begin s coun ting oil pump pulse cycle s.
When it reaches:
• 40 – 65 HP: 4800 pulses
• 75 – 90 HP: 6000 pulses
the EMM: 1. Crankcase oil fittings 006758
Activates S.A.F.E.
Stores service code 117
EMM LED 4: ON (Running)
1
Engine Monitor NO OIL display: ON
If o utboard has be en run fo r more th an 3 hou rs 1. Cylinder block oil fittings 006759
with NO OIL faults (codes 34 & 117), the EMM
Activates SHUTDOWN
Stores service code 33
EMM LED 4: FLASHING
Engine Monitor NO OIL display: FLASHING
162
OILING SYSTEM
COMPONENTS
1 1
Cylinder Recirculation
Internal p owerhead oil drain p assages connect
the intake port areas of the cylin ders to circulate
residual oil in the block.
163
OILING SYSTEM
OIL CONTROL SETTINGS
1 355627
164
OILING SYSTEM
OIL CONTROL SETTINGS
8
1 Dynamic Test Screen 008570A
1. Prime Oil System button
165
OILING SYSTEM
OILING SYSTEM TESTS
1. Oil distribution hoses 007997 The EMM controls the pump by providin g ground
through p in 2 3 (blue wire ) of th e J1-B co nnector
Small bubbles are acceptable. La rge b ubbles and pin B (blue wire) of the oil pump connector.
must be eliminated through continued priming. Acceptable Oil Injection Pump
Test Readings
1 Key switch ON approximately 12 VDC
Control signal approximately 5 Hz
Engine running approximately 55 VDC
166
OILING SYSTEM
OILING SYSTEM TESTS
Use the Oil Injector te st o f Evinrude Diagnostic Set digit al multimeter to a scale that re ads 55 V
software Static Test screen to activate the oil (DC).
pump.
Start the engine. Observe voltage at pin A.
• Voltage at pin A should be approximately 55 V.
• If volt age at p in A is within range, refer to Oil
Injection Pump Resistance Test on p. 167.
• No volt age re ading at pin A, refe r to System
Voltage Test on p. 80.
1 Oil Injection Pump Resistance
Test
Disconnect the battery cables at the battery.
167
OILING SYSTEM
OILING SYSTEM TESTS
Oil Injection Pump Function Test Oil Injection Fittings Flow Test
Remove oil distribution hose from fitting at oil dis- Make sure the oil injection fittings of the cylind er
tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.
port.
Remove oil distributio n hos e from o il distribution
manifold.
1
1
1. Syringe 008069
168
OILING SYSTEM
OIL COMPONENT SERVICING
1
8
1
1. Screws 008072
1
1. Hose support 008070
169
OILING SYSTEM
OIL COMPONENT SERVICING
2-CYLINDER MODELS
Installation
Position oil t ank assembly on powerhead. Cle an
1 mounting screws and ap ply Nut Lock to t hreads.
Install screws and tighten to a torq ue of 30 to 42
in. lbs. (3.5 to 5 N·m).
Install protective sleeves and route oil distribution
hoses from the oil distribu tion ma nifold to the
1. Screws 008074
crankcase oil delivery fittings. Refer to OIL SUP-
PLY DIAGRAMS on p. 156. Secure oil ho ses to
ALL MODELS
crankcase fittings with tie straps.
Disconnect the electrical connector to the oil injec-
tion pump and manifold assembly.
1. Oil pump connector 008075 Run outboard and check for leaks. Use Evinrude
Diagnostics sof tware to activate “Oil Prime.”
Disconnect the electrical co nnector to the lo w oil Check oil flow through oil distrib ution hoses.
switch. Check oil system operation and routing of oil sys-
tem hoses.
170
OILING SYSTEM
OIL COMPONENT SERVICING
1. O-ring 008064
1
2-CYLINDER MODELS
Install oil pump and manifold so that be nd of oil
pick up assembly is positioned to follow th e con-
tour of the oil tank as shown.
1
8
171
OILING SYSTEM
OIL COMPONENT SERVICING
3-CYLINDER MODELS
Install oil pump and manifold straight into oil tank.
ALL MODELS
Install oil pump ret ainer screw(s). T ighten
securely.
172
COOLING SYSTEM
COOLING SYSTEM
TABLE OF CONTENTS
HOSE ROUTING AND WATER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
ADAPTER/INNER EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
WATER PRESSURE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
EMM AND VAPOR SEPARATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
TEMPERATURE SENDER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
173
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS
8
6 5
9
10
3 60, 65 HP
1. Water intake screens
2. Water pump
3. Exhaust housing
4. Cylinder block
5. Pressure relief valve
6. Thermostat
7. Water supply to EMM
8. Water supply, EMM to vapor
2 separator
9. Overboard indicator, outgoing
water from vapor separator
10. Exhaust Water Valve
1
Outgoing water (warm/hot)
Incoming water (cool) 004971
174
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS
3-CYLINDER MODELS
Outgoing water (warm/hot)
8
Incoming water (cool)
001818
175
COOLING SYSTEM
COMPONENTS
176
COOLING SYSTEM
COMPONENTS
Thermostat
The thermostat controls water flow and operating
temperature at lower speeds (below 1800 RPM).
2
Overheating: A restricted or faulty thermostat typ-
ically results in LOW SPEED overheating. 9
Overcooling: Debris may prevent the thermostat
from closing completely.
1. Megaphone 002436
2. Exhaust housing 4 3 2 1
3. Water tube
4. Adapter housing
5. Inner exhaust housing
177
COOLING SYSTEM
COMPONENTS
1. Fitting 002461
178
COOLING SYSTEM
OPERATION
9
1. Thermostat 002441
2. Pressure valve assembly
The thermostat opens when the water temp era- 1. Overboard indicator 004969
179
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
A CAUTION
When servicing the propeller, always shift Monitor Screen 008598
the outboard to NEUTRAL, turn the key
switch OFF, and twist and remove all Typical temperatur e sensor readin gs at IDLE
spark plug leads so the engine cannot be speed should be 155°F ± 5°F (68.3°C ± 3°C).
started accidentally.
Typical temperatu re sensor readings at WOT
Reduce speed to IDLE for five minutes. Check speed should be 160°F ± 40°F (71°C ± 22°C).
IDLE operating temperature. Operating temp erature must not excee d 212°F
Increase speed to 5000 RPM and check tempera- (100°C).
ture.
Pyrometer Method
If engine temperatures are not within range, trou- Use a Temperature Gun, P/N 772018, or a digital
bleshoot cooling system. pyrometer to measure the ou tboard’s operating
temperatures.
If engine temperatu re test s within rang e, but the
engine mon itor d isplay ind icates a “W ATER Measure temperature of the thermostat housing at
TEMP” warning, refer to WATER TEMP/ HOT Cir- the top of cylinder head.
cuit Test on p. 108.
Typical pyrometer readings at IDLE speed should
be 145°F ± 10°F (63°C ± 6°C).
180
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
IMPORTANT: If you get low or in accurate read- Check thermost at for cracks, hea t damage, or
ings with a digital pyrometer, coat the probe loca- signs of corrosion. Check for proper operation.
tion with Thermal Joint Compound, P/N 322170. Thermostat opens at 143°F (62°C).
181
COOLING SYSTEM
TEMPERATURE SENDER SERVICING
008346 008347
Clean sensor threads, sensor, and sensor cavity. Remove spring, thermostat, and gasket.
Installation
Fill bottom of sensor cavity with 0.7 cc of Thermal
Joint Compound, P/N 322170. Sensor cavity
should be filled to 1 in ch (25 mm) below the top
edge of the cavity.
1 in. 1
002444
(25 mm)
Remove the cylinder head if cylinder hea d ther-
mostat seal requires replacement. Place new seal
in the cylinder head with side marke d “T O CYL
3 2
182
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
1 Disassembly
Remove screws and cove r from pressure valve
assembly.
Inspection
Inspect all parts for cracks, heat damage, or signs
of co rrosion. Re place dama ged p arts. Clean
debris from housing and parts.
002443
000756
9
Assembly
Assembly is the rever se of disassemb ly. Pa y
close attent ion when pe rforming the following
additional tasks.
183
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
Inspection
Inspect all parts for cracks, heat damage, or signs
of corrosion. Re place dama ged p arts. Clean
debris from housing and parts.
Assembly
Assembly is the rever se of disassemb ly. Pa y
close attent ion when pe rforming the following
additional tasks.
184
POWERHEAD
POWERHEAD
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
POWERHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
POWERHEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
SYSTEMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
THROTTLE LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
SHIFT LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
POWERHEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CRANKSHAFT AND CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
SHIFT LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
THROTTLE LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
FINAL POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
UPPER MOUNT SERVICING (3-CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
POWERHEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
POWERHEAD MOUNTING – 2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
POWERHEAD MOUNTING – 3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 10
POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
185
POWERHEAD
SERVICE CHART
SERVICE CHART
2-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J B
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
M Q
Apply to water passages Apply to crankcase
mating flange
H
26-30 Ft. lbs.
(35-41 N·m)
F
60-84 In. lbs.
(7-9.5 N·m)
B
F
60-84 In. lbs.
(7-9.5 N·m)
B
18-20 ft. lbs
(24.5-27 N·m)
186
POWERHEAD
SERVICE CHART
2-CYLINDER MODELS
H
G
H
30-32 Ft. lbs.
(41-43 N·m)
Must have
alignment tool H
H
B
A
H
D 10
A Triple-Guard Grease
B Gasket Sealing Compound
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
H Outboard Lubricant
P Permatex No. 2
Q Gel Seal II
002284 Y Extreme Pressure Grease
187
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J B
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
Q
M Apply to crankcase
mating flange
Apply to water passages
F
60-84 In. lbs.
(7-9.5 N·m)
B
H 60-84 In. lbs.
26-30 Ft. lbs. (7-9.5 N·m)
(35-41 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound F
60-84 In. lbs.
D Moly Lube (7-9.5 N·m)
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
H Outboard Lubricant
J Thermal Grease
B
M RTV Sealant
P Permatex No. 2
Q Gel Seal II
Y Extreme Pressure Grease 002281
188
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
H
G
H
30-32 Ft. lbs.
(41-43 N·m)
Must have
alignment tool
A Triple-Guard Grease
B Gasket Sealing Compound
H D Moly Lube
B E Red Ultra Lock
F Blue Nut Lock
A
G Needle Bearing Grease
H Outboard Lubricant
P Permatex No. 2
H
Q Gel Seal II
D
Y Extreme Pressure Grease
10
D
15-20 Ft. lbs.
(20-27 N·m) D
002282
189
POWERHEAD
COMPRESSION TESTING
1. Connectors 008429
190
POWERHEAD
POWERHEAD REMOVAL
Remove pin and wa sher from shif t rod lever to ALL MODELS
release the lower shift rod. Install Lifting Fixture, P/N 396748, on flywheel and
seat the three screws completely.
1
1. Shift rod screw 002171 2
ROPE START MODELS
Remove throttle cable and tiller shift rod.
1
1 1
191
POWERHEAD
POWERHEAD REMOVAL
3-Cylinder Models Remove six retaining screws and exha ust relief
muffler.
A WARNING
Protect against hazardous fuel spray.
Before starting any fuel system service,
carefully relieve fuel system pressure.
Refer to Relieving Fuel System Pressure
on p. 142.
To prevent accidental starting while ser-
vicing, twist and remove spark plug leads.
Disconnect power trim connectors. Install Lifting Fixture, P/N 396748, on flywheel and
seat the three screws completely.
1
002152 2
Remove pin and wa sher from shif t rod lever to
release the lower shift rod.
192
POWERHEAD
POWERHEAD DISASSEMBLY
193
POWERHEAD
POWERHEAD DISASSEMBLY
1 2
1
194
POWERHEAD
POWERHEAD DISASSEMBLY
002234
002137
002124
A WARNING
Wear safety glasses to avoid injury. 002138
Use a 1/8 in. diamet er p in punch to pu sh crank- Separate crankcase and cylinder block. It may be 10
case taper pin toward the front side of the engine. necessary to t ap on crankshaft with a r awhide or
rubber mallet to loosen.
002232
002252
195
POWERHEAD
POWERHEAD DISASSEMBLY
Cylinder Head Removal Use Torquing Socket, P/N 331638, t o loo sen in
stages the ro d cap ret aining screws. DO NOT
Remove thermostat cover and thermostat assem-
remove the screws.
bly. Re fer to THERMOSTAT SERVICING on
p. 182.
