Evinrude Etec E40 50 60
Evinrude Etec E40 50 60
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 Installa-
tion and Predelivery Guide included with the service manual set.
All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5009017.
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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 AA MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE SPECIFICATIONS AB MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE SPECIFICATIONS AA MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PRODUCT REFERENCE AND ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WIRE SIZE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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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 publication is written for qualified, factory- DO NOT perform any work until you have read
trained technicians who are already familiar with and understood these instructions completely.
the use of Evinrude/Johnson Special Tools. The
included information is not a substitute for work Torque wrench tightening 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 patch screws) be required, always
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 parts 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 this 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 may be translated into other lan-
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
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REFERENCE INFORMATION
EMISSION-RELATED INSTALLATION INSTRUCTIONS
7
REFERENCE INFORMATION
MODEL DESIGNATION
MODEL DESIGNATION
DESIGN FEATURES:
B Blue Paint MODEL IDENTIFICATION *
C Counter Rotation The first two characters identify
D Evinrude E-TEC Model Version:
E Electric Start w/Remote Steering AA A First major variant
G Graphite Paint AB A Second major variant
H High Output AF A Third major variant
J Jet Drive Outboards built after April 2012:
M Military • follow the model identification
P Power Trim and Tilt shown above.
R Rope Start w/Tiller Steering • subsequent versions continue
S Saltwater Approved through the alphabet as AG, AH
etc.
T Tiller Steering
• will not use letters from the word
PREFIX: TE Tiller Electric INTRODUCES to identify models.
B Bodensee model V White Paint * Refer to Administrative Bulletin
D ICON model W Commercial Model 2012-03(A) for additional information.
B E 50 DP L AB A
STYLE: HORSEPOWER SHAFT LENGTH: The third character identifies
J Johnson 15 in. Std. Model Revision:
E Evinrude L 20 in. Long AA A First revision
Y 22.5 in. Special AA B Second revision
X 25 in. X-long Subsequent revisions continue
Z 30 in. XX-long through the alphabet in order
(A through Z).
Model and serial numbers are located on the swivel bracket and on the powerhead.
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REFERENCE INFORMATION
MODELS COVERED IN THIS MANUAL
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AA MODELS
Lubrication
NMMA TC-W3 certified
Engine Type In-line, 2 Cylinder, Two-Cycle
Displacement 52.7 cu. in. (864 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 Journal 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)
FUEL
Pump Pressure
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
2+4 ® Fuel Conditioner, Fuel System Cleaner
Additives Use of other additives may result in engine damage.
See Fuel Requirements on p. 135 for additional information
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AA MODELS
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Requirements
25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AB MODELS
Lubrication
NMMA TC-W3 certified
Engine Type In-line, 2 Cylinder, Two-Cycle
Displacement 52.7 cu. in. (864 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 Journal 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)
FUEL
Pump Pressure
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
2+4 ® Fuel Conditioner, Fuel System Cleaner
Additives Use of other additives may result in engine damage.
See Fuel Requirements on p. 135 for additional information
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AB MODELS
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Requirements
25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AA MODELS
Pump Pressure
Maximum Fuel Inlet Vacuum 4 in. Hg.
Minimum Octane 87 AKI (R+M)/2 or 90 RON
®
2+4 Fuel Conditioner, Fuel System Cleaner
Additives Use of other additives may result in engine damage.
See Fuel Requirements on p. 135 for additional information
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REFERENCE INFORMATION
SERVICE SPECIFICATIONS AA MODELS
640 CCA (800 MCA) or 800 CCA (1000 MCA) below 32° F (0° C)
Requirements
25-Amp fully regulated. Refer to Installation and Predelivery Guide for multiple battery
Alternator
applications.
Tachometer Setting 6 pulse (12 pole)
Engine Fuse P/N 967545 – 10 A
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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.
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REFERENCE INFORMATION
WIRE SIZE TABLE
The AWG of a stranded wire is determined by the Example: 41/1.63 means forty–one strands of
total cross sectional area of the conductor. wire, each with a 1.63 mm diameter. This example
Because there are small gaps between the has a cross sectional area of 2.08 mm².
strands, stranded wire will always have a slightly
larger overall diameter than a solid wire of the
same AWG.
Conductor Conductor
Number Number
Wire Strand Cross Wire Strand Cross
AWG of Wire (2)
AWG of Wire
Strands (1)
Diameter Section (3) Strands (1)
Diameter (2)
Section (3)
(in.) (mm) (mm²) (in.) (mm) (mm²)
6/0 3335 0.58 14.73 170.3 12 65 0.0808 2.05 3.31
5/0 2646 0.517 13.12 135.1 13 52 0.072 1.83 2.62
4/0 2109 0.46 11.7 107 14 41 0.0641 1.63 2.08
3/0 1665 0.41 10.4 85 15 32 0.0571 1.45 1.65
2/0 1330 0.365 9.26 67.4 16 26 0.0508 1.29 1.31
1/0 1064 0.325 8.25 53.5 17 21 0.0453 1.15 1.04
1 836 0.289 7.35 42.4 18 16 0.0403 1.02 0.823
2 664 0.258 6.54 33.6 19 13 0.0359 0.912 0.653
3 523 0.229 5.83 26.7 20 10 0.032 0.812 0.518
4 420 0.204 5.19 21.1 21 8 0.0285 0.723 0.41
5 329 0.182 4.62 16.8 22 6 0.0253 0.644 0.326
6 266 0.162 4.11 13.3 23 5 0.0226 0.573 0.258
7 206 0.144 3.66 10.5 24 4 0.0201 0.511 0.205
8 168 0.128 3.26 8.36 25 3 0.0179 0.455 0.162
9 130 0.114 2.91 6.63 27 2 0.0142 0.361 0.102
10 105 0.102 2.59 5.26 30 1 0.01 0.255 0.0509
11 82 0.0907 2.3 4.17
Notes: (1) 30 AWG (0.255 mm) conductor diameter
(2) Single wire strand diameter
(3) Total area cross section of all wire strands
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REFERENCE INFORMATION
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
18
ROUTINE SERVICE
ROUTINE SERVICE
TABLE OF CONTENTS
2
INSPECTION AND MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LIFTING THE OUTBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OUTBOARD RIGGING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SYSTEMCHECK HARNESS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
I-COMMAND NETWORK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WATER PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
BATTERY AND BATTERY CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OETIKER CLAMP SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STEERING FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
THROTTLE FRICTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TILT LIMIT SWITCH ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRIM SENDING UNIT ADJUSTMENT (40 – 60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TRIM SENDING UNIT ADJUSTMENT (75 – 90 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TRIM TAB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DUAL-OUTBOARD ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENGINE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
RUNNING THE OUTBOARD USING A HOSE AND FLUSHING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TILLER HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SWIVEL BRACKET AND TRAILERING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
TILT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
THROTTLE AND SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GEARCASE LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TRIM AND TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INDEXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FUEL AND OIL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OIL FILTERS AND OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
AIR SILENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
HOSES AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ANTI-CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FUEL SYSTEM TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INTERNAL ENGINE TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ADDITIONAL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PRE-SEASON SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SUBMERGED ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
19
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
Grease fittings, lubricate (3) C
Power trim/tilt and fluid level, inspect B
(3) C
Propeller shaft splines, inspect and lubricate
Starter pinion shaft, inspect and lubricate (3) D
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
20
ROUTINE SERVICE
LIFTING THE OUTBOARD
1 2
2
30501
21
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
1 3
1
2 4
2 5
1. Straight section DP0818
2. Angled section DP0817
002104
22
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 gearcase does not
binding or chafing through all engine steering shift fully into FORWARD or REVERSE, refer to
and tilting angles. SHIFT ROD ADJUSTMENT on p. 296, or SHIFT
ROD ADJUSTMENT on p. 319.
Control Cable Installation With remote control lever in NEUTRAL, pull firmly 2
Refer to Control Cable Identification on p. 21. on throttle cable casing to remove slack.
Remove cable retainer from anchor block. Apply With engine throttle lever against stop, place the
Triple-Guard grease to both anchor block pockets. cable trunnion into the upper anchor pocket and
adjust the trunnion nut so the casing fits onto the
throttle lever pin.
1
1. Cable retainer 002099
1
2 1
23
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 to NEUTRAL. Make cal Grease.
sure the engine throttle lever is against the stop. If
not, remove slack by adjusting cable trunnion.
002103
2
1
002102
24
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
1 2 CYLINDER MODELS
To prevent interference with engine cover latch,
2 bundle excess wiring behind 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
25
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
26
ROUTINE SERVICE
OUTBOARD RIGGING CONNECTIONS
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 the EMM. From the Settings
screen, select Engine Options. For an I-Command water pressure display, sev-
eral water pressure sensor kits are available.
Refer to the Evinrude/Johnson Genuine Parts
and Accessories catalog.
27
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
1. Starwasher
Check battery connections frequently. Periodically 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 all wiring connections prior to disas- cause electrical system damage not covered
sembly. under warranty.
Disconnect battery negative (–) cable first and the Tighten all connections securely. Apply Triple-
battery positive (+) cable last. Guard grease to prevent corrosion.
Clean all terminals, battery posts, and connectors A WARNING
with a solution of baking soda and water. Use a
wire brush or 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 positive (+) seek medical attention.
cable to the battery positive (+) post FIRST. Con-
nect the battery negative (–) cable to the battery
negative (–) post LAST.
28
ROUTINE SERVICE
OETIKER CLAMP SERVICING
OETIKER CLAMP 1
SERVICING
Clamp Identification
Use Oetiker clamps for making hose connections. 2
These clamps provide corrosion 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 correct 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 approximately 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 i nc h 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 1-3/4
008458
29
ROUTINE SERVICE
OETIKER CLAMP SERVICING
000108
DP0886
000090
1 2
1. Open clamp 000092
2. Closed clamp
000091
30
ROUTINE SERVICE
ADJUSTMENTS
002191
1. Steering friction adjustment—Manual tilt models 001256
31
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. Rotate 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 the tilt limit switch on all new outboard
installations.
1
Check the clearance between outboard(s) and the
boat’s motor well and transom area. Tilt 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 outboard contacts the boat's motor well
when fully tilted, adjust the tilt limit cam to reduce Repeat this procedure until the tilt limit switch
full-tilt position. stops the outboard's upward travel before it con-
tacts the motor well.
NOTICE The tilt limit cam will not prevent
the outboard from overriding the adjustment if To prevent damage to equipment, provide addi-
the outboard is tilted manually. tional motor well clearance when needed. Con-
sider either changing the outboard mounting
position or modifying the boat if the possibility 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
32
ROUTINE SERVICE
ADJUSTMENTS
4
1
1. Lever DR5090
2. Eccentric cam
1. Trailering lock 18954 3. Contact point
4. Cam screw
33
ROUTINE SERVICE
ADJUSTMENTS
Trim Sending Unit Adjustment Observe the trim gauge. If the needle does not
show center position, tilt the outboard up and
(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.
34
ROUTINE SERVICE
ADJUSTMENTS
IMPORTANT: A single trim tab adjustment will Test the boat and, if needed, repeat the procedure
relieve steering effort under only one set of speed, until steering effort is as equal as possible.
outboard angle and load conditions. No single
adjustment can relieve steering effort under all Outboards with High Transom Heights
conditions. The trim tab may be above the surface of the
water when the outboard is trimmed out. Steering
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 tab and to reduce steering
• With the remote control in NEUTRAL and the effort.
engine OFF, loosen the trim tab screw.
• If the boat pulled to the right, move rear of the Dual Standard Rotation Outboards
trim tab slightly to the right. Move both trim tabs equally and in the same
• If the boat 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.
35
ROUTINE SERVICE
ADJUSTMENTS
6340
36
ROUTINE SERVICE
OPERATIONAL CHECKS
Fuel System
Perform running checks of the fuel system by fol-
lowing these steps:
37
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 range. If the outboard is run on a flush-
ing device, the idle speed and quality may not be
representative of actual in water use.
38
ROUTINE SERVICE
COOLING SYSTEM
002024
39
ROUTINE SERVICE
COOLING SYSTEM
Running the Outboard Using a Install flushing 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
40
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
41
ROUTINE SERVICE
LUBRICATION
1
1 1
2 1. Tilt tube fittings DR38798
1 2
42
ROUTINE SERVICE
LUBRICATION
2
1. Lubricant level plug 001993
2. Lubricant drain/fill plug
43
ROUTINE SERVICE
LUBRICATION
44
ROUTINE SERVICE
LUBRICATION
45
ROUTINE SERVICE
SPARK PLUGS
SPARK PLUGS plug with the OPEN side of the ground electrode
facing the fuel injector.
Spark plugs should be removed and examined
periodically. Replace worn, fouled or damaged
spark plugs.
Removal 1 2
Remove ignition coil above spark plug to gain
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 reach the unshaded area
before the torque of 30 ft. lbs. (41 N·m) is reached,
the spark plug cannot be indexed for that cylinder.
Indexing Try another spark plug and repeat the steps
Spark plug indexing positions the ground elec- above.
trode of the spark plug opposite the fuel injector
nozzle.
46
ROUTINE SERVICE
FUEL AND OIL SYSTEMS
Fuel Filter
Evinrude E-TEC 40–90 HP outboards are
equipped with an in-line fuel filter. Refer to FUEL
COMPONENT SERVICING on p. 146.
40 - 65 HP 002227
A WARNING
Failure to check for fuel leakage could
allow a leak to go undetected, resulting in
fire or explosion.
47
ROUTINE SERVICE
ANTI-CORROSION PROTECTION
48
ROUTINE SERVICE
STORAGE
49
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.
