FUEL SYSTEM 3-41

Fig. 145 Install the VR02 pump using

new a-rings on the fitting

TSM
Fig. 150 Connect the hoses, as tagged Fig.151 ... then reconnect the wiring Fig. 152 If used, secure hoses using
during removal. .. ratchet type clamps

6. Pressurize the fuel system and check for leaks.

7. Install the engine covers (leaving the top cover until after the engine
has been RUN and inspected again for leaks).
8. Reconnect the negative battery cable.
Recirculation System
** CAUTION
After checking or servicing any part of the recirculation system you
should observe all system hoseslfittings while the engine operates to
ensure there are no fuel leaks. Remember that even a small fuel/oil
leak can lead to a fire or explosion. Don't take any risks.

Loop charged Evinrude/Johnson outboards are equipped with a

recirculation system designed, primarily, to drain excessive fuel/oil build-up
in the powerhead crankcase and route it back to the intake manifold. From
the manifold this excess or build-up it is drawn into the crankcase and
eventually burned in the cylinders. The system consists mainly of a series of
hoses, fittings and check valves. If a fitting, hose or check valve is left
plugged or inoperative, the affected cylinder could possibly misfire, the spark
plug become fouled-causing excessive smoke when accelerating from idle
or even burn a piston-resulting in severe damage to the powerhead.
A syringe, a 1/8 in. Inner Diameter (10) piece of clear tubing and some
Isopropyl Alcohol are required to make these simple tests. These items may
also be used to test idle and air bleed passages in the carburetor.
CHECKING THE RECIRCULATION SYSTEM
• See Figures 153 and 154
Functional Check-600 V4N6 Models
• This check assumes that one or more of the operational symptoms
for trouble with the recirculation system are present. These symptoms
include poor or erratic idle, fouled spark plugs in the LOWER cylinders
only, excessive smoke when accelerated after an extended idle or idle
quality that is unusually sensitive to trim angle. If one or more of these
symptoms are NOT present, start your search elsewhere in the fuel/oil
system(s).