002123
002141
196
POWERHEAD
POWERHEAD DISASSEMBLY
Use an approp riate ring exp ander to remove all necting rod. If nece ssary, use Wrist Pin Pressin g
piston rings from pistons. Discard the rings. Tool, P/N 326356, to remove the wrist pin bearing.
A WARNING
Wear safety glasses to avoid injury.
002047
002046 10
The wrist pin fit is loose on both sides. Push the
002263
wrist pin throug h to fre e the p iston from the con-
Remove upper sea l from crankshaft. Discard the
seal. A new up per se al must be inst alled on
assembly.
197
POWERHEAD
POWERHEAD DISASSEMBLY
Remove the upper main bearing. Use a punch to remove the housing seal. Discard
seal.
1
Remove the lower bearing seal housing. Inspect housing and replace if necessary.
002042
002040
002044
198
POWERHEAD
POWERHEAD DISASSEMBLY
Inspect the crankshaft sleeve a nd replace if ne c- Use a be aring sep arator to support th e bearing,
essary. To remove the sleeve, use Slide Hammer, and press off the crankshaft.
P/N 432128, and Large Puller Jaws, P/N 432129.
002052
002041
Remove the lower main bearing only if it needs to Remove center ma in be arings an d sp lit sleeves
be rep laced. Use e xternal retaining ring pliers to for inspection. DO not mix p arts. Note location of
remove the lower bearing retaining ring. bearings for reassembly.
002039 24381
199
POWERHEAD
CYLINDER BLOCK CLEANING
A WARNING
To avoid personal injury, wear eye protec-
1. Crosshatch pattern in cylinder wall 002067
2. Chamfered port edge tion and set compressed air pressure at
less than 25 psi (172 kPa).
Use Gel Seal and Gasket Remover to remove all
traces o f g askets, adhesives, and Gel-Seal II™ Cover the cylinder walls with a libera l amount of
outboard lubricant to prevent corrosion.
200
POWERHEAD
POWERHEAD INSPECTION
POWERHEAD Crankshaft
Measure the diame ter of each crankp in and main
INSPECTION bearing journal. The lower main be aring journal
For d imensions, refer t o SERVICE SPECIFICA- would only b e measu red if the bearing was
TIONS on p. 10. removed for another reason.
Cylinder Head
Check for cylinder head warpage using a piece of
002142
bar stock or mach inist’s straightedge and a feeler
gauge set.
Cylinder Bore
Cylinder head warpage must not exceed 0.006 in. Use a Cylinder Bore Gauge to inspect each cylin-
(0.15 mm) per inch of me asurement. Re place der bore for an o ut-of-round, oversize, or t apered
head if warpage exceeds this dimension. condition. Be sure the gauge is perfectly square in
the bore when measuring.
10
24423
007283
Check fuel deflector pins for damage.
Measure each cylinder in at least two areas. Each
area should b e measur ed twice. The dif ference
between the two measureme nts in each are a is
the cylinder out-of-round dimension.
• The cylinder must not be o ut-of-round by mo re
than 0.004 in. (0.10 mm).
201
POWERHEAD
POWERHEAD INSPECTION
The dimensional dif ference between the two IMPORTANT: Ring end g ap increases ap proxi-
areas is cylinder taper. mately 0.003 in. (0. 076 mm) for e ach 0 .001 in.
• The cylin der t aper must n ot exceed 0.002 in. (0.025 mm) incre ase in cylinder bo re diamet er.
(0.05 mm). DO NOT exceed cylinder oversize dimension.
Pistons Bearings
Visually inspect pistons for sign s of abnormal Inspect center main bearings and split sleeves for
wear, scuffing, cracks, or burning. excess wear, nicks, or scratches. Replace if nec-
essary.
Piston Rings
Inspect crankshaft ro d be arings fo r excess wear,
For new ring sets, place each ring separately in its nicks, or scratches. Replace if necessary.
respective bore. Use a piston to square the ring in
the cylinder. Use a feele r gauge to measu re the
ring end gap.
24381
002143
202
POWERHEAD
POWERHEAD ASSEMBLY
IMPORTANT: Use new wrist pin retaining rings, Lubricate a new driveshaft O-ring and lightly lubri-
gaskets, seals, and O-rings during assembly. cate crankshaf t splines with Moly Lube. Inst all
O-ring in sleeve.
Crankshaft Assembly
Oil the end of the cra nkshaft. Use Crankshaf t
Bearing/Sleeve Installer, P/N 338647, and place a
1
new lower main bearing onto crankshaft with let-
tered side facing th e tool. Inst all bearing un til it
seats on the crankshaft.
2
203
POWERHEAD
POWERHEAD ASSEMBLY
lower housing with exte nded lip facing down. Lubricate upper main bearing with outboard lubri-
Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft.
002037
204
POWERHEAD
POWERHEAD ASSEMBLY
Pistons and Connecting Rods Apply Needle Bearing Grease to the wrist pin
bearings. Inst all the b earings in the small end of
NOTICE It is very important that the pistons the connecting rod. Align be arings with Wrist Pin
in this engine are installed in the correct loca- Bearing Tool, P/N 336660.
tion and direction. Engine damage will occur if
installed incorrectly. 2
1
1. Exhaust side of block 002049
2. Stamped markings
3. Splash bowl
002057
205
POWERHEAD
POWERHEAD ASSEMBLY
Use W rist Pin Cone , P/N 3 18600, and Driver , IMPORTANT: Be sure gap of ring fit s squ arely
P/N 318599, to install new wrist pin retaining rings around dowel pin.
in each wrist pin hole. Gap of retaining ring faces
up, away from notch in piston.
002048
206
POWERHEAD
POWERHEAD ASSEMBLY
002061
Install cylinder hea d with the thermostat to ward
the top. Place ig nition coil bracket s as shown
Apply soa py water to water dam and insert into below.
block.
Apply outb oard lu bricant to screw thre ads an d
install the cylinder head screws. DO NOT use any
sealant or locking compound on threads.
10
1. Water dam 002062
207
POWERHEAD
POWERHEAD ASSEMBLY
2 1
1
2 1
208
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate e ach crankpin and bearing a ssembly IMPORTANT: Be sure alignment dot on rod cap
with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dot s face fly-
up to crankshaft and install bearing halves. wheel.
002115
NOTICE Tightening rod cap screws without
Lubricate rod cap screw threads and under screw Alignment Fixture, P/N 396749, or using an
head mating surface with outboard lubricant. Align incorrect procedure could cause permanent
dot on rod cap with do t on the connecting rod. damage to the connecting rod and crankshaft.
Install rod cap screws finger tight (NO MORE than To maintain accurate torque values, keep
6 in. lbs. (1 N·m) maximum). torque wrench extension length to a minimum.
002116
10
209
POWERHEAD
POWERHEAD ASSEMBLY
Secure restraining jaw “C” and forcing jaw “D” to • Tighten the forcing screw to a torque of 14 to 16
frame. in. lbs. (1.6 to 1.8 N·m).
2
4
002072
210
POWERHEAD
POWERHEAD ASSEMBLY
Test at least three corners of the rod and cap joint IMPORTANT: Gel-Seal II ha s a shelf life o f at
with a pick. Joint must be smooth with no step. least one year when stored at room temperatu re.
Test the Gel-Seal II or replace it if the age of the
tube cannot be determined. Using old Gel-Seal II
could cause crankcase air leaks.
002260
211
POWERHEAD
POWERHEAD ASSEMBLY
Start in the ce nter a nd work out ward in a spiral Note: 3-Cylind er mode ls in clude a double-end ed
pattern. stud and use a lock washer under the J-clamp.
002259
Shift Linkage Installation
Test that the crankshaft spins freely without bind- Place the spring, guide, and ball of the shift detent
ing. assembly in to the cra nkcase. Lubr icate with Tri-
ple-Guard grease.
IMPORTANT: After powerhead ha s be en
assembled, allow at least two hours for Gel-Seal II
to cure before running outboard.
1
Apply Gasket Sealing Compound to both sid es of
a new water cover gasket. Place gasket and cover
on cylinder block.
Apply Nut Lock to cover screws. Position J-
clamps as shown. Tighten all screws to a torque of
60 to 84 in. lbs. (7 to 9.5 N·m).
212
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate sh ift lin kage bosses at the ba se of the Throttle Linkage Installation
crankcase with Triple-Guard grease. Insert bush-
Apply Nut Lock to threads of throttle lever screw.
ings into bosses.
Insert spring into cavity of throttle return lever.
Apply Triple-Guard grease to the shaft and detent
of the sh ift lever assembly . Gu ide sh aft throu gh Install lever, screw, and washer on crankcase and
bushings in crankcase. hook spring on rib as sho wn. Tighten screw to a
torque of 120 to 144 in. lbs. (13.5 to 16 N·m).
Install cotter pin and washer on th e shaft (2-cylin-
der models).
1
Install shift rod lever and tighten retaining screw to
a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
1 4
1
1. Throttle lever spring
10
Apply Nut Lock to thread s of throttle cam screw.
Install cam, screw, and wa sher on cylind er block
213
POWERHEAD
POWERHEAD ASSEMBLY
and tighten screw to a torque of 120 to 144 in. lbs. Final Powerhead Assembly
(13.5 to 16 N·m).
Install the reed plate and throttle body assemblies.
Refer to Intake Manifold Service on p. 149.
2-Cylinder models 002245 Install shift linkage. Refer to Shift Linkage Instal-
1. Throttle lever screw lation on p. 212.
2. Throttle return lever
Install throttle linkage. Refer to Throttle Linkage
Installation on p. 213.
A WARNING
To prevent fire and explosion hazard,
make sure all electrical and ignition wiring
is routed and clamped in original posi-
tions.
214
POWERHEAD
UPPER MOUNT SERVICING (3-CYLINDER)
39820
Installation
002069
Place mount assemblies in position, with flats fac-
Insert suit able pun ch in t aper o f mou nt ret ainer. ing away from each other.
Tap side of punch to loosen mount retainer.
Apply Moly Lube to all sides of retainer and install
between mounts.
002130
002133 10
Dislodge mount assemblies and remove.
Install the retainer screw and tighten to a torque of
15 to 20 ft. lbs. (20 to 27 N·m).
002132
002134
215
POWERHEAD
POWERHEAD INSTALLATION
002269
216
POWERHEAD
POWERHEAD INSTALLATION
Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing.
retaining pin an d washer. Tighten pin to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
1 2
3
4
1
217
POWERHEAD
POWERHEAD INSTALLATION
Install r ecoil st arter ratch et and h ousing on out- Use Lif ting Fixture, P/N 396748, and hoist to
board. Refer to RECOIL STARTER INSTALLA- slowly lower powerhead ont o exhaust hou sing.
TION on p. 369. Guide into positio n over alignment pin at rear of
exhaust housing. If necessary, rotate flywheel in a
clockwise direction to align cranksha ft and drive-
shaft splines.
1
1
1
1
218
POWERHEAD
POWERHEAD INSTALLATION
• Tighten the upper mount screws to a torque of Apply Gasket Sealing Compound to exhaust relief
110 to 130 ft. lbs. (149 to 176 N·m). Make sure muffler gasket and retaining screws. Install muffler
that screw heads are tight against steering arm. and tighten screws to a to rque of 60 to 84 in. lbs.
(7 to 9.5 N·m).
3
1
1. Large powerhead screws 002153
2. Small powerhead screws
3. Upper mount screws
002163
Place the shift rod in the shift rod lever. Install the
retaining pin and washer. Tighten pin to a torque
1 of 60 to 84 in. lbs. (7 to 9.5 N·m).
219
POWERHEAD
POWERHEAD INSTALLATION
Connect the power trim connectors. • Tighten adjustment screws to 60 to 84 in. lbs. (7
to 9.5 N·m).
5
4
3
1
002152 2
Install the lower engine covers. Re fer to LOWER 1. Adjustment screws 002125
COVER SERVICE on p. 50. 2. Shift detent assembly
3. Shift lever pin
4. Trunnion pocket
Shift Linkage Adjustment 5. 7 inch dimension
Adjust shift linkage as follows:
• Loosen adjustment screws on shift lever. Final Adjustments
• Be sure that ball is centered in detent assembly.