50
ROUTINE SERVICE
SUBMERGED ENGINES
SUBMERGED ENGINES Prime oil system and fuel system. Refer to FUEL
SYSTEM PRIMING on p. 140 and Oil Supply
Once an outboard has been submerged in fresh Priming on p. 169. Make sure all oil injection
or salt water, it must be serviced within three (3) hoses are clean and filled with oil.
hours of recovery. Immediate service can mini-
Make sure high pressure fuel system does not
mize the corrosive affect that air has on the pol-
ished surfaces of the crankshaft, connecting rods, contain water. Flush as needed. 2
and internal powerhead bearings. Inject a small amount of outboard lubricant into
spark plug holes and install new spark plugs.
IMPORTANT: If outboard cannot be started or
Refer to Spark Plug Indexing on p. 46.
serviced immediately, it should be resubmerged in
fresh water to avoid exposure to the atmosphere. Reinstall all removed or disconnected parts.
Engine Dropped Overboard Use Evinrude Diagnostics software to:
(Not Running) • Initiate Break-in
• Check fuel pump operation
Disconnect the battery cables at the battery.
• Check injector operation (fuel and oil)
Rinse powerhead with clean water. • Check timing (once outboard is running at full
operating temperature)
Remove spark plug leads and spark plugs.
Run outboard below 1500 RPM for one-half hour.
Place outboard in horizontal position (cylinder
heads down). Slowly rotate flywheel in a clock- Engine Dropped Overboard
wise rotation to work all water out of powerhead.
(Running)
IMPORTANT: If sand or silt may have entered Follow the same procedures as Engine Dropped
the outboard, DO NOT attempt to start it. Disas- Overboard (Not Running). However, if there is
semble and clean. any binding when the flywheel is rotated, it may
indicate a bent connecting rod and no attempt
Disassemble all electrical connectors. Clean con- should be made to start the outboard. Powerhead
nectors and terminals, and treat with water dis- must be disassembled and serviced immediately.
placing electrical spray. Apply Electrical Grease to
terminals prior to reassembly. Coat all exposed Engine Dropped Overboard
solenoid terminals and engine grounds with Black
Neoprene Dip. (In Salt Water)
Follow the same procedures used for Engine
Clean and inspect all electrical components. Dropped Overboard (Not Running) and Engine
Replace damaged or corroded components prior Dropped Overboard (Running). Disassemble
to returning the outboard to service. Electric start- and clean outboards that have been submerged in
ers should be disassembled, cleaned, flushed salt water for prolonged periods of time. Clean or
with clean water, and treated with water displacing replace electrical components as necessary.
electrical spray prior to reassembly.
51
ROUTINE SERVICE
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
52
ENGINE COVER SERVICE
53
ENGINE COVER SERVICE
UPPER COVER SERVICE
1
1
1
1. Bracket 006468
006469
1. Trim/tilt switch connector 002169
54
ENGINE COVER SERVICE
LOWER COVER SERVICE
Lower Cover Installation Start the top front screw next and draw cover
halves together.
Installation of lower motor covers will be easier if
the following steps are performed in order:
• Install air silencer on throttle body.
• Place starboard cover on outboard and route
fuel hose and battery cable through grommet
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
55
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 screw threads. Place spring to 16 in. lbs. (1 to 2 N·m).
washer and hook into position and tighten screw
to a torque of 180 in. lbs. (20 N·m).
3
1
006747
006748
56
ENGINE MANAGEMENT MODULE (EMM)
57
ENGINE MANAGEMENT MODULE (EMM)
DESCRIPTION
DESCRIPTION
1
The Engine Management Module (EMM) is a
water-cooled engine controller. It controls many
outboard systems including alternator output for
2
the 12 V and 55 V circuits. Operating voltage is
supplied to the EMM by the stator.
EMM Connections
When the ignition key is turned ON, LEDs 3 and 4
IMPORTANT: EMM connections and wiring should light, indicating that sensor circuits and the
must be clean and tight. Improper electrical con- stop circuit are working.
nections can damage the EMM. DO NOT run the
As the outboard 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 does NOT light during starting, refer to
• Engine wire harness to EMM connectors; J1-A, EMM LED INDICATORS on p. 81.
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. 81.
58
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)
59
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL SENSORS
60
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
75 - 90 HP MODELS
If cylinder head 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
61
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If cylinder head temperature exceeds 212° F If cylinder head does not reach operating temper-
(100° C) above 3500 RPM, or 230° F (110° C) ature (104°F / 40°C below 2300 RPM) in 10 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 monitors the oil level in the oil
If cylinder head temperature 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 level falls below one-quarter, the
EMM begins counting oil pump pulse cycles.
If cylinder head temperature 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 outboard will not restart after a temperature
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 three pulses with the oil
on p. 66.
level above one-quarter.
If sensor values are less than -15°F (-26.1°C) or
If outboard has been run for more than 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)
62
ENGINE MANAGEMENT MODULE (EMM)
EXTERNAL SENSORS
If TPS voltage is greater than 0.78 volts when the If the sensor is damaged 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 gap between CPS and flywheel
Occurred Fault, refer to Control Cable Installa- encoder ribs is 0.073 inch (1.85 mm).
tion on p. 23. For tiller models, refer to Throttle Use the Evinrude Diagnostics software Monitor
Cable Adjustment on p. 273, or Throttle Cable screen to check CPS operation. The software
Adjustment on p. 284. should show an RPM reading 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.
63
ENGINE MANAGEMENT MODULE (EMM)
INTERNAL EMM FUNCTIONS
64
ENGINE MANAGEMENT MODULE (EMM)
ENGINE MONITOR SYSTEM
ENGINE MONITOR The EMM activates the warning horn and gauge
displays as follows:
SYSTEM • LOW OIL means that oil in the tank is at reserve
level (about 1/4 full).
All remote controlled outboards must be equipped • NO OIL indicates the oil tank is empty.
with an engine monitoring system to warn the • WATER TEMP or HOT indicates an engine or
operator of conditions that could damage the out- EMM overheat condition.
board. • CHECK ENGINE or FAULT is used to indicate
The engine monitor system includes sensors on other fault conditions identified by the EMM.
the outboard and oil tank, a warning horn, a dash- Refer to the EMM Service Code Chart at the
mounted display, and related wiring. back of this manual for a complete list of all fault
The outboard’s EMM sends information about codes.
4
monitored functions to:
• SystemCheck gauges System Self-Test
• An I-Command or ICON display During engine start-up, pause with the key switch
• EMM LED indicators. in the ON position. The horn self-tests by sound-
ing a half-second beep. SystemCheck gauges
IMPORTANT: Operating the outboard without self-test by turning the indicator lights on simulta-
an engine monitor will void the warranty for fail- neously, then off in sequence.
ures related to monitored functions. For informa-
tion about boat mounted Information Display Note: The warning horn does NOT sound in an
System options, refer to the current Predelivery I-Command installation.
and Installation Guide included with the service
manual set.
Service Mode
SystemCheck goes into a service mode if the key
is left ON after self-test (engine NOT running). All
light circuits and sensors are active, but the horn
is not. Grounding the appropriate light circuit wire
will turn the light on, but the horn will not sound.
Refer to SystemCheck CIRCUIT TESTS on
p. 111.
Engine Running
All warning circuits are active when the engine is
running. The horn circuit is active when engine
Typical I-Command and SystemCheck gauges 007988
speed exceeds 500 RPM.
65
ENGINE MANAGEMENT MODULE (EMM)
S.A.F.E. WARNING SYSTEM
66
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Communication
Locate the diagnostic connector on the engine. 1
Remove the cover and install the Diagnostic Inter-
face Cable (P/N 437955).
67
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
If Diagnostic Power Supply Tool, P/N 587005, is The serial number and cylinder location displayed
not available, a Battery Cable, P/N 584348, can on the Injector Coefficients screen must match the
be connected to the engine mounted solenoid. actual cylinder placement for each injector.
Use accessory Key Switch Assembly,
P/N 176408, to control power to the EMM.
1 2
68
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Active Faults
An active fault is a service code that 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 ignition
circuit. Refer to Static Ignition Test on p. 85.
Fuel Test
Use the diagnostics software to test each fuel
injector circuit. Refer to Fuel Injector Static Test
on p. 88.
Oil Injector
Use the diagnostics software to test the oil injec-
tion pump circuit. Refer to OILING SYSTEM
TESTS on p. 170.
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. 88.
Water Injector
This test activates the exhaust water valve sole-
noid (60 - 65 HP). Refer to Exhaust Water Valve
Static Test on p. 90.
69
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
Ignition Test
This test momentarily disables the ignition and
fuel injection circuits to one cylinder. By dropping 1. Oil control setting 008580
one cylinder, RPM and running quality changes
can be observed. Refer to DYNAMIC TESTS on
A CAUTION
p. 80.
Running an Evinrude E-TEC outboard on
Fuel Test other grades of oil while set to the XD100
This test momentarily disables one fuel injector oil ratio will result in increased engine
circuit. By dropping one cylinder, RPM and run- wear and shortened outboard life.
ning quality changes can be observed. Refer to
DYNAMIC TESTS on p. 80.
70
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
71
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
72
ENGINE MANAGEMENT MODULE (EMM)
DIAGNOSTIC SOFTWARE FUNCTIONS
1
Engine Report data files 008593
1. Exports button
2. Data files
73
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.
74
ENGINE MANAGEMENT MODULE (EMM)
EMM SERVICING
Installation
Installation is the reverse of removal. Pay close
attention when performing the following tasks.
1 1
75
ENGINE MANAGEMENT MODULE (EMM)
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
76
SYSTEM ANALYSIS
SYSTEM ANALYSIS
TABLE OF CONTENTS
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
VISUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OPERATIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
DYNAMIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CYLINDER DROP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FUEL CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INDUCTIVE AMP METER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
EMM LED INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
KEY ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5
IGNITION OUTPUT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
REQUIRED IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
WIRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CRANKSHAFT POSITION SENSOR (CPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SYSTEM VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
STATIC IGNITION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RUNNING IGNITION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
IGNITION CONTROL CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
CAPACITOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
FUEL DELIVERY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FUEL PUMP STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FUEL INJECTOR STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
RUNNING FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
EXHAUST WATER VALVE (60HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
EXHAUST WATER VALVE STATIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
EXHAUST WATER VALVEDYNAMIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
77
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
1. Main engine harness ground 002292 Occurred Faults Review Screen 008584
2. Ground stud (battery)
Check the diagnostics software Profiles,
Inspect spark plugs for wear, 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 engine damage could be identified by
the appearance of the spark plugs.
78
SYSTEM ANALYSIS
DIAGNOSTIC PROCEDURES
79
SYSTEM ANALYSIS
DYNAMIC TESTS
80
SYSTEM ANALYSIS
EMM LED INDICATORS
When the EMM is ON (engine not running), the LED 4 – LANYARD/STOP OKAY. For NO LIGHT,
following LEDs should light: check for:
• Grounded stop circuit.
LED 3 – Sensor Circuits working. FLASHING
LIGHT indicates Code 57 – engine will not start. For FLASHING LIGHT, check for:
• Code 29 – EMM temp. OVER range (flashing)
LED 4 – Stop Circuit not grounded–okay to start. • Code 31 – Engine temp. OVER range (flashing)
FLASHING LIGHT indicates severe overheat or • Code 33 – Engine shutdown, excessive no oil
no oil – engine in SHUTDOWN mode. condition
81
SYSTEM ANALYSIS
EMM LED INDICATORS
82
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
EMM
• Controls ignition grounds, injector grounds, and
1. Main engine harness ground 002292
engine timing.
Clean or repair all ground circuits, wiring, and con-
nections as needed.
83
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. 99. • RUNNING - less than 55 V ± 2, check stator
output to EMM. Repair connection or wiring.
Possible faulty stator or EMM. Refer to STATOR
TESTS on p. 101.
84
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
85
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
86
SYSTEM ANALYSIS
IGNITION OUTPUT TESTS
Ignition Control Circuit Tests With EMM OFF, remove the EMM J1-B connector
and test the continuity of each ignition control cir-
Use a digital multimeter to test the following:
cuit (orange). Check resistance between J1-B
• System voltage supply to ignition coil. connector and ignition 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 tests available.
Use an appropriate adapter to connect the red
Before replacing an ignition coil, be sure:
meter lead to pin 3 (white/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 approximately 1 V tion coil connector
less than battery voltage. • A control signal is present on the orange wire of
the ignition coil connector. Refer to Ignition
Control signal test: Control Circuit Tests on p. 87.
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 lead provides conti-
Use an appropriate adapter to connect the red nuity.
meter lead to pin 2 (orange) of the engine harness
connector and the black lead to ground. Activate If all of the above tests are good, and a cylinder
diagnostics software Static Ignition test and does not have spark, replace the ignition coil with
observe meter for consistent reading (approxi- a known good coil.
mately 2 Hz).
Capacitor Test
If control signal is present, connect black meter
lead to pin 1 (black) and repeat test to confirm IMPORTANT: Make sure the capacitor is dis-
harness ground. charged before testing. Make a momentary con-
nection between the two terminals to ground any
stored energy.
87
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Inspect all fuel hoses, filters, and connections. Fuel Injector Static Test
Check quality of fuel supply. Use the Evinrude Diagnostics software Fuel Injec-
tor Static Test to activate each fuel injector. Listen
Fuel Pump Static Test for an audible click from each injector when it is
Use the Evinrude Diagnostics software Fuel Pump actuated. If the injector activates, the EMM and
test to activate the electric fuel pump. If the pump injector circuits are not at fault.
runs, the EMM and fuel pump circuit are not at
fault. IMPORTANT: Do NOT perform static tests using
Diagnostic Power Supply Tool, P/N 587005, with
IMPORTANT: Do NOT perform static tests using internal 9 volt batteries only. This will produce
Diagnostic Power Supply Tool, P/N 587005, with false results. Refer to Communication on p. 67.
internal 9 volt batteries only. This will produce
false results. Refer to Communication on p. 67.
Static Tests Screen 008569A IMPORTANT: This test is operating the injectors
with 12 V battery power on the system voltage
If the pump does not run: (55 V) circuit. Battery must be fully charged and
• Check voltage at pin 1 of fuel pump connector. connections must be clean and tight. Injector acti-
Voltage should be slightly less than 12 V with vation should be carefully confirmed.