Troy's Service Manuals

3-42 FUEL SYSTEM
On 80 Jet-175 Hp (1726/2589cc) V4N6 motors, also known as the 600
loopers, the recirculation system is plumbed in a manner that allows
functional diagnosis to start at the after end of the No. 1 cylinder
recirculation hose. Unfortunately, the functional check only tells you what
fittings or check valves you should check next (when a problem is already
present), and the additional checks involve the removal of the carburetors
and intake manifold for access to the valves/fittings.
Provide the engine a source of cooling water, then start the motor and
allow it to idle until it reaches normal operating temperature. Disconnect the
aft end of the No. 1 cylinder recirculation hose from the fitting on the cylinder
block. Submerge the end of the hose in a cup of water and observe.
• If bubbles appear, refer to Checking Cylinder Block Fittings. On these
models, the carburetors and intake manifold assembly must usually be
removed in order to access the cylinder block fitting and cylinder check
valve.
• If no bubbles appear, inspect the 2 check valves for each cylinder by
injecting them with isopropyl alcohol from the rear of the intake manifold
(yes, the carburetors and intake manifold must be removed for this check as
well). The valve should allow flow only in one direction, from the block side
of the manifold toward the carburetor side of the manifold. If a valve allows
flow in the opposite direction, in both directions or resists flow in both
directions, replace the valve.
• Before re-installing the intake, make sure all recirculation system
passages are clean and free of deposits or debris.
TSM
Checking Cylinder Block Fittings-All Models
Connect a piece of clear tubing to the syringe and fill the syringe and
tubing with Isopropyl Alcohol. Remove the recirculation hose from one of the
crankcase fittings and connect the clear tubing to the fitting.
Press gently on the end of the syringe plunger. If the fluid flows easily,
the fitting is clear. If there is no fluid flow, the fitting is plugged and must be
cleaned with a wire gauge. Insert a wire gauge (such as Evinrude/Johnson
Nipple Cleaning Tool # 326623 or equivalent) through the center of the
fitting. Connect the syringe tubing to the fitting again, and verify the fitting is
clear.
Repeat this test on all remaining recirculation fittings on the crankcase.
In-Line Check Valve Test
• In-line check valves are used on the recirculation system for
120-300 Hp (2000/3000/4000cc) V4N6NS motors, also known as 900
loopers.
900 V4 (1992-1996) and VB Only
• See Figure 154
Disconnect the in-line check valve from the recirculation hose. Connect
the syringe filled with Isopropyl Alcohol and 1/8 in. clear tubing to fitting "A"
on the check valve. Press on the syringe plunger, fluid should flow easily out
fitting "C" only.
Fig. 153 Pushing on the syringe when making a test of the
cylinder block fittings, as described in detail in the procedure
Troy's Service Manuals
Fig. 154 Simple line drawing of the in-line check valve used on 900
looper outboards. Pictured on the left is a valve from a V4 power
powerhead through 1996 and all VS powerheads, while the valve
used on 1997 and later V4 powerheads, as well as all V6 motors is
on the right. The text makes reference to the letters called out on
the drawings.
Move the tubing to fitting "B" and again press on the syringe plunger.
Fluid should flow easily out fitting "C" only.
If the fluid flow was restricted through fitting "C", replace the check valve.
If there was leakage from fittings "A" or "B" during this test, replace the
check valve.
Connect the tubing to fitting "C" on the check valve and press on the
syringe plunger. Fluid should NOT flow from any fitting on the valve. If fluid
flows from a fitting, replace the defective check valve.
900 V4 (1997 and later) and V6 Only
• See Figure 154
Disconnect the in-line check valve from the recirculation hose. Connect
the syringe filled with Isopropyl Alcohol and 1/8 in. clear tubing to fitting "A"
on the check valve. Press on the syringe plunger. Fluid should flow out
through fitting "B". Move the tubing to fitting "B" and again press on the
syringe plunger. Fluid should Not flow out through fitting "A".
If the fluid flow was restricted through fitting "B", replace the check valve.
If there was leakage from fitting "A", replace the check valve.
Check Valve Test at Crankcase-All 90 0 Models
• Use this check valve test for 120-300 Hp (2000/3000/4000cc)
V4N6NS motors, also known as 90 0 loopers.
Disconnect the hose from one of the fittings on the base of the intake
manifold. Connect a syringe filled with Isopropyl Alcohol to the fitting. Press
lightly on the syringe plunger. Fluid should NOT flow through the fitting. If
fluid flows through, replace the check valve.
Now, pull out lightly on the syringe plunger, air should be drawn into
the syringe through the valve. Some dark fluid may be drawn into the
syringe-this is acceptable. If no air or fluid is drawn out with the syringe,
replace the defective check valve.
Intake Manifold Internal Check Valve Tests-90 o V6 Only
• The recirculation system for 1S5-250 Hp (3000cc) V6 motors, also
known as 90 0 looper V6s, utilizes an internal intake manifold check
valve. Use this test to check that valve, but only after all other system
component checks have been made.
Access to the internal check valves requires the carburetors and intake
manifolds be removed first. Using a piece of wire, slip the check valve
out from the recess in the crankcase. Place the small end of the check valve
into a piece of clear vinyl tubing about 6 in. (15.24cm) in length. Be sure not
to cover the holes in the center of the check valve.
Now, gently blow air through the tubing. Air should pass through the
check valve. If no air passes through, the valve is defective and MUST be
replaced.
Using a hand held vacuum pump (or your lungs, but be careful not to
suck in anything too nasty), attach the tubing to the pump and attempt to
draw air through the check valve. No air should pass through the valve and
a vacuum should be indicated on the gauge. If air passes through, the valve
is defective and MUST be replaced.
Test the remaining check valves in the same manner. Replace any
defective valves. Insert the valves into the crankcase. Install the intake
manifolds and carburetors.

Recirculation Hose Routing , (2000f3000f4000cc) V4N6N8 motors, also known as 900 loopers. For
• See Figures 155, 156 and 157
The recirculation hoses should be inspected at least once a season for
condition and security. If any hose is damaged, cracked or hard from age, it
must be replaced in order to draw a vacuum and scavenge any fuel/oil
residue from the crankcase.
FUEL SYSTEM 3-43
• The illustrations given here are for the 120-300 Hp
80 Jet-175 Hp (1726f2589cc) V4N6 motors (the 600 loopers), there are
no inline Ts or check valves. On 60 0 motors, the lines run from fittings
on the cylinders to fittings on the intake manifold only. The lower
cylinder on each bank is plumbed to the carburetor for the highest
cylinder on each bank and vice-versa. On V6 motors, the lowest is
plumbed to the highest, then the middle cylinder is plumbed to the
lowest carburetor and the highest cylinder is plumbed to the middle
carburetor.

TSM
Fig. 155 Line drawing to depict typical recirculation hose routing on a 900 V6 powerhead

Fig. 156 Line drawing depicting typical recirculation hose routing on 900 V4 (1992-96) and V8 powerheads

Fig.157 Line drawing depicting typical recirculation hose routing on 1997 and later 900 V4 powerheads

Troy's Service Manuals