• Adjust shift lever so tha t the screw hole in shift NOTICE After installing a new or rebuilt
rod lever lines up with the hole in the gearcase powerhead, perform the following procedures
shift rod when gearcase is in neutral. before returning outboard to service:
• When correctly adjust ed, the shif t lever will be
• Adjust timing pointer.
parallel with th e ve rtical line of the outbo ard,
and the distance between the shift lever pin and
• Index all sp ark plugs. Refer to Spark Plu g
Indexing on p. 42.
the cen ter of th e shif t cable trun nion pocket
should be approximately 7 in. (17.8 cm). • Use Evinrude Diagnostics software to start pow-
erhead b reak-in o iling. Ref er to Powerhead
IMPORTANT: The shif t rod heig ht is the mo st Break-In on p. 67.
critical of these ad justments and should not be • Use Evinrude Diagnostics software to set TPS
moved durin g this procedure. Re fer to SHIFT calibration. Refer to TPS Calibration on p. 114.
ROD ADJUSTMENT on p. 300, or SHIFT ROD • Use Evinrude Diagnostics sof tware to m ake
ADJUSTMENT on p. 323. sure engine ma nagement software version a nd
revision are current. Update as required.
• Prime fuel system.
• Prime oiling system. Refer to Oil Supply Prim-
ing on p. 165.
• Use Evinrude Diagnostics software to check
engine timing. Ref er t o TIMING ADJUST-
MENTS on p. 113.
• Run outb oard and check for water , fu el, or oil
leaks.
• Make sure en gine rea ches correct op erating
temperature and does not overheat.
220
POWERHEAD
POWERHEAD VIEWS
POWERHEAD VIEWS
006490
10
006491
221
POWERHEAD
POWERHEAD VIEWS
008428
008159
222
POWERHEAD
POWERHEAD VIEWS
008370
10
008185
223
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Front
008160
224
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Rear
10
008161
225
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Top
008162
226
POWERHEAD
POWERHEAD VIEWS
10
008186
227
POWERHEAD
POWERHEAD VIEWS
006760
006761
228
POWERHEAD
POWERHEAD VIEWS
008163
10
008164
229
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Front
008166
230
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Rear
10
008167
231
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Top
008165
232
MIDSECTION
MIDSECTION
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TILT TUBE, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
EXHAUST HOUSING, 40 – 65 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
EXHAUST WATER VALVE (60–65 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
EXHAUST RELIEF MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
EXHAUST HOUSING, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
LOWER MOUNT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
EXHAUST HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
EXHAUST HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
STERN BRACKET, 40 – 60 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
STERN BRACKET, 75 – 90 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
STERN BRACKET, 40 – 60 HP MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
CLAMP SCREW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
TILT ASSIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
STERN BRACKET, 90 HP MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
TILLER HANDLE SERVICE – STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 11
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
TILLER HANDLE SERVICE – LONG HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
233
MIDSECTION
SERVICE CHARTS
SERVICE CHARTS
EXHAUST HOUSING, 40 – 65 HP
F F
24-26 Ft. lbs.
C (32.5-35 N·m) 18-20 Ft. lbs.
(24.5-27 N·m) F
60-84 In. lbs.
(7-9.5 N·m)
B
18-20 ft. lbs
(24.5-27 N·m)
F
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 Blue Nut Lock
G Needle Bearing Grease
P Permatex No. 2
004304 Q Gel Seal II
234
MIDSECTION
SERVICE CHARTS
EXHAUST HOUSING, 75 – 90 HP
E
60-84 In. lbs.
B (7-9.5 N·m)
60-84 In. lbs.
(7-9.5 N·m) B
60-84 In. lbs.
(7-9.5 N·m)
C
A
B
B
18-20 Ft. lbs.
(24.5-27 N·m)
B
60-84 In. lbs.
(7-9.5 N·m)
A 11
F
150-180 In. lbs. C
(17-20 N·m) A Triple-Guard Grease
B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
A
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
P Permatex Number 2
002210 Q Gel Seal II
235
MIDSECTION
SERVICE CHARTS
A
A
A F
144-168 In. lbs.
(16-19 N·m)
IMPORTANT
Use Triple-Guard grease
on all pivot points
A Triple-Guard Grease
002220 B Gasket Sealing Compound
236
MIDSECTION
SERVICE CHARTS
A
10-16 In. lbs.
(1.1-1.8 N·m)
A
IMPORTANT
Use Triple-Guard grease
on all pivot points
40-50 In. lbs.
(4.5-5.5 N·m)
A B
130-150 Ft. lbs.
(176-204 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
F Blue Nut Lock
004105a U Instant Bonding Adhesive
237
MIDSECTION
SERVICE CHARTS
F
144-168 In. lbs.
(16-19 N·m)
IMPORTANT
Use Triple-Guard grease A Triple-Guard Grease
on all pivot points B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
P Permatex No. 2
002221 Q Gel Seal II
238
MIDSECTION
SERVICE CHARTS
IMPORTANT
Use Triple-Guard grease
on all pivot points
A
110-130 Ft. lbs.
(149-176 N·m)
F
18-20 Ft. lbs.
(24-27 N·m)
F
60-84 In. lbs.
A (7-9.5 N·m)
A
F
38-45 Ft. lbs.
A
B A Triple-Guard Grease
130-150 Ft. lbs.
40 Ft. lbs. (54 N·m) (176-204 N·m)
B Gasket Sealing Compound
Marine Sealant C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
P Permatex No. 2
008204 Q Gel Seal II
239
MIDSECTION
SERVICE CHARTS
A
18-20 Ft. lbs.
(24.5-27 N·m)
A
36-40 Ft. lbs.
(49-54 N·m) 18-20 Ft. lbs. 20-30 In. lbs.
(24.5-27 N·m) (2.3-3.4 N·m)
F
F A D
18-20 Ft. lbs.
(24.5-27 N·m)
Switched 12V
For CANbus
Stop Switch
To En gine Tr im
Connector
Tiller Key Switch Start Switch
18-20 Ft. lbs.
To Remote
(24.5-27 N·m) 18-20 Ft. lbs. Trim Gauge
(24.5-27 N·m) Trim Switch
A Triple-Guard Grease
D Moly Lube
006663
F Blue Nut Lock
240
MIDSECTION
TILT TUBE, 75 – 90 HP
Removal
A WARNING
Support the outboard with a suitable hoist.
30747
Pull the locking tabs on the tilt limit cam loose from
the collar.
Thread the spacer f rom Tilt T ube Service Kit,
P/N 434523, on to the st arboard end of th e tilt
tube.
30746
Remove the cam and collar from the tilt tube.
Remove steerin g cab le wiper n ut from tilt tub e.
Thread the adap ter from T ilt T ube Service Kit,
P/N 434523, onto the port end of the tilt tube.
11
30748
30745
241
MIDSECTION
TILT TUBE, 75 – 90 HP
Thread Slide Hammer, P/N 432128, into the Install the starboard locknut.
adapter until at least 2 in. (51 mm) of threa d are
engaged. A 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 b racket,
remove tilt tube from the spacer.
Installation
Thread starboard end of tilt tube into the spacer.
30741
Thread the adapter onto port end of tilt tube.
Use a wood or leather ma llet to t ap the tilt tube Replace steering cable wiper nut on port end of tilt
into position. tube.
30743
30750
242
MIDSECTION
EXHAUST HOUSING, 40 – 65 HP
EXHAUST HOUSING,
40 – 65 HP
The exhaust ho using cont ains no se rviceable
internal p arts. The exhaust wate r valve a nd the
exhaust relief muffler can both be serviced without
removing the exhaust housing.
1
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove th e gearcase . Re fer to Ge arcase 1. Lower side mount 17524
GEARCASE REMOVAL AND INSTALLATION
on p. 296. Remove the three upper mount to exhaust hous-
• Remove th e powerhea d. Refer to Powerhe ad ing screws. Be sure t o su pport exhaust ho using
POWERHEAD REMOVAL on p. 190. so it does not fall.
Remove the three lower mount cover screws.
COA2943
17527
Remove the exhaust housing.
Separate lower mount covers from swivel bracket.
11
1
243
MIDSECTION
EXHAUST HOUSING, 40 – 65 HP
Exhaust Water Valve (60–65 HP) Apply Nut Lock to screws, install and tighten 60 to
84 in. lbs. (7 to 9.5 N.m).
Disconnect water valve electrical connector.
1
1. Exhaust water valve screws 004293
2
3 Exhaust Relief Muffler
Remove exhaust relief muffler cover to inspect fil-
ter element. Clean or replace as needed.
1. Electrical connector 004293
2. Inlet hose
3. Outlet hose
1
Apply Gasket Sealing Compound to co ver gasket
and install cover.
1. Fitting, water passage 004300 Apply Nut Lock to co ver screws an d tighte n to a
torque of 60 to 84 in. lbs. (7 to 9.5 N.m).
Install hoses to fittings on exhaust housing.
244
MIDSECTION
EXHAUST HOUSING, 40 – 65 HP
Exhaust Housing Installation Place lo wer thrust washer on th e stee ring shaf t
and place the lower front mount into position.
Bring the exhaust housing into positio n with the
stern bracket.
1 3
245
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
20” Models
“ 23036
001971
25” Models
“ 32590
246
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
If re moved, coat the lower mount s with soap y Exhaust Housing Installation
water and press into the exhaust housing with the
Bring the exhaust housing into position with th e
“OUTSIDE” mark facing outward.
stern bracket.
001970
001972
25” Models 32590
247
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
1 1
1 1 2
248
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
Cleaning and Inspection Inspect the water tube for obst ructions or kinks,
which may restrict water flow.
A WARNING
Exhaust Housing Assembly
Wear safety glasses to avoid personal
Place a new gasket between the exha ust meg a-
injury, and set compressed air to less than
phone and adapt er housing . Apply Ultra Lock to
25 psi (172 kPa).
the threads of the screws and tighten to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
Clean all parts with parts cleaning solvent and dry
with compressed air . All nu t and screw thread s
coated with thread locking material must be thor- 1
oughly cleaned before a ssembly. When u sing a
thread lo cking pr oduct, be sure to p rime the
threads with Locquic Primer. 2
Examine the upper and lower thrust mounts, and
replace if deteriorated or damaged.
1
Before checking the exhau st housing for distor-
tion, thoroughly clean the top and bottom mating
surfaces and remove all sealer and corrosion. 1. Adapter to megaphone screws 001976
2. Exhaust megaphone
Check the exha ust hou sing for distortion. Place
the housing o n a su rface plate. Use a dial indica- Place a new grommet on the water tube and coat
tor to che ck flatness by measuring the run-out on the outside edge with Adhesive 847.
the top edge of housing. The maximum allowable
run-out is 0.009 in. (0.228 mm). If you do not have
access to a dial indicator and surface plate, seek
the services of a machine shop. DO NOT attempt
to straighten a distorted housing; replace it. 1
IMPORTANT: A d istorted e xhaust h ousing will
cause the upper driveshaft splines to wear exces-
2
sively and will damage the crankshaft splines.
DR2223
249
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
Install the water tube through the top of the inner Apply Adhesive 847 to the bottom flange of the
exhaust housing and align as shown: inner exhaust hou sing. Inst all a new seal. Apply
Triple-Guard grease to outer seal surface.
001982
1. Seal 001973
Place a ne w gasket between the in ner e xhaust 2. Bottom flange
1 1
250
MIDSECTION
STERN BRACKET, 40 – 60 HP POWER TILT
17505
COA2957
11
COA2958
251
MIDSECTION
STERN BRACKET, 40 – 60 HP POWER TILT
To sep arate the swivel b racket from the stern Stern Bracket Assembly
bracket, remove one tilt tube nut.
Assemble the tie bar to the stern b rackets. Place
the ground lead and starwasher between the port
stern bracket and tie bar.
17544
17541
17553
17551
17552
252
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
17506
30738
17507
17509
253
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Remove the steering shaf t and thrust wa sher. It Remove the anode.
may be necessary to tap the st eering shaft out
using a wood dowel and mallet.
1. Anode 30762
30765 / 30764
Remove the trim sen der unit from the port ste rn
bracket an d p ull it s wire s through t he braided
Remove the tilt tube. Refer to TILT TUBE, 75 – 90
tube.
HP on p. 241.
Remove the two tilt tube washers.
30760
30763
254
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Remove the tilt limit switch and ret ainer from the Remove the two trim rod rollers from the swivel
swivel bracket. bracket.
1
2
1
11
1
255
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Stern Bracket Assembly Install the two trim rod rollers on the swivel
bracket. Tighten to a torque of 216 to 240 in. lbs.
IMPORTANT: Before proceeding, make sure all (25 to 27 N·m).
components h ave b een tho roughly clean ed.