KEY ON, or when fuel pump test is activated.
88
SYSTEM ANALYSIS
FUEL DELIVERY TESTS
Results: Results:
No injectors actuate: No light activation on any injector wires (outboard
• Use the Monitor screen of the diagnostics soft- cranks and starter turns flywheel):
ware to make sure voltage is present on the • Check stator input to EMM, CPS operation, and
system voltage circuit. all grounds and wiring connections.
• Refer to Running Fuel System Tests on p. 89. • 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 no light activation on some injector
injector circuit between the injector connector wires:
and injector control wire at the EMM. • Test the resistance of individual injector circuits
• See Fuel Injector Resistance Test on p. 143. 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. 89. • Make sure all grounds are clean and tight.
• See Fuel Injector Resistance Test on p. 143.
Running Fuel System Tests 5
Run or crank the outboard. Steady light activation on all injector wires and
consistent voltage readings, EMM injector control
Use the Evinrude Diagnostics software Monitor function is good:
screen to check system voltage. If voltage is low, • Use the diagnostics software Dynamic Fuel Test
or drops as RPM increases, refer to Stator Volt- to isolate a faulty cylinder. See DYNAMIC
age Output Test on p. 101. TESTS on p. 80.
Use an inductive timing light to monitor the injec-
tor control wire (connector pin 2) for each injector.
Make sure the pickup is attached to only one wire.
Flashes on the timing light indicate current in the
circuit is being switched by the EMM. The
Dynamic Tests screen allows the control signal to
be turned off to a particular injector.
89
SYSTEM ANALYSIS
EXHAUST WATER VALVE (60HP)
(60HP)
During rapid acceleration, the EMM opens a valve
that injects water into the exhaust. This water 1
changes exhaust tuning, boosting midrange
horsepower as the boat comes on plane.
If the valve is stuck open, the outboard may be Start the outboard. No water should flow from the
low on top speed power (above 4600 RPM). hose. If water appears, check for debris in valve
assembly.
Exhaust Water Valve Static Test
Use Evinrude Diagnostics software to test the With the outboard idling, activate the dynamic
water valve solenoid electrical circuit. The water water valve test and check for water flow. A
valve is a 55 volt coil. 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 ounces /
the water valve connector. Voltage should drop minute (550 to 750cc / minute).
while the static test is active.
1
1
90
ELECTRICAL AND IGNITION
91
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
92
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
93
ELECTRICAL AND IGNITION
IGNITION SYSTEM CIRCUIT DIAGRAM, 40 – 60 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
94
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
95
ELECTRICAL AND IGNITION
ELECTRICAL HARNESS CONNECTIONS
96
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
2
Injector, cylinder 3, 75–90 HP
Exhaust water valve, 60 HP
Green
Blue/Red
3
4
Stator winding, 3S
Fuel pump control
Orange
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, 40–60 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
97
ELECTRICAL AND IGNITION
GROUND CIRCUITS
98
ELECTRICAL AND IGNITION
SENSOR TESTS
1
1
99
ELECTRICAL AND IGNITION
SENSOR TESTS
Connect red meter lead to terminal “A” and black Air Temperature Sensor (AT) Test
meter lead to terminal “C.” Rotate the sensor lever
Remove the electrical connector from the air tem-
through its range of travel. Resistance reading
perature sensor.
must change evenly as the sensor lever is moved.
Use a digital multimeter to measure sensor resis-
Connect red meter lead on terminal “B” and black
tance.
meter lead to terminal “C.” Rotate the sensor
lever. Resistance reading must change evenly as AT Sensor Resistance
the sensor lever is moved. 680 Ω ± 5.25% @ 212°F (100°C)
10000 Ω ± 1.5% @ 77°F (25°C)
Engine Temperature Sensor Test 32654 Ω ± 3.0% @ 32°F (0°C)
Remove the electrical connector from the engine
temperature sensor.
1. AT sensor 006613
1
100
ELECTRICAL AND IGNITION
STATOR TESTS
101
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
102
ELECTRICAL AND IGNITION
CHARGING SYSTEM TESTS
Following the manufacturer’s directions, connect Start and run the outboard at approximately 5000
the variable load tester (carbon pile) across the RPM. Use the variable load tester to draw the bat-
battery terminals. Stevens model LB-85 and tery down at a rate equivalent to the stator’s full
Snap-On model MT540D are examples of 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, the battery voltage
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. 101.
4
55 V Alternator Circuit
2 Check battery ground cable for continuity.
1. J2 connector 007261
2. Test probe
103
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
104
ELECTRICAL AND IGNITION
ELECTRIC START CIRCUIT
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)
105
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
POS
4 5 6
3 2 1
2 3
1. Ignition switch, START position – Continuity 000691R
between terminals “B” and “A”; “B” and “S”
2. Terminal “S”, 12 V AB
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)
106
ELECTRICAL AND IGNITION
ELECTRIC START TESTS
Use a digital voltmeter to measure the voltage 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 any voltage reading is greater than 0.5 VDC
check that connections are clean, tight and free of Use a battery rated at 500 CCA (60 amp-hr) or
corrosion. Clean or replace any 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 100
STEP 1: Connect voltmeter positive (+) lead to amp ammeter in series with a heavy jumper
the terminal for the negative (–) battery cable at between the battery positive (+) terminal and the
powerhead. Connect voltmeter negative (–) lead starter positive (+) terminal.
to negative (–) battery post.
• Activate starter motor and observe voltage Fluke model 334 or 336, Snap-On model MT110
or EETA501, and various other ammeters should
6
reading.
be available through local tool suppliers.
V–
NEG V Attach or hold a vibration tachometer, such as a
1
Frahm † Reed tachometer, to the starter.
3 –
2 4
+
107
ELECTRICAL AND IGNITION
REMOTE CONTROL SWITCH TESTS
108
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 the clip on the emergency stop switch or
2. Neutral start switch
key switch. Start the outboard. Pull the clip from
the switch. The outboard must stop running.
Replace switch if results are incorrect.
109
ELECTRICAL AND IGNITION
TILT/TRIM RELAY TEST
TILT/TRIM RELAY TEST The meter must indicate battery voltage (12 V)
with B+ connected to either terminal.
The tilt and trim (TNT) module contains the cir-
cuitry and relays required for power trim and tilt
3
operation.
1
1
Test Procedure
Make sure red and black wires 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)
110
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
111
ELECTRICAL AND IGNITION
SystemCheck CIRCUIT TESTS
the two connectors, replace SystemCheck WATER TEMP/ HOT Circuit Test
gauge.
The tan wire of engine harness and the MWS har-
ness receives a signal from the EMM. The EMM
receives information from the temperature sensor
on the cylinder head.
2 1
1. Purple wire DRC6280
2. Tan/blue wire
002079
Turn the key switch OFF and reconnect all discon-
nected circuits.
Turn the key switch ON. After the normal self-test
sequence, the gauge WATER TEMP / HOT indi-
CHECK ENGINE Circuit Test cator should stay on.
Separate the 6-pin SystemCheck connector of • If LED is not on, test circuit for continuity. Test
MWS instrument harness from engine harness. for continuity of both the engine harness (tan
Black wire (pin 3) must be grounded. wire) and the MWS instrument harness (tan
Using a jumper wire, connect tan/orange wire (pin wire).
2) to a clean engine ground. Turn the key switch OFF and reconnect all discon-
Turn the key switch ON. After the normal self-test nected circuits.
sequence, the CHECK ENGINE light should stay IMPORTANT: To test the temperature sensor
on. itself, refer to Engine Temperature Sensor Test
• If the CHECK ENGINE light is not on, test circuit on p. 100.
for continuity. Check continuity of the MWS
instrument harness (tan/orange wire).
• Check continuity of the engine wire harness
between terminal 2 (tan/orange wire) of the Sys-
temCheck connector and pin 17 of the EMM J1-
A connector.
112
ELECTRICAL AND IGNITION
TACHOMETER CIRCUIT TESTS
2
1
3
002079
113
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
1
Lift flywheel cover to remove.
002087
114
ELECTRICAL AND IGNITION
FLYWHEEL AND STATOR SERVICING
002088
1. Stator screws 006486
Apply Moly Lube grease to the threads of the
puller pressing screw, P/N 307637, and the center To install stator, position stator on cylinder block.
hole of the crankshaft. Apply Nut Lock to screw threads. Install screws
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 puller body with the three shoulder force.
screws and washers. Hold puller body with han-
dle, and tighten pressing screw until flywheel Install the outer edge of flywheel key parallel with
releases. Turn the center screw and lift the fly- centerline of crankshaft.
wheel off of the crankshaft.
1
1
115
ELECTRICAL AND IGNITION
IGNITION COIL SERVICING
1. Screws 008187
116
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
TIMING ADJUSTMENTS the tool. Mark the flywheel directly across from the
pointer. Label this mark “A.”
Timing Pointer
A WARNING
To prevent accidental starting while servic-
ing, disconnect the battery cables at the
battery. Twist and remove all spark plug
leads. 1
117
ELECTRICAL AND IGNITION
TIMING ADJUSTMENTS
location to align with the cast-in TDC boss on the Check ignition timing after any of the following
flywheel. Tighten retaining screw. procedures:
• Powerhead replacement
• Crankshaft replacement
• Flywheel removal or replacement
• CPS replacement
• EMM replacement
• EMM software replacement (reprogramming)
IMPORTANT: Make sure the timing pointer is
set and the outboard reaches operating tempera-
ture before making any timing adjustments.
TPS Calibration
2 3 4 1
Use Evinrude Diagnostics software to tell the
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 after replacing or adjusting
Repeat the entire adjustment 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 Spark Plug Indexing
on p. 46. Do NOT start the outboard.
118
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 covers and air silencer.
Refer to Lower Cover Removal on p. 54. Coat connections with Black Neoprene Dip.
1 1
1. Screws 008189
119
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
SERVICING
1
DEUTSCH Connectors
IMPORTANT: Electrical Grease is recom-
mended. Incorrect grease application can cause 2
electrical or warning system problems.
1. Terminal latch (plug) 42329
2. Terminal latch (receptacle)
To disconnect the connector, press the latch and
pull the connectors apart.
Terminal Installation
To connect the connector, confirm that the seal is Push terminal through seal until it locks into place.
in place. Clean off any old grease and dirt from Fill connector with Electrical Grease to 1/32 in.
connectors. Apply a light coat of Electrical Grease (0.8 mm) below ledge or end of plug.
to seal only. Push connectors together until
latched.
2
1
2
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
120
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
AMP Connectors
IMPORTANT: Always use the appropriate meter
test probes and adapters 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 connectors Terminal Installation
together until latched.
Align terminal with connector 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
121
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
Disconnect Disconnect
Depress BOTH latches and pull connector from Use a screw driver to open latch. Pull connector
plug. from plug.
Connect Connect
Push connector into plug until latches engage. Push connector until seated in plug. Close latch
completely.
1
1
2
1. Latch 002118
1. J2 connector 002120
Terminal Removal 2. Latch (closed)
1 1
1. Latch 002453
2. Lock mechanism
1
Terminal Installation
1. Locking mechanism(s) 002455
Push terminal through seal until it is seated in con-
nector housing. Close lock mechanism.
122
ELECTRICAL AND IGNITION
CONNECTOR SERVICING
1. Latch 002456
2. Terminal with seal
1
Packard Connectors
IMPORTANT: Always use the appropriate meter
test probes and adapters when testing compo-
6
1. Tab DRC5940a
nents fitted with these terminals.
Terminal Installation
Disconnect
Install wire gasket on wires and feed wires
Lift latch(s). Remove connector.
through the correct terminal position of the con-
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 onto
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 of insulation in the insulation crimp
area of the terminal.
Capture all wire strands in crimp; leave no loose
strands. Crimp wire and insulation securely using
crimping pliers.
123
ELECTRICAL AND IGNITION
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
124
FUEL SYSTEM
FUEL SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
FUEL SYSTEM HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FUEL SYSTEM CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
FUEL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
REGULATIONS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
PORTABLE FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL FLOW REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
VAPOR SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL CIRCULATION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL SYSTEM PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
VENT LINE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FUEL SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 7
FUEL SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
VAPOR SEPARATOR VENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FUEL INJECTOR PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FUEL INJECTOR RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
CIRCULATION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
LIFT PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
LIFT PUMP VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
LIFT PUMP DIAPHRAGM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ANTI-SIPHON VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
FUEL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
RELIEVING FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
FUEL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
FUEL LIFT PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
VAPOR SEPARATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
FUEL MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
INTAKE MANIFOLD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
125
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
126
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
127
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
128
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
129
FUEL SYSTEM
FUEL SYSTEM HOSE ROUTING
9
4
9 10 11 2
3
8
7 6
Fuel Supply
12
Fuel Return
1
002148
130
FUEL SYSTEM
3-CYLINDER MODELS
9
4
9 10 11 2
3
8
7 6
Fuel Supply
Fuel Return
12 7
1
5
002148a
131
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
132
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
133
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
134
FUEL SYSTEM
FUEL SYSTEM REQUIREMENTS
135
FUEL SYSTEM
COMPONENTS
COMPONENTS Vacuum from the fuel lift pump pulls fuel from the
fuel tank. Once fuel reaches the pump, internal
The fuel system includes the following compo- pump pressure forces 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. 20 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 float controlling the venting of fuel
vapors.
• Contains a fuel pressure regulator for the high
2-Cylinder models 006558 pressure fuel system.
1. Fuel lift pump
2. Pulse hose fitting
136
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 moves with the fuel
level in the fuel chamber. Hot fuel causes an
Fuel Reservoir increase in vapor pressure. This results in a lower
The vapor separator accumulates fuel in an inter- fuel level in the vapor separator. The float valve
nal fuel reservoir and supplies fuel to the electric drops and the vent opens. This allows fuel vapor
circulation pump. It is water-cooled to enhance to flow to the intake manifold through the vent
vapor separating capabilities. hose.