Replace any seals t hat have bee n removed.
Inspect all thru st wash ers and bu shings for evi-
dence of deterioration.
Install the detent roller and spring and the tilt sup-
port with bushing in the swivel bracket. T ighten
bushing to a torque of 28 to 30 f t. lbs. (38 to 41 1
N·m).
30752
2
1
256
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Install the tilt limit switch and retainer on the swivel • Coat the bushing s and sea l lip s with Triple-
bracket. Tighten screws to a torque of 40 to 50 in. Guard grease.
lbs. (4.5 to 5.5 N·m).
2 30765 / 30764
30761
30735
257
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
1. Bumpers COA2949
30767 2
258
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Slide the pivot sha ft and upp er thrust washer out Loosen t he ste ering friction screw while pu shing
of the swivel bracket. outward on the steering friction p in. When the pin
is flush with the inside surface of the ca sting,
remove the steering friction thrust ring.
Tighten the ste ering friction screw until the ste er-
ing friction pin can be removed. Then, remove the
steering friction screw.
11
COA2958
1. Setscrews COA2961
259
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Drive the steering frict ion bushing up and out of Remove the two st ern bracket flange screws a nd
the swivel bracket. separate the stern bracket s from the swive l
bracket.
COA2974
1. Flange screws COA2992
Remove t he thrust rod fro m the stern b rackets.
Remove on e tilt tube nut, and remo ve tilt tube Place the tilt/ru n lever in the RUN positio n.
from the ste rn bracket s and swivel bracket. Loosen the bellcrank setscrew.
Remove the port and st arboard stop link screws
and nuts from the stern brackets.
2
3
1. Bellcrank setscrew COA2976
1. Thrust rod COA2991R Remove the tilt/run lever, port stop link, and bush-
2. Tilt tube nut
3. Stop link screw and nut
ing from the swivel bracket.
3
2
260
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Remove the st arboard sto p link retaining screw Stern Bracket Assembly
and nut from the swivel bracket.
Place the reve rse lock sp rings in the swive l
bracket. Insert the reverse lock pins in the swive l
1 bracket and p art wa y throu gh the reverse lock
springs. Place the reverse lock assembly between
the springs. Push the pins through the springs and
the reverse lock assembly.
1. Washers COA2982
11
COA2980
261
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Install th e bushing, the po rt stop link, and the Place the swivel bracket between the stern brack-
tilt/run lever in the swivel bracket. The tilt/run lever ets.
should be in the RUN position.
Install the tilt tube through the following parts and
install the tilt tube nuts loosely:
3 • Starboard stern bracket
• Thrust washer
• Bushing
• Swivel bracket
1 • Bushing
2 • Thrust washer
• Port stern bracket
Apply Nut Lock to threads of the two flange
screws. Inst all the two screws through the st ar-
002204
1. Tilt/run lever
2. Port stop link
board st ern bra cket fla nge into the po rt ste rn
3. Bushing bracket flange. Tighten the screws to a torqu e of
144 to 168 in. lbs. (16 to 19 N·m).
Install the wave washer and th e bellcrank on the
tilt/run shaft. Tighten the setscrew. Tighten the tilt tube nuts to a torque of 45 to 50 ft.
lbs. (61 to 68 N·m).
1 2
1 1
262
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Install and tighten the nut to a torque of 144 to 168 Place the steerin g friction bu shing in the swivel
in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews.
1 2
263
MIDSECTION
STERN BRACKET, 40 – 60 HP MANUAL TILT
Apply Nut Lock to th reads of the upper mount to 1. Stop link screw 006651
steering arm screws. Positio n the uppe r rubber
mount, the upper mount washers, and th e retain- Remove both cotter pins and washers. Use appro-
ing wa shers on the ste ering arm with the word priate tool to remove upper pivot pin.
“UP” on the mount facing up. Be sure to place the
ground lead be tween the moun t (st arboard side)
and the steering arm. Install and tighten the mount 1 1
retaining scr ews to a torque of 24 to 26 f t. lb s.
(32.5 to 35 N·m). 2 2
3
5 1
3 4 4
2
5
3
1. Bushings 003939
2. Washers
4 3. Pivot pin
4. Cotter pins
264
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
003940
11
265
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
Remove cotter pins, pins and locking lever. Remove port reverse lock link.
1
1
1
1
266
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
Remove retaining ring and bellcrank shaf t spacer Remove port trail lock leve r and trail lock shaf t as
from reverse lock pivot shaft. an assembly.
1
1
1. Retaining ring 006693 1. Port trail lock lever and shaft 006704
Remove screw from trail lock lever . Remove trail Remove p ort and starboard trail lock shaf t bush-
lock lever and reverse lock pivot shaf t from swivel ings from swivel bracket.
bracket.
1
1
1. Trail lock shaft bushings 006687
1. Trail lock lever 006692
2. Reverse lock pivot shaft
11
267
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
Stern Bracket Assembly Apply blue Nut Lock to screw and assemble port
trail lock le ver on tra il lo ck shaf t wi th screw ,
Reverse Lock and Trail Lock Reference washer and nylon washer. Install in swivel bracket
from port side. DO NOT tighten screw at this time.
268
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
Assemble st arboard t rail lock lever and trail lock Install remaining bellcrank shaft spacer on reverse
spring to reverse lock pivot shaft. lock pivot shaft, then install retaining ring.
3 1
1
2
1. Reverse lock pivot shaft 006692 Install the port re verse lock link on t he swive l
2. Trail lock lever bracket. Install washer screw. Apply blue Nut Lock
to screw thre ads a nd in stall washer an d screw .
11
269
MIDSECTION
STERN BRACKET, 90 HP MANUAL TILT
Tighten screw to a torque of 60 to 84 in. lbs. (7 to Install reverse lock r elease collar a nd t ighten set
9.54 N·m). screw.
1. Port reverse lock link 006695 1. Reverse lock release collar 006697
2. Set screw
1 1
1 2
270
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
A WARNING
To avoid accidental starting of engine
while servicing, twist and remove all spark
plug leads.
2
3 11
1
271
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
1
24294
24288
2
Remove the throttle control plate.
1
1. Twist-Grip Remover 002189
2. Screw
1 2 3 2 1
1. Helix halves COA2674
2. Rollers
3. Guides
272
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
Remove the th rottle cable re taining clip. Pry the outer handle. After removing, chip away remnants
cable trunnion o ut of t he steerin g han dle a nd of inner handle.
remove cable.
2 1
24284
1. Retaining clip 24286 Remove throttle cable seal from the inner handle.
2. Cable trunnion
Assembly
Install the throttle cable seal in inner handle.
24285
273
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
Install the metal outer handle over the plastic inner Install the throttle control plate on outer handle.
handle and drive the outer handle into place.
1
24294
24285
Lubricate e nd of t he pin, guides, rollers, h elix
Install the handle en d of the th rottle ca ble. Snap grooves, an d inner handle g uide slot with Moly
the th rottle cable tru nnion into the recess in the Lube. Place the guides over the roller pin and into
handle. Install the retainer clip. the slots of t he inner handle. Place the rollers on
the ends of th e roller p in. Assemble the h elix
halves o n th e h andle a nd slide the grip over t he
helix.
24293
1. Throttle cable trunnion 24282
2. Retainer clip 24286
274
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
A CAUTION
1 The steering handle nut must have a nylon
patch for locking. Replace the nut if it has
lost its locking feature. Tighten the nut so
the steering handle can be pivoted and
1. Indicator line 002190
maintained in any position.
Slide the protective sle eve ove r the stop switch
leads and throttle cable and inst all stop switch
cover.
1. Screw 31194
24291
Route t hrottle cab le and electrical ha rness
through grommet in lo wer motor cover . Connect
harness to engine wiring harness.
1
11
24288
275
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
4
1 1
2
1
1
276
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
A WARNING
To avoid accidental starting of engine
while servicing, twist and remove all spark
plug leads.
277
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
1. Screw 006362
1
1. Screw 006361
006713
278
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Disconnect trim switch co nnector. Remove con- Remove the throttle friction control.
nector from trim switch wires. Refe r to CONNEC-
TOR SERVICING on p. 116. 1
1. Retainer 006674
2. Throttle cable trunnion
006681
006712
279
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Use an app ropriate tool to ca refully pry up on the Remove cotter pin from shift handle pin. Remove
inner handle retaining tab. shift cable.
1
1
Use a wooden dowel and a soft mallet to remove Remove shift handle screw and washer . Remove
the inner handle. shift handle, bushing and washer.
1
Remove shift cable retainer from shift cable trun- Remove shift handle detent ball, spring and guide.
nion.
1
1
280
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Remove the shift pin if necessary. Coat de tent ball, spring a nd guide with Triple-
Guard grease and install into shif t ha ndle. Place
1 one washer on shift handle mounting boss.
1
Assembly 3
Apply Nut Lock to th reads of shif t pin and install
shift pin into shift handle. Tighten to a torque of 18
to 22 ft. lbs. (24.5 to 29 N·m).
1
1. Bushing 006717
2. Washer
3. Screw
281
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Install shift cable on shift pin with a new cotter pin. Secure tab of the inner h andle into the outer han-
dle. Tab must be flush with the back of the flange
1 and top of tab must be flush with top of flange.
Install shift cable retainer on shift cable trunnion. 1. Back of flange 006682
006681
006680
282
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Install the throttle control plate on outer handle. ing. If wire guide is forced into place, it WILL dam-
age trim switch wiring.
1
1 2
IMPORTANT: Trim switc h wiring m ust NO T be Make sure trim switch wi ring is NOT twiste d
twisted through the throttle twist grip or inner tiller before proceeding.
handle / wire guide. 1
Insert wire guide into inner steering handle.
2
1 2
283
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Install the handle en d of the th rottle ca ble. Snap Place th e gu ides over the roller p in a nd into t he
the th rottle cable tru nnion into the recess in the slots of the inner handle. Place the rollers on t he
handle. Install the retainer clip. ends of the roller pin.
1 1
006718
1. Pin 006712
284
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
1
006713
1. Screw 006361
1. Screw 006362
285
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Route shift and throttle cables and electrical har- Control Cable Installation
ness through grommet in lower motor cover. Con-
nect harness to engine wiring harness. IMPORTANT: DO NOT complete fina l att ach-
ment of cables to shif t and throttle levers until all
cables, wires, an d h oses have be en routed a nd
grommet has been pla ced in to the lower engine
cover.
2
1 1
1. Bracket 006314
1
286
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Throttle Cable Adjustment Install washer, cable an chor, and cable anchor
Place t hrottle cab le in position. Use Ball Socket screw o n th rottle body b oss. Tighten screw
Installer too l, P/N 342225, to snap t hrottle cab le securely.
connector onto throttle lever.
4
1
1 2
287
MIDSECTION
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
288
GEARCASE
GEARCASE
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
GEARCASE TYPES, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
PROPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
GEARCASE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 12
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
289
GEARCASE
SERVICE CHARTS
SERVICE CHARTS
40 – 65 HP
A
A
C
10-12 Ft. lbs.
(13.5-16 N·m) A
A 28-30 Ft. lbs.
(38-40 N·m)
X A 60-84 In. lbs.
18-20 Ft. lbs.
(24.5-27 N·m) (7-9.5 N·m) A
G 18-20 Ft. lbs.
(24.5-27 N·m)
F
48-80 In. lbs.
J (5.5-9 N·m)
40-45 Ft. lbs.
(54-60 N·m)
B
A 35-40 Ft. lbs.
(47-54 N·m)
A G
B
B
A Triple-Guard Grease
A B Gasket Sealing Compound
C Adhesive 847
D Moly Lube
E Red Ultra Lock
F Blue Nut Lock
G Needle Bearing Grease
H Gearcase Lubricant
006482 X see Service Manual
290
GEARCASE
SERVICE CHARTS
“S”–TYPE GEARCASE
D B
C A B
B
F 18-20 Ft. Lbs.
(24-27 N·m)
A
A 26-28 Ft. lbs.
(35-38 N·m) A
C A 45-50 Ft. lbs.
(61-68 N·m)
B
X
A A 60-84 In. lbs.
18-20 Ft. lbs. 60-84 In. lbs. (7-9.5 N·m)
G (24-27 N·m) (7-9.5 N·m)
26-28 Ft. lbs.
(35-38 N·m)
14-18 In. lbs.
(1.5-2 N·m)
J
100-110 Ft. lbs.
(136-149 N·m)
B 60-84 In. lbs.