Cooling As the vapor pressure in the vapor separator
Water is used to cool the fuel as it flows through decreases, the fuel level begins to increase. An 7
the vapor separator. The cooling passage of the increase in the fuel level raises the float valve and
separator self-drains when the outboard is stored the vent closes.
vertically. Refer to HOSE ROUTING AND WATER
FLOW DIAGRAMS on p. 178. 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 injectors enters the fuel
chamber of the vapor separator through a pres-
sure regulator. The pressure regulator maintains
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
137
FUEL SYSTEM
COMPONENTS
Fuel Injectors
Fuel injectors are fuel metering, electric solenoids
(55 V) bolted directly to the cylinder head. The
1. Fuel pump electrical connector 006557 EMM controls the activation of each injector by
rapidly connecting and disconnecting the injec-
tor’s internal coil to ground.
138
FUEL SYSTEM
COMPONENTS
006619
139
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.
140
FUEL SYSTEM
FUEL SYSTEM TESTS
141
FUEL SYSTEM
FUEL SYSTEM TESTS
Make sure filter is not clogged. Clean or replace 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. 173.
hose to the fuel return fitting of vapor separator.
Relieve fuel system pressure. Refer to Relieving
Apply pressure to check regulator operation. The Fuel System Pressure on p. 146.
pressure should open check valve at approxi-
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 injector to 30 psi
(207 kPa). Pressure must hold for at least five
minutes.
1
2 2
3 1
1. Filter 000249r
2. Fuel return fitting
3. Pressure regulator
142
FUEL SYSTEM
FUEL SYSTEM TESTS
Use a digital multimeter to measure the injector Use a digital multimeter with appropriate adapter
coil resistance. leads to measure the fuel pump circuit and 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 digital multimeter with appropriate 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 psi (0 to 103 kPa) Fuel Pressure
Measure resistance between pin 1 (white/red) of Gauge, P/N 5006397 or equivalent, to the lower
injector connector (connected) and the appropri- fuel pressure test fitting.
ate pin location of EMM J1-B connector (discon-
nected). Refer to engine wiring diagram for
1
specific EMM J1-B connector pin location for the
injector circuit being tested (blue, purple or green).
143
FUEL SYSTEM
FUEL SYSTEM TESTS
No pressure:
• Check pulse hoses and fittings restrictions.
• Check fuel flow through fuel lift pump. Use fuel
primer or primer bulb to force fuel through
000243
pump.
• Momentarily prime or squeeze primer bulb to START outboard and run at FULL THROTTLE for
check gauge operation. at least two minutes. Monitor clear vinyl hose for
• Check pulse hose and fittings for restrictions. the presence of air. Air bubbles indicate a faulty
hose, connection, or fuel tank pick-up. Repair, if
Lift Pump Vacuum Test necessary, before proceeding.
Confirm fuel supply to the fuel lift pump.
There should be no air or vapor bubbles visible in
Temporarily install a vacuum gauge, T-fitting, and the clear hose. The maximum inlet fuel vacuum
8 in. (20.3 cm) of clear vinyl hose between the fuel should not exceed 4 in. Hg. (13.5 kPa) at the inlet
supply hose and fuel lift pump (inlet). Secure con- to the fuel lift pump under any operating condi-
nections with tie straps to prevent fuel or air leaks. tions (IDLE to WOT).
144
FUEL SYSTEM
FUEL SYSTEM TESTS
145
FUEL SYSTEM
FUEL COMPONENT SERVICING
146
FUEL SYSTEM
FUEL COMPONENT SERVICING
2
1
1. Screws 002194
147
FUEL SYSTEM
FUEL COMPONENT SERVICING
007860
148
FUEL SYSTEM
FUEL COMPONENT SERVICING
1 2
1. Retainer 005342
2. Manifold fitting groove
2 7
Install the fuel manifolds to the fuel pump assem-
bly and secure with clamps:
1. Fuel supply manifold 006555
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 assembly. Refer to Oil Tank
retainers from fuel injectors.
Assembly on p. 173.
1. Screw 006559
149
FUEL SYSTEM
FUEL COMPONENT SERVICING
Injector Coefficients Screen 008568 Turn the nut of the fuel injector puller counter–
clockwise several turns. Place the fuel injector
Use caution when handling fuel injectors. Prevent puller on the fuel injector housing.
dirt and debris from entering fuel inlet and outlet
1
ports of injectors or fuel manifolds. Cover the
injector nozzle port in cylinder head to prevent
contamination of combustion chamber.
Removal
Disconnect the battery cables at the battery.
2
Relieve fuel system pressure. Refer to Relieving
Fuel System Pressure on p. 146.
150
FUEL SYSTEM
FUEL COMPONENT SERVICING
Align the angled edges of both sides of the tool Turn the puller nut until the fuel injector is
base with the edge of the fuel injector housing as removed from the fuel injector housing.
shown.
1
1
1. Adaptor 002196
151
FUEL SYSTEM
FUEL COMPONENT SERVICING
Install injector into mount housing. Press on injec- Select the Replace Injector button.
tor face until injector seats in mount housing.
002318
1. “Replace Injector” button 008568A
152
FUEL SYSTEM
FUEL COMPONENT SERVICING
Make sure the serial number displayed on the through mounting flange of injector and into cylin-
screen matches the serial number printed on the der head.
serial number label of the replacement injector.
002316
A CAUTION
All injector components must be clean to
ensure correct torque tightening specifi-
cations. To prevent fuel leakage, carefully
follow these installation instructions. Tighten Screws in Stages 006562
153
FUEL SYSTEM
FUEL COMPONENT SERVICING
1 2
002496
1
002504
154
FUEL SYSTEM
FUEL COMPONENT SERVICING
1
002326
Installation
Place reed plate assembly on cylinder/crankcase.
Apply Nut Lock to two reed plate screws. Install
and tighten screws to a torque of 60 to 120 in. lbs.
(7 to 13.5 N·m).
7
1. Straight-edge 002324
Assembly
Remove old adhesive from reed valve retaining
screws.
002505
002333
155
FUEL SYSTEM
FUEL COMPONENT SERVICING
002501
156
OILING SYSTEM
OILING SYSTEM
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
OIL SUPPLY DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
OIL RECIRCULATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OILING SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
OIL SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
RECOMMENDED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
ELECTRICAL CIRCUIT (55 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
LOW OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
NO OIL WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
CYLINDER AND CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
OIL RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
OIL CONTROL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
OIL INJECTION RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
BREAK-IN OILING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OIL SUPPLY PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
OILING SYSTEM TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
OIL INJECTION PUMP VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
OIL INJECTION PUMP RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
OIL INJECTION PUMP FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
OIL INJECTION FITTINGS FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8
LOW OIL SENDING UNIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
OIL COMPONENT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL DISTRIBUTION HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
OIL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
157
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
158
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
159
OILING SYSTEM
OIL SUPPLY DIAGRAMS
3 1
1 6
008060
160
OILING SYSTEM
75 – 90 HP
5
3
5 1
5
2
4
8
1 6
008061
161
OILING SYSTEM
OIL RECIRCULATION DIAGRAMS
002483a
75 – 90 HP
162
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
3
12
13
14
4
5
6
J2 8
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)
163
OILING SYSTEM
OIL SYSTEM REQUIREMENTS
008062
164
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 style pump. It draws oil from the oil tank and 3. Pickup tube and filter
supplies pressurized oil to the oil manifold. The
EMM supplies 55 V and controls activation of the Electrical Circuit (55 V)
pump. The oil injector is powered by the 55 V electrical 8
circuit. The EMM controls pump operation by rap-
idly connecting and disconnecting the pump’s
internal coil to ground.
165
OILING SYSTEM
COMPONENTS
NO OIL Warning 1
When the oil level falls below one-quarter, the
EMM begins counting oil pump pulse cycles.
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 outboard has been run for more than 3 hours 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
166
OILING SYSTEM
COMPONENTS
1 1
Cylinder Recirculation
Internal powerhead oil drain passages connect
the intake port areas of the cylinders to circulate
residual oil in the block.
167
OILING SYSTEM
OIL CONTROL SETTINGS
1 355627
168
OILING SYSTEM
OIL CONTROL SETTINGS
8
1 Dynamic Test Screen 008570A
1. Prime Oil System button
169
OILING SYSTEM
OILING SYSTEM TESTS
1. Oil distribution hoses 007997 The EMM controls the pump by providing ground
through pin 23 (blue wire) of the J1-B connector
Small bubbles are acceptable. Large bubbles 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
170
OILING SYSTEM
OILING SYSTEM TESTS
Use the Oil Injector test of Evinrude Diagnostic Set digital multimeter to a scale that reads 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 voltage at pin A is within range, refer to Oil
Injection Pump Resistance Test on p. 171.
• No voltage reading at pin A, refer to System
Voltage Test on p. 84.
1 Oil Injection Pump Resistance
Test
Disconnect the battery cables at the battery.
171
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 cylinder
tribution manifold. Do not lose the brass hose sup- and crankcase assembly allow fluid to move.
port.
Remove oil distribution hose from oil distribution
manifold.
1
1
1. Syringe 008069
172
OILING SYSTEM
OIL COMPONENT SERVICING
1
8
1
1. Screws 008072
1
1. Hose support 008070
173
OILING SYSTEM
OIL COMPONENT SERVICING
2-CYLINDER MODELS
Installation
Position oil tank assembly on powerhead. Clean
1 mounting screws and apply Nut Lock to threads.
Install screws and tighten to a torque of 30 to 42
in. lbs. (3.5 to 5 N·m).
Install protective sleeves and route oil distribution
hoses from the oil distribution manifold to the
1. Screws 008074
crankcase oil delivery fittings. Refer to OIL SUP-
PLY DIAGRAMS on p. 160. Secure oil hoses 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 software to activate “Oil Prime.”
Disconnect the electrical connector to the low oil Check oil flow through oil distribution hoses.
switch. Check oil system operation and routing of oil sys-
tem hoses.
174
OILING SYSTEM
OIL COMPONENT SERVICING
1. O-ring 008064
1
2-CYLINDER MODELS
Install oil pump and manifold so that bend of oil
pick up assembly is positioned to follow the con-
tour of the oil tank as shown.
1
8
175
OILING SYSTEM
OIL COMPONENT SERVICING
3-CYLINDER MODELS
Install oil pump and manifold straight into oil tank.
ALL MODELS
Install oil pump retainer screw(s). Tighten
securely.
176
COOLING SYSTEM
COOLING SYSTEM
TABLE OF CONTENTS
HOSE ROUTING AND WATER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
WATER PUMP AND INTAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
WATER SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
ADAPTER/INNER EXHAUST HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
BLOCK VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
WATER PRESSURE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
CYLINDER BLOCK / CYLINDER HEAD COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
EMM AND VAPOR SEPARATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ENGINE TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
SOFTWARE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
PYROMETER METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
IDLE OPERATING TEMPERATURE TROUBLESHOOTING (BELOW RANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
TEMPERATURE SENDER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
THERMOSTAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
PRESSURE RELIEF VALVE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
177
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
178
COOLING SYSTEM
HOSE ROUTING AND WATER FLOW DIAGRAMS
3-CYLINDER MODELS
Outgoing water (warm/hot)
8
Incoming water (cool)
001818
179
COOLING SYSTEM
COMPONENTS
180
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
181
COOLING SYSTEM
COMPONENTS
1. Fitting 002461
182
COOLING SYSTEM
OPERATION
9
1. Thermostat 002441
2. Pressure valve assembly
The thermostat opens when the water tempera- 1. Overboard indicator 004969
183
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 temperature sensor readings 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 temperature 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 temperature must not exceed 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 outboard’s operating
temperatures.
If engine temperature tests within range, but the
engine monitor display indicates a “WATER Measure temperature of the thermostat housing at
TEMP” warning, refer to WATER TEMP/ HOT Cir- the top of cylinder head.
cuit Test on p. 112.
Typical pyrometer readings at IDLE speed should
be 145°F ± 10°F (63°C ± 6°C).
184
COOLING SYSTEM
ENGINE TEMPERATURE CHECK
IMPORTANT: If you get low or inaccurate read- Check thermostat for cracks, heat 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).
185
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 inch (25 mm) below the top
edge of the cavity.
1 in. 1
002444
(25 mm)
Remove the cylinder head if cylinder head ther-
mostat seal requires replacement. Place new seal
in the cylinder head with side marked “TO CYL
HEAD” facing thermostat. Refer to Cylinder Head
3 2
186
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
Installation on p. 211.
PRESSURE RELIEF
VALVE SERVICING
The pressure relief valve assembly should be ser-
viced at the same time as the thermostat.
1
Disassembly
Remove screws and cover from pressure valve
assembly.
Inspection
Inspect all parts for cracks, heat damage, or signs
of corrosion. Replace damaged parts. Clean
debris from housing and parts.
002443
000756
Assembly 9
Assembly is the reverse of disassembly. Pay
close attention when performing the following
additional tasks.
187
COOLING SYSTEM
PRESSURE RELIEF VALVE SERVICING
Inspection
Inspect all parts for cracks, heat damage, or signs
of corrosion. Replace damaged parts. Clean
debris from housing and parts.
Assembly
Assembly is the reverse of disassembly. Pay
close attention when performing the following
additional tasks.
188
POWERHEAD
POWERHEAD
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
COMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
POWERHEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
POWERHEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
SYSTEMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
THROTTLE LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
SHIFT LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
CYLINDER BLOCK CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
POWERHEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
CRANKSHAFT AND CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
SHIFT LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
THROTTLE LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
FINAL POWERHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
UPPER MOUNT SERVICING (3-CYLINDER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
POWERHEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
POWERHEAD MOUNTING – 2-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
POWERHEAD MOUNTING – 3-CYLINDER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
FINAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 10
POWERHEAD VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2-CYLINDER PORT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3-CYLINDER PORT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
189
POWERHEAD
SERVICE CHART
SERVICE CHART
2-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J A
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
X
15-30 Ft. lbs.