35-40 Ft. lbs. (7-9.5 N·m)
A (47-54 N·m)
A B
B
291
GEARCASE
SERVICE CHARTS
C B
24-36 In. lbs.
(3-4 N·m) B B
60-84 In. lbs.
(7-9.5 N·m) 120-144 In. lbs.
A
(13.5-16.5 N·m)
D B
A B
60-84 In. lbs.
C A (7-9.5 N·m)
B B
A B
B
E
15-20 In. lbs.
(1.7-2.3 N·m)
B
292
GEARCASE
GEARCASE TYPES, 75 – 90 HP
GEARCASE TYPES, 75 – 90 HP
Gearcase General Service Procedure
Outboard Model Type Comparison Comparison
(L) Models with Unique housing, shafts,
“S”
20 in. shaft gears, and bearings
Similar
(X) Models with Unique housing, shafts,
“O”
25 in. shaft gears, and bearings
293
GEARCASE
PROPELLER SERVICE
2 1
1. Right-hand rotation (clockwise) 000033
2. Left-hand rotation (counterclockwise)
A WARNING
For dual-outboard installations, always 001992
check to be sure propellers are installed
on the correct engines before aggres- Install the propeller nut and tighten to a torque of:
sively operating the boat. • With Keeper – 70 to 80 ft. lbs. (95 to 109 N·m)
• Without Ke eper – 120 t o 144 in. lbs. (13.6 to
16.3 N·m)
294
GEARCASE
GEARCASE LEAK TEST
295
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
GEARCASE SERVICE, 40 – 65 HP MODELS
1
1
296
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
2
1
30385
297
GEARCASE SERVICE, 40 – 65 HP MODELS
WATER PUMP SERVICE
1
1. Trim tab screw 001996
Place the shift rod in the shift rod lever. Install the
retaining pin an d washer. Tighten pin to a torque 1. Impeller housing screws 001203
1
1
298
GEARCASE SERVICE, 40 – 65 HP MODELS
WATER PUMP SERVICE
1. Impeller 001216
2. O-ring seal
3
1
1
Lightly coa t the inside of the liner with Triple- The sharp edge of t he key is the le ading edge in
Guard grease. With a co unterclockwise rot ation, clockwise rotation.
install the impeller into the liner with the slot for the
impeller key facing out. Slide the water pump down the driveshaft. Alig n
impeller slot with the impeller key . Rot ate th e
driveshaft to engage the key with the impeller, and
12
299
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFT ROD ADJUSTMENT
300
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
Remove the propeller and mounting hardware. • Gearcase Anodes — If anodes have eroded to
two-thirds their origina l size, t hey must b e
Drain a nd inspect o il as d escribed in Gearcase replaced.
Lubricant on p. 39.
Remove gearcase. Refe r to GEARCASE
REMOVAL AND INSTALLATION on p. 296.
301
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
Propeller Shaft Bearing Housing Remove the two ret aining ring s using Ret aining
Ring Pliers, P/N 331045.
Removal
Use a 5/16 in. thin wall socket to remove the four A CAUTION
screws with O-rings ho lding th e pr opeller shaf t
Retaining rings are under extreme pres-
bearing housing.
sure during removal and installation. To
prevent personal injury, wear safety
glasses and proceed with care to avoid
unsnapping the ring from the pliers. After
the retaining rings are removed far
enough from the gearcase to clear the
housing, release the tension on the pliers
while retaining ring is still around the pro-
peller shaft.
COA3571
1
9437
302
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
Remove the larger th rust washer, t hrust bearing, Remove th e four driveshaf t bearing ho using
and reverse gear from the gearcase. Remove the screws.
smaller thrust washer located in front of the gear.
1
1
1 1
2
1. Driveshaft bearing housing screws COA3671
12
1. Holding socket COA3573T
2. 11/16 Wrench
COA3159
303
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE DISASSEMBLY
3
COA3666
1. Drive shaft COA3664
2. Puller IMPORTANT: Make sure oil fill/drain plug is
3. Backing plate
removed from gearcase.
COA3575
304
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
3
6
4 7
1. 1/4-20 X 1/2 in. Hex head screw 824182
2.
3.
1 in. O.D. Flat washer
Spacer, P/N 326584
12
1. Flange Nut, P/N 326586 813305 4. Plate, P/N 391260
2. Plate, P/N 391260 5. Rod, P/N 326582
3. Rod, P/N 326582 6. Installer, P/N 326575
4. Remover, P/N 326580 7. 1/4-20 X 1 1/4 in. Hex head screw
Use a 1 in. wrench to hold the remover in place. IMPORTANT: Spacers a re dif ferent size s an d
Use a 3/4 in . wrench to turn flang e nut clockwise cannot be interchanged.
and draw the bearing up from the housing.
305
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Place the bearing on the installer tool with the let- unwrapping it from aro und the clut ch dog. Dis-
tered side of the bearing facing the top of t he card the spring.
gearcase. Use Needle Bearing grease to hold the
bearing on the tool.
Wear safety glasses to avoid injury. Remove the ge ar, thrust bearing, and thrust
washer from the shift housing.
IMPORTANT: The shif t h ousing and forward
gear bea ring are serviced as an asse mbly. If
either are worn or damaged, replace the complete 1
assembly.
1. Gear COA3562
2. Thrust bearing
3. Thrust washer
306
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Remove th e shif t lever pin from the ho using. Shift Housing Assembly
Remove shif t shaf t, crad le an d shif t leve r. Move
shifter detent as need ed to help ease removal of IMPORTANT: Clean and inspect all parts before
parts. beginning assemb ly pro cedures. Replace any
damaged parts.
5 4 Lightly coat the detent ball and spring with Needle
Bearing grease. I nsert the sp ring in t he h ousing,
then the ball.
3
1
2
A WARNING
Wear safety glasses to avoid personal
injury. The detent ball and spring and 4518
DSC02506
307
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
With shif ter detent in NEUTRAL , inst all arms of Coat thrust bearing and thrust washer with Needle
shift lever int o det ent slot s. Alig n th e pivot holes Bearing grease. Place t he bearing on the ba ck of
and insert the ret aining pin. Push shifter det ent the gear. Set the washer on top of the thrust bear-
down. ing. Insert the ge ar, bearing, and washer into t he
bearing housing.
1 3
2
1
1. Grooved end COA3591
001219
308
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Slide the pro peller shaft onto the shif t shaft, align Clean the bearing ho using in solven t to re move
the hole in the sh aft with the h ole in the clutch sealer from the seal bore and the O-ring groove.
dog, inst all the pin and then, a new cl utch dog
retaining sp ring. Place th ree coils over each e nd Lightly apply Gasket Sealing Compound to a new
of the pin, MAKING SURE NONE OF THE COILS O-ring. Install the O-ring in top groove of the bear-
OVERLAP OR ARE LOOSE. ing housing. Do not allow sealant in oil passage.
1 2
1. Retaining spring COA3592
12
DRC5720
14155
309
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Propeller Shaft Bearing Housing port the b ridge, and tighten jaws securely behind
the bearing.
Service
Rear Seal Removal
Remove se als using Puller Bridge, P/N 432127,
and Lar ge Puller Jaws, P/N 432129. Pla ce the
plate on top of the housing to support the brid ge,
and tighten jaws securely behind the inner seal.
21067
21045
310
GEARCASE SERVICE, 40 – 65 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Thoroughly clean the four bearing housing retain- Rear Seal Installation
ing screws in solvent. Discard the O-rings. Apply Gasket Sealing Compound to metal casings
of the seals before installing.
Bearing Installation
Oil, then install new bearings in bearing housing. Use Seal Installation Tool to install new seals back
to back in bearing housing.
Place the lettered end of the bearing case on the
bearing inst aller, then press th e bea ring into the Seal Installation Tool:
housing u ntil the too l seat s. When in stalled, the • P/N 326551
lettered end of the bearing should be visible.
Install inner seal with lip facing toward the bearing
Bearing Installation Tool: housing, then outer seal with lip facing away from
• P/N 326562 the bearing housing.
1
2
12
311
GEARCASE SERVICE, 40 – 65 HP MODELS
DRIVESHAFT SHIMMING
Lightly coat the threads of the pinion nut with out- Rotate the driveshaf t several revolutions to se at
board lubricant and tighten to a torque of 40 to 45 bearings.
ft. lbs. (54 to 60 N·m).
Lay the tool b ase on it s side . Place the shim
IMPORTANT: The origina l pinion nut may be gauge bar against guide pins of the tool base.
used for shimming, but must NOT be used in final
assembly.
1 2
312
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE ASSEMBLY
1
005417
2
Remove t he nut an d pinion from the driveshaf t. 12
Discard the nut.
1. O-ring 006649
2. Groove
313
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE ASSEMBLY
Apply Triple-Guard grease to the threa ded end of Place the cover seal on the shift rod cover.
the shift rod a nd insert it through the cover. Turn
the shift rod while pushing it through the cover to
avoid damaging the O-ring.
1
1 3
1
2
1. Cover gasket COA3545
314
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE ASSEMBLY
the driveshaft bearing housing. Do not coat inside Lightly coat the thre ads of a new pinion nut with
bearing housing bore surface of the gearcase. outboard lubricant. Use Pinion Nut Starting Tool,
P/N 320675, to install nut on the driveshaft. Turn
the driveshaft by han d to thread the nut on to
shaft.
6207
12
315
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE ASSEMBLY
Use Driveshaft Holding Socket, P/N 334995, and assembly onto the propeller shaft until it en gages
an 11/16 in. open-end wrench, to tighten the pin- the pinion gear.
ion n ut to a torque of 40 t o 45 ft. lbs. (54 to 60 s
N·m). Pad handle of the wrench to prevent dam-
age to gearcase.
2
1
1
A CAUTION
Retaining rings are under extreme pres-
sure during installation. Wear safety
1. Small thrust washer COA3597 glasses and proceed with care to avoid
unsnapping the ring from the pliers.
Oil and inst all thrust bear ing a nd la rger thru st
washer on hu b of reverse gear. Slide the gear
316
GEARCASE SERVICE, 40 – 65 HP MODELS
GEARCASE ASSEMBLY
Make su re the retaining rings are sea ted in the Install O-rin g in groove in the bearing hou sing.
grooves in the gearcase. Lightly apply Gasket Sealing Compound to th e
O-ring flange and aft support flange of the bearing
housing. Do not allow se aler to contact either for-
ward thrust surface or bearings in the housing.
12
317
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
GEARCASE SERVICE, 75 – 90 HP MODELS
1
1
2
Note where the index mark on the gearcase aligns Remove the four 3/8-16 x 1.75 in. gearcase retain-
with the index number of the adjustable trim tab so ing screws and washers.
the trim tab can be installed in the same position.
Remove the trim tab retaining screw and trim tab
from the gearcase.
3
318
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
30385
1
Apply Adhesive 847 to the lower exhaust housing 1. 3/8 in. screws 001990
seals’ inner surfaces. Place two new seals on the
housing. Apply Triple-Guard grease to the seals’
outer surfaces and pla ce the housing on the
gearcase.
2
1
12
1. 3/8 in screw COA3139
2. 7/16 in. screw
319
GEARCASE SERVICE, 75 – 90 HP MODELS
WATER PUMP SERVICE
1
1
1
2
Place the shift rod in the shift rod lever. Install the Slide the wate r pump of f th e drivesh aft. Re move
retaining pin an d washer. Tighten pin to a torque the impeller key , O-rin g, impeller plate, and gas-
of 60 to 84 in. lbs. (7 to 9.5 N·m). ket. Discard the gasket.
2
1
1
320
GEARCASE SERVICE, 75 – 90 HP MODELS
WATER PUMP SERVICE
321
GEARCASE SERVICE, 75 – 90 HP MODELS
WATER PUMP SERVICE
Apply a thin bea d of Adhesive 847 in the s eal slide water pump down over key. Be sure impeller
groove, and install the special shaped O-ring seal. key does not fall out of position.
1
1
Apply Gasket Sealing Compound to both sid es of NOTICE Make sure the impeller engages the
a new impeller plate gasket. Install the gasket and impeller key. Serious powerhead damage will
impeller plate. result if impeller key is not in place.
Apply Triple-Guard g rease to a new impeller O- Align the impeller housing with the gear case.
ring. Slide the O-ring down the driveshaft and half Apply Gasket Sealing Compound to threads of the
way over installed impeller key to temporarily hold four impeller ho using screws. Inst all the screws
key in place. and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5
N·m).
On 25 in. models, pla ce water tub e spacer and
grommet on the impeller housing cover.
3
2
1
2
4 1
32728
The sharp edge o f the ke y is the leadin g edge in 25 in. Model Water Tube Spacer
1. Spacer
clockwise rotation. 2. Grommet
Slide the water pump down the drivesha ft. Align NOTICE Before installing gearcase, shift rod
impeller slot with th e impeller key . Rot ate the
adjustment MUST be checked. Refer to SHIFT
driveshaft to engage the key with the impeller, and
ROD ADJUSTMENT on p. 323.
322
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFT ROD ADJUSTMENT
COA6166
12
323
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
Remove the propeller and mounting hardware. • Gearcase Anodes — If anodes have eroded to
two-thirds their origina l size, t hey must be
Drain a nd inspect o il as d escribed in Gearcase replaced.
Lubricant on p. 39.
Remove gearcase. Refe r to GEARCASE
REMOVAL AND INSTALLATION on p. 318.
324
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
Propeller Shaft Bearing Housing Assemble components and pull the bearing hous-
ing from the gearcase.
Removal
Remove the t wo screws, washers, and ret ainers
holding the propeller shaft bearing housing.
22775
Remove wedge, screw, and washer (“O” Type). Pinion Gear and Driveshaft
Removal
Adjust the sh ift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
DSM02291 1
DSC02361
325
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
1
1. Driveshaft bearing housing screws COA3153
3
1
1. Drive shaft 41177
2. Puller
3. Backing plate
2
4 If upper driveshaft becomes separated from lower
driveshaft, use Lower Driveshaf t Puller ,
3 P/N 342681, t o remove . Inst all puller into lower
driveshaft and turn 90° to position hook under pin
COA3558
1.
2.
Bearing housing
Shims
in driveshaft. Thread Slide Hammer, P/N 391008,
3. Thrust bearing into puller and remove driveshaft.
4. Thrust washer
46905
COA3159
326
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
0.125 in.
(3.2 mm)
1
1. Roll pin DR4610
29338
12
29330
327
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE HOUSING INSPECTION
004315
1
1. Gauging shaft 004347
328
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
2
3
1
5
6 12
7
6
1. 1/4-20 X 1/2 in. Hex head screw 824182
1. 1/4-20 x 1/2 in. Hex Head Screw 824163 2. 1 in. O.D. Flat washer
2. 1 in. O.D. Flat Washer 3. Spacer, P/N 341437
3. Plate, P/N 391260 4. Plate, P/N 391260
4. Rod, P/N 326582 5. Rod, P/N 326582
5. Installer/Remover, P/N 326574 6. Installer/Remover, P/N 326574
6. 1/4-20 x 1 1/4 in. Hex Head Screw 7. 1/4-20 X 1 1/4 in. Hex head screw
329
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
“O” Type Gearcases Place a new O-ring on the pinion bearing retaining
screw. Appl y G asket Sealing Compound to O-
1 ring. Apply Nut Lock to screw thre ads. Install the
2 screw and tighten to a torque of 60 to 84 in. lbs. (7
3* to 9.5 N·m).
4
7
1. 1/4-20 X 1/2 in. Hex head screw 824182
2. 1 in. O.D. Flat washer 1. O-ring DRC7416
3. Spacer, P/N 326584
4. Plate and Bearing P/N 391260
5. Rod P/N 326582 Shift Housing Disassembly
6. Installer/Remover, P/N 350958
A WARNING
7. 1/4-20 X 1 1/4 in. Hex head screw
IMPORTANT: Spacers are dif ferent sizes a nd Wear safety glasses to avoid injury.
cannot be interchanged.
Apply Needle Bearing grease to the needle bear- IMPORTANT: The shift housing and bearing are
ings an d insert them into the be aring case (“O” serviced as an assembly . If e ither are wo rn or
Type gearcases). damaged, replace the complete assembly.
Place the bearing on the installer tool with the let- Insert a suit able tool under one end of the clutch
tered side of the bearing facing the top of t he dog spring a nd remove it from it s g roove by
gearcase. Use Needle Bearing grease to hold the unwrapping it from aro und the clut ch dog. Dis-
bearing on the tool. card the spring.
330
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Push the pin o ut of the clutch dog . Remove all shifter detent as needed to help ease re moval of
parts. parts.
5 4
3
1
2
2
1. Gear COA3562
2. Thrust bearing
3. Thrust washer 1
Remove th e shif t lever pin from the ho using.
Remove shif t shaf t, crad le an d shif t leve r. Move
331
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
4520
4518
DSC02506
TYPICAL 4512
1. Cradle
2. Shift shaft
332
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Place the shift lever arms into the recesses of the Align holes in the clutch dog with slot in the pro-
shift cradle. Pull shifter dete nt back up to NEU- peller shaft. Install the clutch dog on the shaft with
TRAL position to ho ld the cradle and sh aft in “PROP END” facing rear of the shaft.
place.
NOTICE The clutch dog is not symmetrical.
If installed backward, it will not fully engage
and will immediately damage itself and the
gears.
001219
1
1. Retaining spring COB3101
12
333
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Driveshaft Bearing Housing NOTICE Do not install the O-ring in the bear-
Service ing housing’s bottom groove. The bottom
groove is an oil passage. Gearcase damage
The driveshaft bearing is not serviceable. Replace
could result.
the b earing h ousing assembly if the be aring is
worn or da maged. Also, inspect the driveshaft
bearing surface if the bearing is damaged.
1
Seal Removal
Remove the drivesha ft bearing housing seals
using Puller Bridge, P/N 432127, and Large Puller 2
Jaws, P/N 432129. Discard the seals.
334
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
1. Anode 001220
12
13522
335
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
336
GEARCASE SERVICE, 75 – 90 HP MODELS
DRIVESHAFT SHIMMING
1 2
3 4
12
1. Driveshaft bearing housing COA3565
2. Thrust washer 1. Shim gauge bar COA3567
3. Thrust bearing
4. Pinion
Check squareness of the be aring housing mount-
IMPORTANT: The origina l pinion nut may be ing surface by holding the shim gauge bar against
used for shimming, but must NOT be used in final the pinion while rot ating just the bearing hous-
assembly. ing. Use a fe eler g auge to me asure cle arance
337
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Check clea rance again. The measurement Be sure the thrust bearing and the thrust washer
between the gau ge bar and pinion should be are in the proper position. Insert the shaft assem-
0.020 in. (0.508 mm). bly fully in to the gea rcase wh ile aligning shif t
housing pin wit h hole in forward e nd of gea rcase
housing.
005417
338
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Shift Rod Housing Installation Apply Gasket Sealing Compound to both sides of
a new shift rod cover gasket. Place the gasket on
Lubricate a new shif t rod cover O-ring with Triple-
the gearcase.
Guard grease. Install the O-ring into t he shift rod
cover. Thread th e shif t ro d into t he shif ter detent abo ut
four turns.
IMPORTANT: Make sure O-ring is fully seated
in groove.
2
1 2
1
1. Grommet COA3568
2. Shift rod spacer
COA3569
Apply Triple-Guard grease to the threa ded end of
the shift rod a nd insert it through the cover. Turn
the shift rod while p ushing it through the cover to
Refer to SHIFT ROD ADJUSTMENT on p. 323. 12
avoid damaging the O-ring.
339
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Pinion Gear and Driveshaft IMPORTANT: The inside t aper of the p inion
gear and the driveshaft taper MUST be com-
Installation pletely free of grease. Clean the t apers with
Refer to DRIVESHAFT SHIMMING on p. 337 Cleaning Solvent. Use a shop towel free of grease
before proceeding. and lint.
Install new seals in drivesh aft bearing housing. Place the pinion gear into the gearcase. Insert the
Refer to Driveshaft Bearing Housing Service on driveshaft into th e gearcase and through the pin-
p. 334. ion gear.
Place the driveshaft thrust bearing, thrust washer, Lightly coat the thre ads of a new pinion nut with
and correct shim(s) on the driveshaft as shown. outboard lubricant. Use Pinion Nut Starting Tool,
P/N 342216, to install nut on the driveshaft. Turn
the driveshaft by han d to thread the nut on to
shaft.
3
1
2
1 1
340
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Use Driveshaft Holding Socket, P/N 311875, Pin- Lightly apply Gasket Sealing Compound to a new
ion Nut Hold er, P/N 334455, and W rench bearing housing O-ring. Install O-ring in groove in
Retainer, P/N 341438, to tigh ten the pinion nut to the housing.
a torqu e of 100 to 110 f t. lb s. (136 to 149 N·m).
Pad handle o f ho lder to pr event damage to Install hou sing into ge arcase. Align screw holes
gearcase. with retainer slots in gearcase.
1
2
12
341
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Install wed ge, screw , and wa sher. Ap ply Ultra Confirm that torque on the wedge screw is 15 to
Lock to threads and tig hten screw to a torq ue of 20 in. lbs. (1.7 to 2.3 N·m).
15 to 20 in. lbs. (1.7 to 2.3 N·m).
Final Assembly and Adjustment
To complete gearcase assembly, refer to:
• GEARCASE LEAK TEST on p. 295
• WATER PUMP SERVICE on p. 320
• SHIFT ROD ADJUSTMENT on p. 323
• GEARCASE REMOVAL AND INSTALLATION
on p. 318
• Gearcase Lubricant on p. 39
• Propeller Hardware Installation on p. 294
• Trim Tab Adjustment on p. 31.
DSM02291
During bre ak-in pe riod of a reassembled
DSC02361 gearcase, change the gearcase lubricant between
10 to 20 hours of operation.
342
TRIM AND TILT
13
343
TRIM AND TILT
SERVICE CHART
SERVICE CHART
40 - 60 HP MODELS
30 to 50 in. lbs.
(4 to 5.6 N·m)
45 to 55 in. lbs.
(5 to 6 N·m)
W
45 to 55 in. lbs.
(5 to 6 N·m)
A
W
A Triple-Guard Grease
007632 W Biodegradable TNT Fluid
344
TRIM AND TILT
SERVICE CHART
75 - 90 HP MODELS
30 to 50 In. lbs.
(4 to 5.6 N·m)
45 to 55 In. lbs.
(5 to 6 N·m) W
45 to 55 In. lbs.
(5 to 6 N·m)
13
A Triple-Guard Grease
005002 W Biodegradable TNT Fluid
345
TRIM AND TILT
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION
The power tr im/tilt hydraulic system is completely
contained between the outboard's stern brackets.
346
TRIM AND TILT
SYSTEM DESCRIPTION
13
347
TRIM AND TILT
ROUTINE INSPECTIONS
348
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
13
349
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
Test results include three basic possibilities: Monitor motor RPM and current draw.
IMPORTANT: Securely fasten m otor i n a su it- The motor shaft must rotate counterclockwise, as
able fixture before proceeding with this test. viewed from the pump end, when po sitive (+) is
applied to the green lead, and negative (–) is
Use a battery rated at 360 CCA (50 Ah) or higher applied to the blue lead.
that is in good condition and fully charged to per-
form this test. Blue lead (+) Green lead (+)
Green lead (-) Blue lead (-)
Connect a 0 to 25 A ammeter in series with the
battery positive (+) terminal, ammete r red le ad
toward terminal.
Attach or hold a vibration or mechanical tachome-
ter to the motor while performing this test.
DR4238r
350
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
DRC6245
STEP 2
Remove th e white/t an lead fro m the trim gau ge
“S” terminal. With key switch ON, gau ge shou ld
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
13
351
TRIM AND TILT
TRIM AND TILT REPLACEMENT
Removal
Raise the outboard and engage the tilt support.
25078
40 – 60 HP MODELS
Remove the spring clip from the cylinder pin.
000686
15493
352
TRIM AND TILT
TRIM AND TILT REPLACEMENT
Remove one of the locknuts from the angle adjust- Use a punch to remove the upper pin.
ment ro d. Remove the rod from the stern brack-
ets.
25065
25077
25076
25064
13
353
TRIM AND TILT
TRIM AND TILT REPLACEMENT
Remove the un it fro m th e ste rn bracket s far Lubricate th e an gle adjustment ro d with Triple-
enough to remove the ground lead from the pump Guard grease. Install the rod. Tighten the locknuts
motor mounting screw. to a torque of 20 to 25 ft. lbs. (27 to 34 N·m).