(20-41 N·m)
M, X
Q, X
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)
190
POWERHEAD
SERVICE CHART
2-CYLINDER MODELS
H
G
H, X
30-32 Ft. lbs.
(41-43 N·m)
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
X See Service Manual Procedure
002284 Y Extreme Pressure Grease
191
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
F
60-84 In. lbs.
(7-9.5 N·m)
J A
A 120-144 In. lbs.
(13.5-16 N·m)
H
168-192 In. lbs.
(19-21.5 N·m)
X
15-30 Ft. lbs.
(20-41 N·m)
M, X Q, X
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
D Moly Lube F
60-84 In. lbs.
E Red Ultra Lock (7-9.5 N·m)
F Blue Nut Lock
G Needle Bearing Grease
H Outboard Lubricant
J Thermal Grease
M RTV Sealant
P Permatex No. 2 B
Q Gel Seal II
X See Service Manual Procedure
Y Extreme Pressure Grease 002281
192
POWERHEAD
SERVICE CHART
3-CYLINDER MODELS
H
G
H, X
30-32 Ft. lbs.
(41-43 N·m)
A Triple-Guard Grease
B Gasket Sealing Compound
D Moly Lube
H E Red Ultra Lock
B F Blue Nut Lock
D
15-20 Ft. lbs.
(20-27 N·m) D
002282
193
POWERHEAD
COMPRESSION TESTING
1. Connectors 008429
194
POWERHEAD
POWERHEAD REMOVAL
Remove pin and washer from shift 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
195
POWERHEAD
POWERHEAD REMOVAL
Disconnect power trim connectors. Install Lifting Fixture, P/N 396748, on flywheel and
seat the three screws completely.
1
002152 2
Remove pin and washer from shift rod lever to
release the lower shift rod.
196
POWERHEAD
POWERHEAD DISASSEMBLY
197
POWERHEAD
POWERHEAD DISASSEMBLY
1 2
1
198
POWERHEAD
POWERHEAD DISASSEMBLY
002234
002137
002124
A WARNING
Wear safety glasses to avoid injury. 002138
Use a 1/8 in. diameter pin punch to push crank- Separate crankcase and cylinder block. It may be 10
case taper pin toward the front side of the engine. necessary to tap on crankshaft with a rawhide or
rubber mallet to loosen.
002232
002252
199
POWERHEAD
POWERHEAD DISASSEMBLY
002123
002141
200
POWERHEAD
POWERHEAD DISASSEMBLY
Use an appropriate ring expander to remove all necting rod. If necessary, use Wrist Pin Pressing
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 through to free the piston from the con-
Remove upper seal from crankshaft. Discard the
seal. A new upper seal must be installed on
assembly.
201
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.
Remove the O-ring from crankshaft sleeve and
inspect it. Replace the O-ring if it is not in good
condition.
002042
002040
002044
202
POWERHEAD
POWERHEAD DISASSEMBLY
Inspect the crankshaft sleeve and replace if nec- Use a bearing separator to support the 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 main bearings and split sleeves
be replaced. Use external retaining ring pliers to for inspection. DO not mix parts. Note location of
remove the lower bearing retaining ring. bearings for reassembly.
002039 24381
203
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 of gaskets, adhesives, and Gel-Seal II™ Cover the cylinder walls with a liberal amount of
outboard lubricant to prevent corrosion.
204
POWERHEAD
POWERHEAD INSPECTION
POWERHEAD Crankshaft
Measure the diameter of each crankpin and main
INSPECTION bearing journal. The lower main bearing journal
For dimensions, refer to SERVICE SPECIFICA- would only be measured if the bearing was
TIONS AB MODELS on p. 12. removed for another reason.
Cylinder Head
Check for cylinder head warpage using a piece of
002142
bar stock or machinist’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 measurement. Replace der bore for an out-of-round, oversize, or tapered
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 be measured twice. The difference
between the two measurements in each area is
the cylinder out-of-round dimension.
• The cylinder must not be out-of-round by more
than 0.004 in. (0.10 mm).
205
POWERHEAD
POWERHEAD INSPECTION
The dimensional difference between the two IMPORTANT: Ring end gap increases approxi-
areas is cylinder taper. mately 0.003 in. (0.076 mm) for each 0.001 in.
• The cylinder taper must not exceed 0.002 in. (0.025 mm) increase in cylinder bore diameter.
(0.05 mm). DO NOT exceed cylinder oversize dimension.
Pistons Bearings
Visually inspect pistons for signs 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 rod bearings for 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 feeler gauge to measure the
ring end gap.
24381
002143
206
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 crankshaft splines with Moly Lube. Install
O-ring in sleeve.
Crankshaft Assembly
Oil the end of the crankshaft. Use Crankshaft
Bearing/Sleeve Installer, P/N 338647, and place a
1
new lower main bearing onto crankshaft with let-
tered side facing the tool. Install bearing until it
seats on the crankshaft.
2
207
POWERHEAD
POWERHEAD ASSEMBLY
lower housing with extended lip facing down. Lubricate upper main bearing with outboard lubri-
Lubricate seal lip with Triple-Guard grease. cant and install on crankshaft.
002037
208
POWERHEAD
POWERHEAD ASSEMBLY
Pistons and Connecting Rods Apply Needle Bearing Grease to the wrist pin
bearings. Install the bearings in the small end of
NOTICE It is very important that the pistons the connecting rod. Align bearings 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
209
POWERHEAD
POWERHEAD ASSEMBLY
Use Wrist Pin Cone, P/N 318600, and Driver, IMPORTANT: Be sure gap of ring fits squarely
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
210
POWERHEAD
POWERHEAD ASSEMBLY
Cylinder Head Installation Apply a 1/16 in. (2 mm) bead of RTV Adhesive
around each water passage on the block and cyl-
Install a new thermostat seal in cylinder head with
inder head as shown.
side marked “TO CYL HEAD” facing toward ther-
mostat.
002061
Install cylinder head with the thermostat toward
the top. Place ignition coil brackets as shown
Apply soapy water to water dam and insert into below.
block.
Apply outboard lubricant to screw threads and
install the cylinder head screws. DO NOT use any
sealant or locking compound on threads.
10
1. Water dam 002062
211
POWERHEAD
POWERHEAD ASSEMBLY
2 1
1
2 1
212
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate each crankpin and bearing assembly IMPORTANT: Be sure alignment dot on rod cap
with outboard lubricant. Slowly pull connecting rod matches dot on rod and that both dots 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 dot 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
213
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
214
POWERHEAD
POWERHEAD ASSEMBLY
Test at least three corners of the rod and cap joint IMPORTANT: Gel-Seal II has a shelf life of at
with a pick. Joint must be smooth with no step. least one year when stored at room temperature.
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
215
POWERHEAD
POWERHEAD ASSEMBLY
Start in the center and work outward in a spiral Note: 3-Cylinder models include a double-ended
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 into the crankcase. Lubricate with Tri-
ple-Guard grease.
IMPORTANT: After powerhead has been
assembled, allow at least two hours for Gel-Seal II
to cure before running outboard.
1
Apply Gasket Sealing Compound to both sides 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).
216
POWERHEAD
POWERHEAD ASSEMBLY
Lubricate shift linkage bosses at the base 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 shift lever assembly. Guide shaft through Install lever, screw, and washer on crankcase and
bushings in crankcase. hook spring on rib as shown. Tighten screw to a
torque of 120 to 144 in. lbs. (13.5 to 16 N·m).
Install cotter pin and washer on the 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 threads of throttle cam screw.
Install cam, screw, and washer on cylinder block
217
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. 154.
2-Cylinder models 002245 Install shift linkage. Refer to Shift Linkage Instal-
1. Throttle lever screw lation on p. 216.
2. Throttle return lever
Install throttle linkage. Refer to Throttle Linkage
Installation on p. 217.
A WARNING
To prevent fire and explosion hazard,
make sure all electrical and ignition wiring
is routed and clamped in original posi-
tions.
218
POWERHEAD
UPPER MOUNT SERVICING (3-CYLINDER)
39820
Installation
002069
Place mount assemblies in position, with flats fac-
Insert suitable punch in taper of mount retainer. 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
219
POWERHEAD
POWERHEAD INSTALLATION
002269
220
POWERHEAD
POWERHEAD INSTALLATION
Place the shift rod in the shift rod lever. Install the Connect cooling water hoses to exhaust housing.
retaining pin and washer. Tighten pin to a torque
of 60 to 84 in. lbs. (7 to 9.5 N·m).
1 2
3
4
1
221
POWERHEAD
POWERHEAD INSTALLATION
1 1
222
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 torque 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).
223
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. Refer to LOWER 1. Adjustment screws 002125
COVER SERVICE on p. 54. 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 that 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 adjusted, the shift lever will be
• Adjust timing pointer.
parallel with the vertical line of the outboard,
and the distance between the shift lever pin and
• Index all spark plugs. Refer to Spark Plug
Indexing on p. 46.
the center of the shift cable trunnion pocket
should be approximately 7 in. (17.8 cm). • Use Evinrude Diagnostics software to start pow-
erhead break-in oiling. Refer to Powerhead
IMPORTANT: The shift rod height is the most Break-In on p. 71.
critical of these adjustments and should not be • Use Evinrude Diagnostics software to set TPS
moved during this procedure. Refer to SHIFT calibration. Refer to TPS Calibration on p. 118.
ROD ADJUSTMENT on p. 296, or SHIFT ROD • Use Evinrude Diagnostics software to make
ADJUSTMENT on p. 319. sure engine management software version and
revision are current. Update as required.
• Prime fuel system.
• Prime oiling system. Refer to Oil Supply Prim-
ing on p. 169.
• Use Evinrude Diagnostics software to check
engine timing. Refer to TIMING ADJUST-
MENTS on p. 117.
• Run outboard and check for water, fuel, or oil
leaks.
• Make sure engine reaches correct operating
temperature and does not overheat.
224
POWERHEAD
POWERHEAD VIEWS
POWERHEAD VIEWS
006490
10
006491
225
POWERHEAD
POWERHEAD VIEWS
008428
008159
226
POWERHEAD
POWERHEAD VIEWS
008370
10
008185
227
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Front
008160
228
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Rear
10
008161
229
POWERHEAD
POWERHEAD VIEWS
2-Cylinder Top
008162
230
POWERHEAD
POWERHEAD VIEWS
10
008186
231
POWERHEAD
POWERHEAD VIEWS
006760
006761
232
POWERHEAD
POWERHEAD VIEWS
008163
10
008164
233
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Front
008166
234
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Rear
10
008167
235
POWERHEAD
POWERHEAD VIEWS
3-Cylinder Top
008165
236
MIDSECTION
MIDSECTION
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
TILT TUBE, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
EXHAUST HOUSING, 40 – 60 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EXHAUST WATER VALVE (60 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
EXHAUST RELIEF MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
EXHAUST HOUSING, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
EXHAUST HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
LOWER MOUNT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
EXHAUST HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
EXHAUST HOUSING DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
EXHAUST HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
STERN BRACKET, 40 – 60 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
STERN BRACKET, 75 – 90 HP POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
STERN BRACKET, 40 HP MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
CLAMP SCREW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
STERN BRACKET DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
STERN BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
TILT ASSIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
TILLER HANDLE SERVICE – STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 11
TILLER HANDLE SERVICE – LONG HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
CONTROL CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
237
MIDSECTION
SERVICE CHARTS
SERVICE CHARTS
EXHAUST HOUSING, 40 – 60 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
238
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
239
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
240
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)
*
40 Ft. lbs.
(54 N·m)
120-144 In. lbs.
(13.5-16.5 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
241
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
242
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)
To Engine Key
Switch Connector
Connector
To Remote
Key Switch
11
Switched 12V
For CANbus
Stop Switch
To Engine Trim
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
243
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 from Tilt Tube Service Kit,
P/N 434523, onto the starboard end of the tilt
tube.
30746
Remove the cam and collar from the tilt tube.
Remove steering cable wiper nut from tilt tube.
Thread the adapter from Tilt Tube Service Kit,
P/N 434523, onto the port end of the tilt tube.
30748
30745
244
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 thread 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 bracket,
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 mallet to tap the tilt tube Replace steering cable wiper nut on port end of tilt
into position. tube.
30743
245
MIDSECTION
EXHAUST HOUSING, 40 – 60 HP
EXHAUST HOUSING,
40 – 60 HP
The exhaust housing contains no serviceable
internal parts. The exhaust water valve and the
exhaust relief muffler can both be serviced without
removing the exhaust housing.
1
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove the gearcase. Refer to Gearcase 1. Lower side mount 17524
GEARCASE REMOVAL AND INSTALLATION
on p. 292. Remove the three upper mount to exhaust hous-
• Remove the powerhead. Refer to Powerhead ing screws. Be sure to support exhaust housing
POWERHEAD REMOVAL on p. 194. 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.
246
MIDSECTION
EXHAUST HOUSING, 40 – 60 HP
Exhaust Water Valve (60 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 cover gasket
and install cover.
1. Fitting, water passage 004300 Apply Nut Lock to cover screws and tighten to a
torque of 60 to 84 in. lbs. (7 to 9.5 N.m).
Install hoses to fittings on exhaust housing. 11
Place water valve and bracket in position.
247
MIDSECTION
EXHAUST HOUSING, 40 – 60 HP
Exhaust Housing Installation Place lower thrust washer on the steering shaft
and place the lower front mount into position.
Bring the exhaust housing into position with the
stern bracket.
1 3
248
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
75 – 90 HP
Exhaust Housing Removal
Before removing the exhaust housing:
• Remove the gearcase. Refer to GEARCASE
REMOVAL AND INSTALLATION on p. 292.
• Remove the powerhead. Refer to POWER-
HEAD REMOVAL on p. 194.
20” Models
“ 23036
001971
25” Models
“ 32590 11
249
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
If removed, coat the lower mounts with soapy Exhaust Housing Installation
water and press into the exhaust housing with the
Bring the exhaust housing into position with the
“OUTSIDE” mark facing outward.
stern bracket.
001970
001972
25” Models 32590
250
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
1 1
1 1
11
2
251
MIDSECTION
EXHAUST HOUSING, 75 – 90 HP
Cleaning and Inspection Inspect the water tube for obstructions or kinks,
which may restrict water flow.
A WARNING
Exhaust Housing Assembly
Wear safety glasses to avoid personal
Place a new gasket between the exhaust mega-
injury, and set compressed air to less than
phone and adapter 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 nut and screw threads
coated with thread locking material must be thor- 1
oughly cleaned before assembly. When using a
thread locking product, be sure to prime the
threads with Locquic Primer. 2
Examine the upper and lower thrust mounts, and
replace if deteriorated or damaged.
1
Before checking the exhaust 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 exhaust housing for distortion. Place
the housing on a surface plate. Use a dial indica- Place a new grommet on the water tube and coat
tor to check 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 distorted exhaust housing will
cause the upper driveshaft splines to wear exces-
2
sively and will damage the crankshaft splines.
DR2223
252
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 housing. Install a new seal. Apply
Triple-Guard grease to outer seal surface.
001982
1. Seal 001973
Place a new gasket between the inner exhaust 2. Bottom flange
1 1
11
253
MIDSECTION
STERN BRACKET, 40 – 60 HP POWER TILT
17505
COA2957
COA2958
254
MIDSECTION
STERN BRACKET, 40 – 60 HP POWER TILT
To separate the swivel bracket from the stern Stern Bracket Assembly
bracket, remove one tilt tube nut.
Assemble the tie bar to the stern brackets. Place
the ground lead and starwasher between the port
stern bracket and tie bar.
17544
17541
17553
11
17551
17552
255
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
17506
30738
17507
17509
256
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Remove the steering shaft and thrust washer. It Remove the anode.
may be necessary to tap the steering shaft out
using a wood dowel and mallet.
1. Anode 30762
30765 / 30764
Remove the trim sender unit from the port stern
bracket and pull its wires through the braided
Remove the tilt tube. Refer to TILT TUBE, 75 – 90
tube.
HP on p. 244.
11
30760
30763
257
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Remove the tilt limit switch and retainer from the Remove the two trim rod rollers from the swivel
swivel bracket. bracket.
1
2
1
258
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 have been thoroughly cleaned.
Replace any seals that have been removed.
Inspect all thrust washers and bushings for evi-
dence of deterioration.
Install the detent roller and spring and the tilt sup-
port with bushing in the swivel bracket. Tighten
bushing to a torque of 28 to 30 ft. lbs. (38 to 41 1
N·m).
30752
11
2
1
259
MIDSECTION
STERN BRACKET, 75 – 90 HP POWER TILT
Install the tilt limit switch and retainer on the swivel • Coat the bushings and seal lips 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
260
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
1. Bumpers COA2949
30767 2
261
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Slide the pivot shaft and upper thrust washer out Loosen the steering friction screw while pushing
of the swivel bracket. outward on the steering friction pin. When the pin
is flush with the inside surface of the casting,
remove the steering friction thrust ring.
COA2958
1. Setscrews COA2961
262
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Drive the steering friction bushing up and out of Remove the two stern bracket flange screws and
the swivel bracket. separate the stern brackets from the swivel
bracket.
COA2974
1. Flange screws COA2992
Remove the thrust rod from the stern brackets.
Remove one tilt tube nut, and remove tilt tube Place the tilt/run lever in the RUN position.
from the stern brackets and swivel bracket. Loosen the bellcrank setscrew.
Remove the port and starboard 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 ing from the swivel bracket.
3. Stop link screw and nut
1
11
3
2
263
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Remove the starboard stop link retaining screw Stern Bracket Assembly
and nut from the swivel bracket.
Place the reverse lock springs in the swivel
bracket. Insert the reverse lock pins in the swivel
1 bracket and part way through 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
COA2980
264
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Install the bushing, the port 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. Install the two screws through the star-
1. Tilt/run lever 002204
2. Port stop link
board stern bracket flange into the port stern
3. Bushing bracket flange. Tighten the screws to a torque of
144 to 168 in. lbs. (16 to 19 N·m).
Install the wave washer and the 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
265
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Install and tighten the nut to a torque of 144 to 168 Place the steering friction bushing in the swivel
in. lbs. (16 to 19 N·m). bracket with groove in line with the setscrews.
1 2
266
MIDSECTION
STERN BRACKET, 40 HP MANUAL TILT
Install new upper and lower seals in the swivel Tilt Assist Cylinder
bracket with lips of seals facing away from the
The optional accessory tilt assist cylinder can be
bracket.
replaced without disassembly of the stern brack-
Slide the upper thrust washer on the pivot shaft. ets.
Slide the pivot shaft through the swivel bracket.
A WARNING
Support the outboard with a suitable hoist.
5 1 3
3
2 4 4
5
3
11
1. Bushings 003939
4 2. Washers
3. Pivot pin
4. Cotter pins
267
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
268
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
1
1. Electrical cover 002509
11
1
1. Screw 31194 1 2 3 2 1
1. Helix halves COA2674
2. Rollers
3. Guides
269
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
Pull the throttle pin out of the cable. Remove the throttle cable retaining clip. Pry the
cable trunnion out of the steering handle and
remove cable.
2 1
24294
1. Retaining clip 24286
Remove stop switch cover screws and cover/stop 2. Cable trunnion
switch assembly.
IMPORTANT: DO NOT remove the inner handle
except to replace it.
24288
270
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
outer handle. After removing, chip away remnants Install the metal outer handle over the plastic inner
of inner handle. handle and drive the outer handle into place.
24284
31202
Remove throttle cable seal from the inner handle.
Secure tab of the inner handle into recess of the
Inspection outer handle with the steel pin.
Inspect the throttle cable for kinks and wear.
Replace if necessary.
Inspect the steering handle components for wear,
cracks, or damage. Replace parts if necessary.
Assembly
Install the throttle cable seal in inner handle.
1
11
20849
271
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
Install the throttle control plate on outer handle. Be sure the twist-grip's speed indicator line is
positioned with the speed range symbol on the
1 handle. Snap the grip into place.
24294
24291
Lubricate end of the pin, guides, rollers, helix
grooves, and inner handle guide slot with Moly
Lube. Place the guides over the roller pin and into
the slots of the inner handle. Place the rollers on
the ends of the roller pin. Assemble the helix
halves on the handle and slide the grip over the
helix.
24288
24293
272
MIDSECTION
TILLER HANDLE SERVICE – STANDARD
A CAUTION
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. Electrical cover 002509
maintained in any position.
1
1
1. Screw 31194
273
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
274
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Remove the electrical cover. Remove the screws attaching tiller bracket to
steering arm. Remove tiller bracket and handle.
1. Screw 006362
275
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Remove stop switch cover screws, unplug stop Remove the helix halves, rollers, and guides.
switch electrical connector and remove stop
switch assembly.
1 2 3 2 1
1. Helix halves COA2674
2. Rollers
3. Guides
006713
006712
276
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Remove the throttle cable retaining clip. Pry the Use a wooden dowel and a soft mallet to remove
cable trunnion out of the steering handle and the inner handle.
remove cable.
1
006678
1. Retainer 006674
2. Throttle cable trunnion Remove shift cable retainer from shift cable trun-
nion.
The trim switch wiring can now be removed from
the inner handle. 1
Remove the screw and washer retaining the inner
handle tab.
277
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Remove shift handle screw and washer. Remove Inspect the shift cable for kinks and wear. Replace
shift handle, bushing and washer. if necessary.
1 Inspect the steering handle components for wear,
cracks, or damage. Replace parts if necessary.
Assembly
Apply Nut Lock to threads of shift 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
Inspection
Inspect the throttle cable for kinks and wear.
Replace if necessary.
278
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Coat bushing and washer with Triple-Guard Install shift cable retainer on shift cable trunnion.
grease. Apply Nut Lock to threads of screw.
1
1
006680
11
279
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
IMPORTANT: Turn self-tapping screw counter- Insert wire guide into inner steering handle.
clock-wise until threads of screw engage threads
1 2
of screw boss. Failure to follow this procedure will
damage the screw boss threads. Once threads
are engaged, tighten screw so that there is no
space between tab, washer and screw. Top of tab
MUST be flush with top of flange.
3
1. Inner tiller handle 006726
2. Wire guide
3. Trim switch wires
3
1. Inner tiller handle 006684
2. Wire guide
1. Throttle friction control 006671
3. Trim switch wires
280
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Make sure trim switch wiring is NOT twisted Lubricate end of the pin, guides, rollers, helix
before proceeding. halves, and inner handle guide slot with Moly
Lube.
1
3
1 2 3 2 1
1. Inner tiller handle 006675
2. Wire guide 1. Helix halves COA2674
3. Trim switch wires 2. Rollers
3. Guides
Install the handle end of the throttle cable. Snap
the throttle cable trunnion into the recess in the Place the guides over the roller pin and into the
handle. Install the retainer clip. slots of the inner handle. Place the rollers on the
ends of the roller pin.
1
1
Push the throttle cable pin through the end of the Assemble the helix halves on the handle and slide
throttle cable. the grip over the helix.
1
11
281
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
Carefully pull trim switch wires through inner tiller Install bottom cover of tiller handle with seven
handle as twist grip assembly is installed. screws.
1 1
1
1. Screw 006361
006713
282
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
1. Bracket 006314
2
1
1 11
1. Shift lever pin 002100
2. Trunnion nut
283
MIDSECTION
TILLER HANDLE SERVICE – LONG HANDLE
• Push the clip towards the hole while lifting on Install washer, cable anchor, and cable anchor
the curved end with the pliers. screw on throttle body boss. Tighten screw
• Be sure retainer clip fully engages the pin. securely.
• Lock the retainer by moving the angled section
behind the straight section.
4
1
2
1
3
284
GEARCASE
GEARCASE
TABLE OF CONTENTS
SERVICE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
GEARCASE TYPES, 75 – 90 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
PROPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
GEARCASE LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
SHIFT ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
PRE-DISASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
PROPELLER SHAFT BEARING HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
PINION GEAR AND DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
SHIFT HOUSING, GEAR AND PROPELLER SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
GEARCASE HOUSING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
SHIFTER, BEARING AND SEAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
DRIVESHAFT SHIMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
12
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
WATER INTAKE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
SHIFT HOUSING, GEAR, AND PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
SHIFT ROD HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
PINION GEAR AND DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
PROPELLER SHAFT BEARING HOUSING AND GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
FINAL ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
285
GEARCASE
SERVICE CHARTS
SERVICE CHARTS
40 – 60 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
286
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
287
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
288
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
289
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 Keeper – 120 to 144 in. lbs. (13.6 to
16.3 N·m)
290
GEARCASE
GEARCASE LEAK TEST
291
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE REMOVAL Remove the 5/16-18 x 1.25 in. screw and washer,
and remove 7/16-14 x 3.5 in. screw and washer.
AND INSTALLATION
Gearcase Removal
1
A WARNING 2
To prevent accidental starting while ser-
vicing, twist and remove all spark plug
leads.
During service, the outboard may drop
unexpectedly. Avoid personal injury;
always support the outboard’s weight with 1. 5/16-18 x 1.25 in. screw 001995
2. 7/16-14 x 3.5 in. screw
a suitable hoist or the tilt support bracket
during service.
Remove the four 3/8-16 x 1.5 in. gearcase retain-
ing screws and washers.
Remove pin and washer from shift rod lever to
release the lower shift rod.
1
1
292
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
2
1
30385
293
GEARCASE SERVICE, 40 – 60 HP MODELS
WATER PUMP SERVICE
Adjustment on p. 35.
WATER PUMP SERVICE
1
Disassembly
Remove the four impeller housing screws.
1
1
A WARNING
1. Impeller plate 001214
To prevent loss of operator control, check 2. Drive key
for proper shifting operation and adjust, if
necessary. Remove all the parts from the housing.
Inspection
IMPORTANT: During break-in period of a reas-
sembled gearcase, change the gearcase lubricant Check impeller for overheating, hub separation,
between 10 to 20 hours of operation. and other wear or damage.
294
GEARCASE SERVICE, 40 – 60 HP MODELS
WATER PUMP SERVICE
1. Impeller 001216
2. O-ring seal
3
1
1
Lightly coat the inside of the liner with Triple- The sharp edge of the key is the leading edge in
Guard grease. With a counterclockwise rotation, clockwise rotation.
install the impeller into the liner with the slot for the
impeller key facing out. Slide the water pump down the driveshaft. Align
impeller slot with the impeller key. Rotate the
driveshaft to engage the key with the impeller, and
12
295
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFT ROD ADJUSTMENT
296
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE DISASSEMBLY
297
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE DISASSEMBLY
Propeller Shaft Bearing Housing Remove the two retaining rings using Retaining
Ring Pliers, P/N 331045.
Removal
Use a 5/16 in. thin wall socket to remove the four A CAUTION
screws with O-rings holding the propeller shaft
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
298
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE DISASSEMBLY
Remove the larger thrust washer, thrust bearing, Remove the four driveshaft bearing housing
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
1. Larger thrust washer COA3514 Remove the driveshaft from the gearcase. The
2. Thrust bearing
3. Reverse gear bearing housing, shims, thrust bearing, and thrust
washer will come out with the driveshaft.
Pinion Gear and Driveshaft
Removal
1
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
2
Use Driveshaft Holding Socket, P/N 334995, and 4
an 11/16 in. open-end wrench to loosen and
remove the pinion nut from the bottom of the 3
driveshaft. Pad handle of the wrench to prevent
damage to gearcase. 1. Bearing housing COA3558
2. Shims
3. Thrust bearing
4. Thrust washer
1
If driveshaft cannot be removed, refer to Locked
Driveshaft Removal on p. 300.