15591
354
TRIM AND TILT
TRIM AND TILT REPLACEMENT
25079
25064
13
355
TRIM AND TILT
TRIM AND TILT SERVICE
A WARNING
There may be high pressure behind some
power trim valves. To avoid injury when
removing manual release valve, be sure to
cover valve with a shop cloth until the
pressure is released. Wear safety glasses.
356
TRIM AND TILT
TRIM AND TILT SERVICE
Slowly remove the man ual release valve. Th ere Remove t he fou r larg e mo tor flange retaining
may be pressure be hind the valve—wear safety screws. Remove the motor and discard O-rin g,
glasses. screws, and washers.
Inspect the manua l release valve. Disca rd the O- Remove drive coupler from either the motor or the
rings on the housing. pump assembly.
007108
002532
13
357
TRIM AND TILT
TRIM AND TILT SERVICE
40 - 60 HP Models 002529
002533
75 - 90 HP Models 004285
40 - 60 HP Models 002531
1
75 - 90 HP Models 004282
358
TRIM AND TILT
TRIM AND TILT SERVICE
40 - 60 HP Models 007646
75 - 90 HP Models 004278
13
359
TRIM AND TILT
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
360
MANUAL STARTER
MANUAL STARTER
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
RECOIL STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
RECOIL STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
RECOIL STARTER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
14
361
MANUAL STARTER
SERVICE CHART
SERVICE CHART
60 to 84 in lbs.
(7 to 9.5 N·m)
F
96 to 120 in lbs.
(11 to 13.5 N·m)
362
MANUAL STARTER
RECOIL STARTER REMOVAL
Remove the clamp holding the oiling system wir- Pull the st arter rope out far enough to tie a slip
ing harness. knot in t he ro pe. Remove t he e nd o f th e st arter
rope from the handle anchor and remove the han-
Remove the three st arter housing screws and dle. Release the slip knot and ease the rope back
washers. in until the rewind spring is fully unwound. If nec-
essary, remove the starter handle bracket from the
1 starter housing.
2
2
1
2
1. Clamp 002515
2. Starter housing screws (3)
007853
Lift starter housing from outboard. 1. Slip knot
2. Rope anchor
1
1
2
1. Ratchet 006483
1. Rope guide 007854
2. Pulley support
14
363
MANUAL STARTER
RECOIL STARTER DISASSEMBLY
Remove the nut from the starter pawl ret aining Use a screwdriver to pry open the pulley lock ring,
screw. and remove ring from the starter.
1
1
1. Nut 007855
Remove the friction plates and friction plate spring
washer.
Remove the starter pawl retaining screw, washer,
and starter pawl plate with plate return spring from
the starter assembly.
1 2
4
2
3 1
1. Friction plates 34854
2. Friction plate spring washer
1. Screw 007856 Hold the pulley in the starter housing while turning
2. Washer the st arter over, legs do wn. Hold fingers clear of
3.
4.
Plate
Spring the pulley an d jar th e st arter h ousing aga inst a
bench to dislodge the rewind sp ring an d pulley .
Remove st arter hou sing spring and starter p awl Remove the pulley bushing from the pulley.
with spring washer from the starter assembly.
2 3
007857
1. Spring 34855
2. Starter pawl
3. Spring washer (under starter pawl)
364
MANUAL STARTER
RECOIL STARTER CLEANING AND INSPECTION
2
1
1. Base CO3593
2. Plate
14
365
MANUAL STARTER
RECOIL STARTER ASSEMBLY
Apply Triple-Guard grease or Lubriplate 777 to the Install t he rewin d sp ring into the st arter hou sing.
rewind sp ring. Install the re wind spring into the Locate the out er loop of the rewin d spring on the
spring winder base with open loop of spring facing pin in the starter housing. Press down through the
inward. Insert the pin of the crank and pin assem- holes in the spring winder base to tra nsfer t he
bly into the loop of the rewind spring. Secure the rewind spring into the starter housing.
crank and pin assembly to the starter winder base
with the crank retainer screw.
1
1. Outer loop CO3584
2. Pin
CO3591
Apply Triple-Guard grease or Lubriplate 777 to the
Rotate the crank and pin assembly in the direction pulley bushing. Inst all the pulley bushin g in the
shown on the tool. Wind the spring into the starter pulley. Place the pulley shim on the pulley.
winder base until end of spring contacts the starter
winder base.
1. Bushing COA1364
2. Shim
CO3589
366
MANUAL STARTER
RECOIL STARTER ASSEMBLY
inner loop of t he spring in the slot of the pulley, Place th e st arter hou sing sp ring in t he st arter
and install the pulley in the starter housing. housing.
2
2
1 3
1
2
14
367
MANUAL STARTER
RECOIL STARTER ASSEMBLY
Install the starter p awl plate ret aining screw a nd If removed, install the starter handle bracket to the
washer into t he starter housing. Tighten screw to starter housing. Tighten screws securely.
a torque of 96 to 120 in. lbs. (11 to 13.5 N·m).
1 1
COA1373
368
MANUAL STARTER
RECOIL STARTER INSTALLATION
007858
2
1
1
14
369
MANUAL STARTER
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
370
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 a nd 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 bolt s and nu ts are of ten u sed to hold ste ering, shif t, and thro ttle re mote cont rol
cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with o ther
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 Operat or ca nnot slow do wn the ou tboard o r shif t into NEUTRAL gea r (stop prope ller), Ope rator
could panic and lose control of boat.
S–5
SAFETY
• If steering system comes ap art, 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
A 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 carbo n
monoxide (CO), which is odo rless, colorless, and tasteless, and ca n lead to unconsciousness, brain
damage, or de ath if inh aled in suf ficient conc entrations. CO accumula tion can occur while do cked,
anchored, or underway, and in many confined areas such as the boat cab in, cockpit, swim platform,
and heads. It can b e worsened or caused by weat her, mooring and operating conditions, and other
boats. Avoid exh aust fumes fro m th e engine o r other boats, provide p roper ventilation, shut off th e
engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accu-
mulation. In hig h concentrations, CO can be fat al within minutes. Lower con centrations are just as
lethal over long periods of time.
S–19
SAFETY
A 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 char ger plug out of 1 10 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 t ake resp onsibility for the safe mainte nance practices and proce-
dures of your repair shop, co-workers, and technicians?
3) Do you understand all the safety precautions and instructions contained in this entire
service manual?
4) Will you follow all safety warnings, precau tions, 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 commo n shop safety practices to protect your-
self and others around you?
7) When replacement p arts 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 rec ommendations in this service m anual before you s er-
vice any boat or outboard?
9) Do you underst and that safety -related a ccidents can be caused by carelessness,
fatigue, overload, preoccupation, unfamiliarity of operator with the product, drugs and
alcohol, just to name a few?
S–24
INDEX
INDEX
A Pinion Gear 305, 329
Abbreviations 6 Propeller Shaft 310, 335, 336
Accessories Wrist Pin 197, 205
Battery Cable, P/N 584348 64 Break-In
XD100 Outboard Oil Decal, P/N 352369 EMM Programming 165, 220
164 Gearcase 298, 317, 320, 342
Adjustments Oiling 165
Control Cable 19, 276, 286 Procedure 67
Shift Linkage 220
Shift Rod 11, 13, 300, 323 C
Steering Friction 27 Capacitor Test 83
Throttle Friction 27 Clamp Screw 258
Tilt Limit Switch 28 Connecting Rods
Timing Pointer 113 Installation on Crankshaft 209
TPS Calibration 114 Installation on Piston 205
Trim Sending Unit 29, 30 Orientation 205, 209
Trim Tab 31 Removal from Crankshaft 196
Air Silencer 43 Removal from Piston 197
Air Temperature Sensor TIghtening 209
Connections 92 Control Cable
Description 57 Adjustments 19
Resistance Test 96 Installation 19
Alternator Circuit Test 99 Cooling System
AMP Connector Servicing 117 Adapter Housing 177
Anodes Components 176
Anti-Corrosion 44 Cylinder Block Venting 178
Continuity Check 44 EMM and Vapor Separator Cooling 179
Gearcase 301, 324 Engine Temperature Check 180
Propeller Shaft Bearing Housing 310, 335 Exhaust Housing 176
Stern Bracket 252, 254, 257 Flushing 35
Hose Routing and Water Flow 174
B Operating Temperatures 11, 13, 34
Batteries Operation 179
Charging System Tests 98 Pressure Relief Valve 177, 183
Connections 24 Running on a hose 36
Maintenance 24 Thermostat 11, 13, 177
Requirements 11, 13 Thermostats 177, 182
Storage 46 Vapor Separator 133
Bearing Water Intake Screens 34, 305, 328, 338
Connecting Rod 209 Water Pump 176, 298, 320
Crankshaft 198, 199, 203, 204 Water Supply Tube 176, 248, 249
Driveshaft 309, 334 Corrosion
I–1
INDEX
Anodes 44, 252, 254, 257, 301, 310, 324, 335 Oiling Rate 66, 164
Cylinder walls 200 Reports 69
Long Term Storage 45 Sensor Monitoring 95
Metal components 44 Service Codes 65
Steering Cable 37 Static Ignition Test 81
Cover Service 50 Timing Verification 67, 114
Crankcase TPS Calibration 68, 114
Assembly 211 Driveshaft
Disassembly 195 Installation 314, 340
Crankshaft Removal 303, 325
Assembly 203, 208 Service 327
Disassembly 197 Shimming 312, 337
Inspection 201 Driveshaft Bearing Housing 309, 334
Crankshaft Position Sensor Dual-Outboard
Description 59 Alignment 32
Operation Test 80 I-Command settings 23
Resistance Test 95
Cylinder Bore E
Honing 200 Electrical Circuits
Inspection 201 EMM Pin Locations 92
Cylinder Head Fuse 94
Inspection 201 Ground Circuits 94
Installation 207 Key Switch 102
Removal 196 Start Circuit 100
SystemCheck 107
D Electrical Connectors
Deutsch Connector Servicing 116 AMP Connectors 117
Diagnostic Procedures Deutsch Connectors 116
Dynamic Tests 76 Packard Connectors 119
Fuel Delivery Tests 84 Electrical Harness
Ignition Tests 79 Connections 20, 21
LED Indicators 77 Emergency Stop Switch
Strategy 74 Operation Check 33
Diagnostic Software Test 105
Break-In Programming 165 Emissions Information 7
Communication With Outboard 63 EMM
Crankshaft Position Sensor 80 12 V Circuit Sensor 56
Cylinder Drop Tests 76 Connections 54, 55, 92
Diagnostic Procedures Overview 74 Diagnostics 63, 74
Fuel Injector Programming 68, 146 Functions 54, 60
Fuel Injector Tests 84 LED Indicators 77
Fuel Pump Test 84 Sensors 56, 57
I-Command settings 23 Service Codes 65
Idle Speed Control 68 Servicing 70
Oil Injector Test 167 Software Replacement 69
Oil Priming 170 Timing Verification 114
I–2
INDEX
I–3
INDEX
I–4
INDEX
I–5
INDEX
I–6
INDEX
Backing Plate, P/N 325867 304, 326 Key Switch Assembly, P/N 176408 64
Ball Socket Installer tool, P/N 342225 276, Large Puller Jaws, P/N 432129 199, 309,
287 310, 334, 335
Ball Socket Remover tool, P/N 342226149, Lifting Fixture, P/N 396748 191, 192, 216,
271, 277 218
Battery Cable, P/N 584348 64 Lower Driveshaft Puller, P/N 342681 326
Bearing Installation Tool, P/N 326562 311, Oetiker Pincers, P/N 787145 26
336 Peak Reading Voltmeter, P/N 507972 98
Bearing Installation Tool, P/N 339750 336 Pinion Bearing Remover and Installer, P/N
Bearing Puller, P/N 432130 310 5005927 305
Bootstrap Tool, P/N 586551 69 Pinion Bearing Remover/Installer, P/N