Remove the pinion gear from the gearcase.
12
1. Holding socket COA3573T
2. 11/16 Wrench
COA3159
299
GEARCASE SERVICE, 40 – 60 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
300
GEARCASE SERVICE, 40 – 60 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 are different sizes and
Use a 3/4 in. wrench to turn flange nut clockwise cannot be interchanged.
and draw the bearing up from the housing.
301
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Place the bearing on the installer tool with the let- unwrapping it from around the clutch dog. Dis-
tered side of the bearing facing the top of the card the spring.
gearcase. Use Needle Bearing grease to hold the
bearing on the tool.
Wear safety glasses to avoid injury. Remove the gear, thrust bearing, and thrust
washer from the shift housing.
IMPORTANT: The shift housing and forward
gear bearing are serviced as an assembly. If
either are worn or damaged, replace the complete 1
assembly.
1. Gear COA3562
2. Thrust bearing
3. Thrust washer
302
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Remove the shift lever pin from the housing. Shift Housing Assembly
Remove shift shaft, cradle and shift lever. Move
shifter detent as needed to help ease removal of IMPORTANT: Clean and inspect all parts before
parts. beginning assembly procedures. Replace any
damaged parts.
5 4 Lightly coat the detent ball and spring with Needle
Bearing grease. Insert the spring in the housing,
then the ball.
3
1
2
A WARNING
Wear safety glasses to avoid personal
injury. The detent ball and spring and 4518
DSC02506
303
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
With shifter detent in NEUTRAL, install arms of Coat thrust bearing and thrust washer with Needle
shift lever into detent slots. Align the pivot holes Bearing grease. Place the bearing on the back of
and insert the retaining pin. Push shifter detent the gear. Set the washer on top of the thrust bear-
down. ing. Insert the gear, bearing, and washer into the
bearing housing.
1 3
2
1
1. Grooved end COA3591
001219
304
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Slide the propeller shaft onto the shift shaft, align Clean the bearing housing in solvent to remove
the hole in the shaft with the hole in the clutch sealer from the seal bore and the O-ring groove.
dog, install the pin and then, a new clutch dog
retaining spring. Place three coils over each end 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
305
GEARCASE SERVICE, 40 – 60 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Propeller Shaft Bearing Housing port the bridge, and tighten jaws securely behind
the bearing.
Service
Rear Seal Removal
Remove seals using Puller Bridge, P/N 432127,
and Large Puller Jaws, P/N 432129. Place the
plate on top of the housing to support the bridge,
and tighten jaws securely behind the inner seal.
21067
21045
306
GEARCASE SERVICE, 40 – 60 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 installer, then press the bearing into the Seal Installation Tool:
housing until the tool seats. When installed, 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
307
GEARCASE SERVICE, 40 – 60 HP MODELS
DRIVESHAFT SHIMMING
Lightly coat the threads of the pinion nut with out- Rotate the driveshaft several revolutions to seat
board lubricant and tighten to a torque of 40 to 45 bearings.
ft. lbs. (54 to 60 N·m).
Lay the tool base on its side. Place the shim
IMPORTANT: The original 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
308
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE ASSEMBLY
1
005417
2
Remove the nut and pinion from the driveshaft. 12
Discard the nut.
1. O-ring 006649
2. Groove
309
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE ASSEMBLY
Apply Triple-Guard grease to the threaded end of Place the cover seal on the shift rod cover.
the shift rod and 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
310
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE ASSEMBLY
the driveshaft bearing housing. Do not coat inside Lightly coat the threads 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 hand to thread the nut on to
shaft.
6207
12
311
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE ASSEMBLY
Use Driveshaft Holding Socket, P/N 334995, and assembly onto the propeller shaft until it engages
an 11/16 in. open-end wrench, to tighten the pin- the pinion gear.
ion nut to a torque of 40 to 45 ft. lbs. (54 to 60s
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 install thrust bearing and larger thrust
washer on hub of reverse gear. Slide the gear
312
GEARCASE SERVICE, 40 – 60 HP MODELS
GEARCASE ASSEMBLY
Make sure the retaining rings are seated in the Install O-ring in groove in the bearing housing.
grooves in the gearcase. Lightly apply Gasket Sealing Compound to the
O-ring flange and aft support flange of the bearing
housing. Do not allow sealer to contact either for-
ward thrust surface or bearings in the housing.
12
313
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL AND INSTALLATION
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE REMOVAL Remove the 3/8-16 in. screw and washer, and
remove 7/16-14 x 3.5 in. screw and washer.
AND INSTALLATION
1
Gearcase Removal
A WARNING
To prevent accidental starting while ser-
vicing, twist and remove all spark plug
leads.
During service, the outboard may drop 2
unexpectedly. Avoid personal injury;
always support the outboard’s weight with
O Type Gearcases 006869
a suitable hoist or the tilt support bracket 1. 3/8-16 x 3.5 in. screw
during service. 2. 7/16-14 x 3.5 in. screw
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
314
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 place the housing on the
gearcase.
2
1
12
1. 3/8 in screw COA3139
2. 7/16 in. screw
315
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 water pump off the driveshaft. Remove
retaining pin and washer. Tighten pin to a torque the impeller key, O-ring, impeller plate, and gas-
of 60 to 84 in. lbs. (7 to 9.5 N·m). ket. Discard the gasket.
2
1
1
316
GEARCASE SERVICE, 75 – 90 HP MODELS
WATER PUMP SERVICE
1. O-ring 34814 Lightly coat the inside of the liner with Triple-
Guard grease. With a counterclockwise rotation,
Lightly coat the exterior rim of the impeller cup install the impeller into the liner with the slot for the
with Gasket Sealing Compound. Install the cup in impeller key facing out.
the impeller housing. The cup locks in place in the
housing with a square index tab. 12
Make sure vent hole in impeller cup is open.
317
GEARCASE SERVICE, 75 – 90 HP MODELS
WATER PUMP SERVICE
Apply a thin bead of Adhesive 847 in the seal 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 sides 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 grease to a new impeller O- Align the impeller housing with the gearcase.
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 housing screws. Install 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, place water tube spacer and
grommet on the impeller housing cover.
3
2
1
2
4 1
Slide the water pump down the driveshaft. Align NOTICE Before installing gearcase, shift rod
impeller slot with the impeller key. Rotate the
adjustment MUST be checked. Refer to SHIFT
driveshaft to engage the key with the impeller, and
ROD ADJUSTMENT on p. 319.
318
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFT ROD ADJUSTMENT
COA6166
12
319
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
320
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 two screws, washers, and retainers
holding the propeller shaft bearing housing.
22775
Remove wedge, screw, and washer (“O” Type). Pinion Gear and Driveshaft
Removal
Adjust the shift rod to move the clutch dog as far
forward as possible. This will help ease removal of
the pinion nut.
DSM02291 1
DSC02361
321
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 Driveshaft Puller,
3 P/N 342681, to remove. Install puller into lower
driveshaft and turn 90° to position hook under pin
1. Bearing housing COA3558
2. Shims
in driveshaft. Thread Slide Hammer, P/N 391008,
3. Thrust bearing into puller and remove driveshaft.
4. Thrust washer
46905
COA3159
322
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE DISASSEMBLY
0.125 in.
(3.2 mm)
1
1. Roll pin DR4610
29338
12
29330
323
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE HOUSING INSPECTION
004315
1
1. Gauging shaft 004347
324
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
325
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. Apply Gasket Sealing Compound to O-
1 ring. Apply Nut Lock to screw threads. 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 different sizes and 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 and insert them into the bearing case (“O” serviced as an assembly. If either are worn or
Type gearcases). damaged, replace the complete assembly.
Place the bearing on the installer tool with the let- Insert a suitable tool under one end of the clutch
tered side of the bearing facing the top of the dog spring and remove it from its groove by
gearcase. Use Needle Bearing grease to hold the unwrapping it from around the clutch dog. Dis-
bearing on the tool. card the spring.
326
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Push the pin out of the clutch dog. Remove all shifter detent as needed to help ease removal of
parts. parts.
5 4
3
1
2
2
1. Gear COA3562
2. Thrust bearing
3. Thrust washer 1
Remove the shift lever pin from the housing.
Remove shift shaft, cradle and shift lever. Move
327
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
4520
4518
DSC02506
TYPICAL 4512
1. Cradle
2. Shift shaft
328
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 detent back up to NEU- peller shaft. Install the clutch dog on the shaft with
TRAL position to hold the cradle and shaft in “PROP END” facing rear of the shaft.
place.
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
329
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 bearing housing assembly if the bearing is
worn or damaged. Also, inspect the driveshaft
bearing surface if the bearing is damaged.
1
Seal Removal
Remove the driveshaft bearing housing seals
using Puller Bridge, P/N 432127, and Large Puller 2
Jaws, P/N 432129. Discard the seals.
330
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
Propeller Shaft Bearing Housing Inspect the bearing housing anode. Replace
anode if it is reduced to two-thirds of original size.
Service Tighten screws to a torque of 108 to 132 in. lbs.
Rear Seal Removal (12 to 15 N·m).
Remove seals using Puller Bridge, P/N 432127,
and Small Puller Jaws, P/N 432131. Place the
plate on top of the housing to support the bridge, 1
and tighten jaws securely behind the inner seal.
1. Anode 001220
12
13522
331
GEARCASE SERVICE, 75 – 90 HP MODELS
SHIFTER, BEARING AND SEAL SERVICE
332
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 bearing housing mount-
IMPORTANT: The original 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 rotating just the bearing hous-
assembly. ing. Use a feeler gauge to measure clearance
333
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Check clearance again. The measurement Be sure the thrust bearing and the thrust washer
between the gauge bar and pinion should be are in the proper position. Insert the shaft assem-
0.020 in. (0.508 mm). bly fully into the gearcase while aligning shift
housing pin with hole in forward end of gearcase
housing.
005417
334
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 shift rod cover O-ring with Triple-
the gearcase.
Guard grease. Install the O-ring into the shift rod
cover. Thread the shift rod into the shifter detent about
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 threaded end of
the shift rod and insert it through the cover. Turn
the shift rod while pushing it through the cover to
Refer to SHIFT ROD ADJUSTMENT on p. 319. 12
avoid damaging the O-ring.
335
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Pinion Gear and Driveshaft IMPORTANT: The inside taper of the pinion
gear and the driveshaft taper MUST be com-
Installation pletely free of grease. Clean the tapers with
Refer to DRIVESHAFT SHIMMING on p. 333 Cleaning Solvent. Use a shop towel free of grease
before proceeding. and lint.
Install new seals in driveshaft bearing housing. Place the pinion gear into the gearcase. Insert the
Refer to Driveshaft Bearing Housing Service on driveshaft into the gearcase and through the pin-
p. 330. ion gear.
Place the driveshaft thrust bearing, thrust washer, Lightly coat the threads 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 hand to thread the nut on to
shaft.
3
1
2
1 1
336
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 Holder, P/N 334455, and Wrench bearing housing O-ring. Install O-ring in groove in
Retainer, P/N 341438, to tighten the pinion nut to the housing.
a torque of 100 to 110 ft. lbs. (136 to 149 N·m).
Pad handle of holder to prevent damage to Install housing into gearcase. Align screw holes
gearcase. with retainer slots in gearcase.
1
2
12
337
GEARCASE SERVICE, 75 – 90 HP MODELS
GEARCASE ASSEMBLY
Install wedge, screw, and washer. Apply Ultra Confirm that torque on the wedge screw is 15 to
Lock to threads and tighten screw to a torque 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. 291
• WATER PUMP SERVICE on p. 316
• SHIFT ROD ADJUSTMENT on p. 319
• GEARCASE REMOVAL AND INSTALLATION
on p. 314
• Gearcase Lubricant on p. 43
• Propeller Hardware Installation on p. 290
• Trim Tab Adjustment on p. 35.
DSM02291
During break-in period of a reassembled
DSC02361 gearcase, change the gearcase lubricant between
10 to 20 hours of operation.
338
TRIM AND TILT
13
339
TRIM AND TILT
SERVICE CHARTS
SERVICE CHARTS
40 - 60 HP MODELS
30 to 50 in. lbs.
(4 to 5.6 N·m)
60 to 85 ft. lbs.
(82 to 115 N·m)
45 to 55 in. lbs.
(5 to 6 N·m)
W
45 to 55 in. lbs.
(5 to 6 N·m)
E
A 60 to 85 ft. lbs.
(82 to 115 N·m)
A Triple-Guard Grease
E Red Ultra Lock
008842 W Biodegradable TNT Fluid
340
TRIM AND TILT
SERVICE CHART
SERVICE CHART
75 - 90 HP MODELS
30 to 50 In. lbs.
(4 to 5.6 N·m)
60 to 85 ft. lbs.
(82 to 115 N·m)
45 to 55 In. lbs.
(5 to 6 N·m) W
E
60 to 85 ft. lbs.
(82 to 115 N·m)
45 to 55 In. lbs.
(5 to 6 N·m)
A
E
84 to 106 in. lbs.
(9.5 to 12 N·m)
13
A Triple-Guard Grease
E Red Ultra Lock
008841 W Biodegradable TNT Fluid
341
TRIM AND TILT
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION
The power trim/tilt hydraulic system is completely
contained between the outboard's stern brackets.
342
TRIM AND TILT
SYSTEM DESCRIPTION
13
343
TRIM AND TILT
ROUTINE INSPECTIONS
344
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
13
345
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
Test results include three basic possibilities: Monitor motor RPM and current draw.
IMPORTANT: Securely fasten motor in a suit- The motor shaft must rotate counterclockwise, as
able fixture before proceeding with this test. viewed from the pump end, when positive (+) 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, ammeter red lead
toward terminal.