Collar, P/N 328363 312 5005927 305, 329
Collar, P/N 341440 337 Pinion Nut Holder, P/N 334455 325, 341
Connector Service Tool, P/N 342667 116 Pinion Nut Starting Tool, P/N 320675 315
Crankshaft Bearing/Sleeve Installer, P/N Pinion Nut Starting Tool, P/N 342216 340
338647 203 Piston Stop Tool, P/N 342679 113
Crimp Tool, AMP 117 Primary Lock Tool, P/N 777077 117
Crimping Pliers, P/N 322696 116 Puller Bridge, P/N 432127 309, 310, 334,
Diagnostic Interface Cable, P/N 437955 63 335
Diagnostic Power Supply, P/N 587005 63, Puller, P/N 387206 304
80 Retaining Ring Pliers, P/N 331045 302, 316
Driveshaft Holding Socket, P/N 311875 Rod Cap Alignment Fixture, P/N 396749
325, 341 209
Driveshaft Holding Socket, P/N 334995 Seal Installation Tool, P/N 326551 311, 336
303, 316 Seal Installation Tool, P/N 330268 334
Driveshaft Puller, P/N 390706 326 Seal Installation Tool, P/N 336311 336
Driveshaft Seal Protector, P/N 312403312, Seal Installer, P/N 342665 309
313, 315 Secondary Lock Installer, P/N 777079 117
Driveshaft Seal Protector, P/N 318674337, Secondary Lock Tool, P/N 777078 117
338, 340 Shim Gauge Bar, P/N 328366 312
Driveshaft Shimming Tool, P/N 5005925 Shim Gauge Bar, P/N 328367 337
312, 337 Slide Hammer Adapter, P/N 340624 352
Electrical Test Probe Kit, P/N 342677 99 Slide Hammer Adaptor Kit, P/N 390898146
Flywheel Holder, P/N 771311 111 Slide Hammer, P/N 391008 146, 203, 326,
Fuel Pressure Gauge, P/N 5006397 139 352
Fuel Pressure Gauge, P/N 5007100 137, Slide Hammer, P/N 432128 199, 242
142 Small Puller Jaws, P/N 432131 335
Gauging Head, P/N 352879 328 Starter Rope Threading Tool, P/N 378774
Gearcase Alignment Gauge Kit, P/N 368
5006349 328 Starter Winder/Installer Kit, P/N 392093
Gearcase Filler, P/N 501882 40 365
Gearcase Pressure Tester, P/N 507977 Stator Test Adaptor, P/N 5005799 97, 98
295 Syringe, P/N 346936 168
Gearcase Vacuum Tester, P/N 507982 295 Temperature Gun, P/N 772018 180, 181
Guide Pins, P/N 383175 317 Terminal Release Tool, P/N 351413 118
Injector Test Fitting Kit, P/N 5005844 138 Thermal Joint Compound, P/N 322170 181
I–7
INDEX
I–8
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
quality
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 diagnostics program to check
consumption
Outboard mounted too low Check installation height of outboard
(normal if occurs after
winterization) Check vapor separator assembly for proper
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
Hose Routing and Water Flow Diagram
40 – 65 E-TEC Inline 2 Cylinder
8
6 5
9
10
3 60, 65 HP
1
Outgoing water (warm/hot)
Incoming water (cool)
002222E
Hose Routing and Water Flow Diagram 8
75-90 HP EVINRUDE ETEC
9
10 4
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
I-Command Keyswitch/TNT Wiring Harness
A A A. Trim down
B B B. Trim up
C C C. Trim sender
47 ohm 5 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-)
008051
Lanyard Switch / Emergency Stop Circuits
M
A
Single Outboard
C
B S
M
3
4
2
5
6
1
M M
A A
Dual Outboards
C C S
B S B
M M
3
4
2
5
6
1
3
4
2
5
6
1
000705
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
DRC6278R
Evinrude E-TEC
EMM LED Diagnostic Indicators
1
2 Exception: ALL LED’s ON / FLASHING indicates
3 Winterization Mode
4
2 2
3
40 – 65 HP E-TEC B
A 1
1 1 9
6 7 8 1 2
1 1
2 2
13 13
A
B
12
1. Air Temperature Sensor C 11
10
2. Throttle Position Sensor 2
3. Neutral Switch CA B
4. Stator 4 14 1 14 1
2 5 3 4 16 123 4 2 2
5. Crankshaft Position Sensor 6 532 1 4
BAC 21
3
3
6. Trim/Tilt Connector 5
7. SystemCheck Connector 1
2
1
2
8. Key Switch Connector
9. High Pressure Fuel Pump
15 FUSE
23. Capacitor 28
29
20 12
12 3
4
30 21 13
13
5 J1-A
24. Trim/Tilt Motor 31 22
23
14
14
15
15 6 19
32 7
33 24 16
16
25. Water Valve Connector 17 8
34 25 17 9
A B
2 1
25
23 6 5 4 3 2 1
9
24 10
1
2
11
3
12
A B 12
2 1
13
4
5
J2
14
6
15
7
16
8
26
1 1
2 2
3 3
3 3
27 2 2
1 1
008037
2 2
3 1 2 3
75 – 90 HP E-TEC B
A
1
1 1 9
6 8 13 13 13
7 1
2
A 12
B 11
1. Air Temperature Sensor C
10
2. Throttle Position Sensor
2
3. Neutral Switch CA B 14 14 14
4. Stator 4
123 4
5. Crankshaft Position Sensor 2 5 3 4 16
BAC
21
6 532 1 4
6. Trim/Tilt Connector 1
2
321 1
2
321 1
2
321
7. SystemCheck Connector 5
8. Key Switch Connector
9. High Pressure Fuel Pump
15
10. CANbus Connector
FUSE
A B
2 1
24 6 5 4 3 2 1
9
1
10
2
25 11
3
12
A B 2 1
13
4
5
J2
14
6
15
7
16
8
26 2 2
1 1
1 1
2 2
3 3
3 3
27 2 2
1 1
008038
EVINRUDE 40 – 90 HP EMM SERVICE CODE CHART
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
Throttle Position Sensor TPS Voltage > 0.78 V with key ON (or cranking). Becomes stored fault when outboard starts.
11 - - 2 seconds
(TPS) out of idle range When both hard and stored faults are present, check for improperly adjusted throttle cable.
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 0.8 seconds
(TPS) circuit fault Check sensor resistance—3000 to 7000 Ω (between pins A and B) & 4000 to 8000 Ω (between pins A and C)
13 TPS below range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds TPS Voltage < 0.2 V. Check linkage and IDLE stop.
14 TPS above range LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds TPS Voltage > 4.85 V. Check linkage and WOT stop.
15 ROM (EMM program) 3 - - - ROM “CHECKSUM” failure. Check software program number in EMM. Reload or replace with proper program.
Crankshaft Position Sensor (CPS) LED 2: OFF (Cranking) EMM counts losses of synchronization with crankshaft sensor. Check CPS mounting and resistance. Air gap range: 00.036 to
16 - 10 instances
Intermittent loss of SYNC LED 3: ON (Running) 0.110 in. (1 to 2.8 mm), nominal 0.073 in. (1.85 mm) Resistance: 560 Ω ± 10% @ 77°F (25°C)
17 55 V circuit BELOW range 3 3 LED 1: ON (Running) CHECK ENGINE 1 minute System Voltage < 45 V. 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. 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) - 8 seconds EMM Temperature < -71° F (-57.4° C), or > 313° F (156° C).
24 EMM Temperature BELOW range 3 LED 3: OFF (Cranking) / ON (Running) - 8 seconds EMM Temperature < -22 ° F (-30° C).
25 EMM Temperature ABOVE range 3 3 LED 4: ON (Running) WATER TEMP/HOT 8 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 < 12.5 V. 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.
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 4 seconds
(FLASHING) returns to operating range. Check outboard and EMM cooling systems.
2-Cylinder models: Engine Temperature > 248° F (120° C)
WATER TEMP/HOT 3-Cylinder models: Engine Temperature > 212° F (100° C) above 3500 RPM, or
31 Engine temperature OVER range 3 LED 4: FLASHING 8 seconds
(FLASHING) 3-Cylinder models: Engine Temperature > 230° F (110° C) below 3500 RPM
Engine SHUTDOWN. Check cooling system. 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) 3 hours Outboard has run three hours with code 34 or 117. 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—22 Ω.
40 Engine Temperature ABOVE range–Low speed 3 LED 4: ON (Running) WATER TEMP/HOT 8 seconds 3-Cylinder models only. Engine Temperature > 212° F (100° C) below 3500 RPM.
Engine Temperature < -15° F (-26.2° C), or > 332° F (166.5° C).
41 Engine Temperature Sensor circuit fault LED 3: OFF (Cranking) / ON (Running) - 8 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
42 Engine Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Engine Temperature < -4° F (-20° C). Check engine temperature and sensor resistance.
2-Cylinder models: Engine Temperature > 212° F (100° C).
43 Engine Temperature ABOVE range 3 LED 4: ON (Running) WATER TEMP/HOT 8 seconds 3-Cylinder models: Engine Temperature > 194° F (90° C) above 3500 RPM
Engine limited to 1200 RPM. Check cooling system.
Pressure < 3.9 in. Hg (13.3 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 - - 8 seconds
Check atmospheric condition for comparison. Clear code and retest.
45 BP Sensor BELOW range 3 - - 8 seconds Pressure < 20.7 in. Hg (70 kPa).
46 BP Sensor ABOVE range 3 - - 8 seconds Pressure > 31 in. Hg (105 kPa).
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
Air temperature < -58° F (-49.9° C), or > 218° F (103.2° C).
47 Air Temperature (AT) circuit fault LED 3: OFF (Cranking) / ON (Running) CHECK ENGINE 8 seconds
Check 5 V circuit and ground (NEG), and sensor resistance—9000 to 11000 Ω @ 77°F (25°C).
48 Air Temperature BELOW range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Air temperature < -22° F (-30° C).
49 Air Temperature ABOVE range LED 3: OFF (Cranking) / ON (Running) - 8 seconds Air temperature > 158° F (70° C).
51 Fuel injector circuit #1 OPEN LED 2: ON (Running) - 2 seconds
52 Fuel injector circuit #2 OPEN LED 2: ON (Running) - 2 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
53 Fuel injector circuit #3 OPEN LED 2: ON (Running) - 2 seconds
CHECK ENGINE TPS < 5% and RPM > 3000. Engine SHUTDOWN. Will NOT restart until code has been cleared. The problem could be caused by
57 High RPM with low TPS setting 3 3 LED 3: FLASHING 10 seconds
(FLASHING) uncontrolled fuel entering the engine. DO NOT attempt to start the outboard until the problem has been found and repaired.
Engine temperature < 104° F (40° C) with engine speed < 2300 RPM.
58 Operating temperature not reached LED 3: OFF (Cranking) / ON (Running) - 10 minutes
Check thermostat and pressure relief valve.
61 Fuel injector circuit #1 SHORTED LED 2: ON (Running) - 8 seconds
62 Fuel injector circuit #2 SHORTED LED 2: ON (Running) - 8 seconds Check injector/circuit resistance—2 to 3 Ω @ 72°F (22°C).
63 Fuel injector circuit #3 SHORTED LED 2: ON (Running) - 8 seconds
78 Sensor supply voltage fault 3 LED 3: OFF (Cranking) / ON (Running) - 10 seconds Sensor voltage < 4.75 V. Check sensors and related wiring. Check for pinched or chafed wiring.
81 Ignition timing circuit #1 OPEN LED 2: ON (Running) - 10 instances
82 Ignition timing circuit #2 OPEN LED 2: ON (Running) - 10 instances EMM counts failed ignition events. Check wiring. Test with known good ignition coil.
83 Ignition timing circuit #3 OPEN LED 2: ON (Running) - 10 instances
90 Water injection solenoid SHORTED LED 2: ON (Running) - 8 seconds Check circuit resistance—295 Ω ± 20 @ 77°F (25°C).
91 Fuel pump circuit OPEN LED 2: ON (Running) - 8 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
93 Water injection solenoid OPEN LED 2: ON (Running) - 8 seconds Check circuit resistance—295 Ω ± 20 @ 77°F (25°C).
94 Fuel pump circuit SHORTED LED 2: ON (Running) - 2 seconds Check pump/circuit resistance—2 to 3 Ω @ 77°F (25°C).
101 Ignition timing circuit #1 SHORTED LED 2: ON (Running) - 20 instances
102 Ignition timing circuit #2 SHORTED LED 2: ON (Running) - 20 instances EMM counts failed ignition events. Check wiring. Test with known good ignition coil.
103 Ignition timing circuit #3 SHORTED LED 2: ON (Running) - 20 instances
4800 Pulses (2-Cyl) EMM counts oil pump pulses after LOW OIL switch closes. Engine limited to 1200 RPM.
117 Critical LOW OIL detected 3 3 LED 4: ON (Running) NO OIL
6000 Pulses (3-Cyl) Stop outboard and add oil to tank. Warning resets after three oil pump pulses.
NOTE: Always note service codes before clearing codes. Clear stored codes using diagnostic software. Clearing some codes requires turning EMM “OFF” and then “ON” again.