DR4238r
346
TRIM AND TILT
ELECTRICAL CIRCUIT TESTS
DRC6245
STEP 2
Remove the white/tan lead from the trim gauge
“S” terminal. With key switch ON, gauge should
indicate full-trim DOWN position. Now connect a
jumper wire between terminals “S” and “G.” Gauge
should indicate full-trim UP position.
• If results are different, replace the trim gauge.
• If results agree, refer to Trim Sender Test. DRC6247
DRC6246A
13
347
TRIM AND TILT
TRIM AND TILT REPLACEMENT
TRIM AND TILT Separate the trim/tilt unit wires in the braided tube
to permit removal through the hole in the stern
REPLACEMENT bracket.
Removal
Raise the outboard and engage the tilt support.
25078
40 – 60 HP MODELS
Remove the spring clip from the cylinder pin.
000686
15493
348
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 rod. Remove the rod from the stern brack-
ets.
25065
25077
25076
25064
13
349
TRIM AND TILT
TRIM AND TILT REPLACEMENT
Remove the unit from the stern brackets far Lubricate the angle adjustment rod 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
350
TRIM AND TILT
TRIM AND TILT REPLACEMENT
25079
25064
13
351
TRIM AND TILT
TRIM AND TILT SERVICE
TRIM AND TILT SERVICE Screw the manual release valve in. Remove the
retaining ring using a small pick or screwdriver.
Thoroughly clean the unit before disassembling. Discard the retaining ring.
Scrub all outside surfaces with a stiff brush and
hot, soapy water to prevent surface dirt from con-
taminating internal parts.
352
TRIM AND TILT
TRIM AND TILT SERVICE
Slowly remove the manual release valve. There Tighten the valve to a torque of 45 to 55 in. lbs. (5
may be pressure behind the valve—wear safety to 6 N·m).
glasses.
40 - 60 HP Models 002529
40 - 60 HP Models 002529
75 - 90 HP Models 004285
75 - 90 HP Models 004285
Install new retaining ring in groove.
Inspect the manual release valve. Discard the O-
rings on the housing.
007108
1. Retaining ring 002534
Oil O-rings and install them on the manual release
valve. Oil and install the manual release valve.
13
353
TRIM AND TILT
TRIM AND TILT SERVICE
Piston Seal and End Cap Drain remaining trim and tilt fluid from the cylinder
of the trim and tilt assembly.
Trim and Tilt Seal Tool Kit, P/N 5008918, is
required for service of the piston and end cap Use hydraulic cylinder rod holder set, P/N 983213
assemblies. to hold the rod in a vice as shown.
Removal Remove fastener and washer from piston assem-
Refer to Removal on p. 348 for trim and tilt bly.
assembly removal procedure.
Note: Use spanner wrench, P/N T-552, to remove
Dissassembly fastener from piston of trim and tilt assembly,
Place the trim and tilt assembly in a holding fix- P/N 5005756.
ture. Be sure the rod is fully extended. Remove 3 2
the fill plug.
Drain trim and tilt fluid from the trim and tilt assem-
bly.
1
1
1. Hydraulic cylinder rod holder set 008818
2. Fastener
3. Washer
354
TRIM AND TILT
TRIM AND TILT SERVICE
Remove seal and o-ring from the piston. NOTICE Use of damaged components can
result in leaks or incorrect operation of trim
1 and tilt assembly.
Assembly
2 IMPORTANT: Always use the correct trim/tilt
fluid. Some trim and tilt assemblies use Power
Trim/Tilt and Steering Fluid, and some use
Evinrude/Johnson Biodegradable Trim/Tilt Fluid.
Refer to the correct service manual.
40 – 60 HP MODELS
1. Seal 008820 Install a new o-ring into the piston. Refer to SER-
2. O-ring
VICE CHARTS on p. 340.
Remove the piston from the rod.
2. O-ring 008823
Inspection
Remove ALL debris. Thoroughly clean and dry all
1
parts before continuing. Remove ALL old thread
locking compound from threaded parts.
355
TRIM AND TILT
TRIM AND TILT SERVICE
NOT damaged or twisted. Remove and reinstall Assemble the piston as shown in the SERVICE
the o-ring correctly if necessary. CHARTS on p. 340.
1. O-ring 008825
rod.
Apply trim/tilt fluid to the inside diameter of the
resizing fixture. Place the resizing fixture over the
piston with the tapered end up. Slide the resizing
fixture down past the piston.
008826
356
TRIM AND TILT
TRIM AND TILT SERVICE
chart. Part number is stamped on the bottom of Place the loading mandrel, on the piston. Make
the housing of trim and tilt assemblies. sure the edge of the loading mandrel is flush with
the top edge of the seal groove in the piston.
1. Shim 008830
008832
13
357
TRIM AND TILT
TRIM AND TILT SERVICE
Place the seal on the loading mandrel. Lift the resizing fixture up over the piston as
shown.
1. Seal 008833
1. Resizing fixture 008835
Slowly move the seal pusher down the mandrel.
Use the seal pusher to slide the seal into the Lift resizing fixture over the seal while observing
groove of the piston. the seal. Use a blunt edged tool to hold the seal in
position if any portion of the seal moves out of the
IMPORTANT: Prevent the seal from sliding past groove of the piston.
the seal groove. Position one hand even with the
bottom of the seal groove as shown. The seal can
be damaged if it slides past the seal groove.
1. Tool 008836
1 2. Seal
1. Seal installed in groove of piston 008834 Continue lifting the resizing fixture until the bottom
of the resizing fixture is flush with the piston as
Remove the pusher tool, loading mandrel, and shown.
shim from the piston.
358
TRIM AND TILT
TRIM AND TILT SERVICE
Leave the resizing fixture in place for at least five cylinder could cause difficulty purging air from the
minutes. trim and tilt assembly.
2
1. Bottom of the resizing fixture flush with the piston 008837 008839
2. Piston
008840
1. Seal 008838
359
TRIM AND TILT
TRIM AND TILT SERVICE
002533
40 - 60 HP Models 002531
Position the motor on the manifold and install four
new screws and lock washers. Tighten the screws
35 to 50 in. lbs. (4 to 5.6 N·m).
75 - 90 HP Models 004282
75 - 90 HP Models 004282
002532
360
TRIM AND TILT
TRIM AND TILT SERVICE
40 - 60 HP Models 007646
75 - 90 HP Models 004278
13
361
TRIM AND TILT
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
362
MANUAL STARTER
MANUAL STARTER
TABLE OF CONTENTS
SERVICE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
RECOIL STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECOIL STARTER CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
RECOIL STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
RECOIL STARTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
14
363
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)
364
MANUAL STARTER
RECOIL STARTER REMOVAL
Remove the clamp holding the oiling system wir- Pull the starter rope out far enough to tie a slip
ing harness. knot in the rope. Remove the end of the starter
rope from the handle anchor and remove the han-
Remove the three starter 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)
1
1
2
1. Ratchet 006483
1. Rope guide 007854
2. Pulley support
14
365
MANUAL STARTER
RECOIL STARTER DISASSEMBLY
Remove the nut from the starter pawl retaining 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 starter over, legs down. Hold fingers clear of
3. Plate
4. Spring the pulley and jar the starter housing against a
bench to dislodge the rewind spring and pulley.
Remove starter housing spring and starter pawl 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)
366
MANUAL STARTER
RECOIL STARTER CLEANING AND INSPECTION
2
1
1. Base CO3593
2. Plate
14
367
MANUAL STARTER
RECOIL STARTER ASSEMBLY
Apply Triple-Guard grease or Lubriplate 777 to the Install the rewind spring into the starter housing.
rewind spring. Install the rewind spring into the Locate the outer loop of the rewind 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 transfer the
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. Install the pulley bushing 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
368
MANUAL STARTER
RECOIL STARTER ASSEMBLY
inner loop of the spring in the slot of the pulley, Place the starter housing spring in the starter
and install the pulley in the starter housing. housing.
2
2
1 3
1
2
14
369
MANUAL STARTER
RECOIL STARTER ASSEMBLY
Install the starter pawl plate retaining screw and If removed, install the starter handle bracket to the
washer into the 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
370
MANUAL STARTER
RECOIL STARTER INSTALLATION
007858
2
1
1
14
371
MANUAL STARTER
NOTES
NOTES
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
372
SAFETY
SAFETY
TABLE OF CONTENTS
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM . . . . . . . . . . . . . . . . . . . . . . . . 3
OUTBOARD SHIFT SYSTEMS AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OUTBOARD SPEED CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OUTBOARD STEERING CONTROL SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OUTBOARD FUEL, ELECTRICAL SYSTEM, AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OUTBOARD MOUNTING SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IF WEAKENED, PARTS COULD FAIL LATER ON THE WATER, WHEN NOT EXPECTED . . . . . . . . . . . . . . . . . . . 12
OUTBOARD HYDRAULIC TILT/TRIM SHOCK ABSORPTION SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . 13
OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SUMMING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM . . . . . . . . . . . . . . . . . . . . . . . . 17
HANDLING OUTBOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HANDLING LEAD/ACID BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GASOLINE – HANDLE WITH CARE! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HAZARDOUS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SAFETY AWARENESS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
S–1
S–2
SAFETY
Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manu-
facturers are careful to make sure:
• Product user is informed; and
• Products are safe and reliable.
It is up to you, the people who...
• Rig boats;
• Fix machinery; and
• Maintain equipment
...to keep the products safe and reliable.
This section talks about safe boating and how you can help make it safe. Some of these safety issues
you will know, others you may not.
First!
A word about parts... Plain parts; special parts; all parts!
Second!
• Special locking bolts and nuts are often used to hold steering, shift, and throttle remote control
cables to the outboard.
• When you take any outboard off a boat, keep track of special nuts and bolts. Do not mix with other
parts. Store them on the outboard, then they are there when you need them.
• When the outboard is returned to the boat, use only the special nuts and bolts to hold remote steer-
ing, shift, and throttle cables to the outboard.
S–3
SAFETY
IF... IF...
NEUTRAL FORWARD
S–4
SAFETY
If Operator cannot slow down the outboard or shift into NEUTRAL gear (stop propeller), Operator
could panic and lose control of boat.
S–5
SAFETY
• If steering system comes apart, boat might turn suddenly and circle. Persons thrown into the water
could be hit.
S–6
SAFETY
Replace damaged parts. If weakened, parts could fail later on the water when least expected.
S–7
SAFETY
• When not boating, fuel leaking in car trunk or van, or place where portable tank is stored (base-
ment or cottage), could be ignited by any open flame or spark (furnace pilot light, etc.).
• When boating, fuel leaking under the engine cover could be ignited by a damaged or deteriorated
electrical part or loose wire connection making stray sparks.
GA
S
Remember:
S–8
SAFETY
If electrical parts are replaced or even removed from the outboard, check the following:
Wire and high voltage lead routing
• As shown in service manual
• Away from moving parts which could cut wires or wire insulation
• Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads
Sleeves, boots, shields
• In position (to avoid shock hazard)
• Not torn or cracked
Spark Plugs
• Avoid rough handling that
could crack ceramic part of
plug. (Sparks may jump
across outside of plug.)
In transom area:
All Connections
• Clean Electric Cable
• Tight • Not rubbing on sharp objects
(Prevents sparks) • Enough slack to allow full turn-
ing without pull loads on cable
(prevents sparks)
Batteries
• Secure in approved battery
box or battery tray
• Battery terminals insulated
• No strain on cables
S–9
SAFETY
After repair on any part of the fuel system, pressure test engine portion of fuel system as shown:
When Storing:
Squeeze until
bulb feels hard
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 carbon
monoxide (CO), which is odorless, colorless, and tasteless, and can lead to unconsciousness, brain
damage, or death if inhaled in sufficient concentrations. CO accumulation can occur while docked,
anchored, or underway, and in many confined areas such as the boat cabin, cockpit, swim platform,
and heads. It can be worsened or caused by weather, mooring and operating conditions, and other
boats. Avoid exhaust fumes from the engine or other boats, provide proper ventilation, shut off the
engine when not needed, and be aware of the risk of backdrafting and conditions that create CO accu-
mulation. In high concentrations, CO can be fatal within minutes. Lower concentrations are just as
lethal over long periods of time.
S–19
SAFETY
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 charger plug out of 110 V
posts. You will make sparks and outlet
serious burns are possible. • Take charger cables off battery
posts
S–21
SAFETY
20
Parts By
Air Volume
• Always store gasoline outside in a safe can (flame arrester and pressure relief valve in pour spout).
• Fill portable tanks outside of boat. Spillage will collect in bottom of boat.
• Use fuel as fuel ONLY, not for a cleaner or degreaser.
• If fumes are smelled in shop, basement, or garage, immediately:
– Put out open flames, cigarettes, sparking devices;
– Wipe up spill or leak;
– Get towels and rags outside fast;
– Open doors and windows; and
– Check lowest area for fumes.
Be aware of items in and around repair area which can ignite fumes. Control them if fumes are smelled.
• Matches, cigarettes, blow torches, welders
• Electric motors (with unsealed cases)
• Electric generators (with unsealed cases)
• Light switches
• Appliance pilot lights or electric ignitors (furnace, dryer, water heaters)
• Loose wires on running outboards
• Other variables which may ignite fumes
S–22
SAFETY
Hazardous Products
READ
• “How and where to use”
• “How to give First Aid.” Have recommended First Aid materials on hand should an
emergency arise
• “How to dispose of can”
And remember: Little children are very curious and will try to taste
everything so keep containers away from children!
S–23
SAFETY
2) Are you ready to take responsibility for the safe maintenance practices and proce-
dures of your repair shop, co-workers, and technicians?
3) Do you understand all the safety precautions and instructions contained in this entire
service manual?
4) Will you follow all safety warnings, precautions, instructions and recommendations
outlined in this service manual?
5) Do you understand that the service manual as a whole and this Safety section, in par-
ticular, contain essential information to help prevent personal injury and damage to
equipment and your customers?
6) Have you received training related to common shop safety practices to protect your-
self and others around you?
7) When replacement parts are required, will you use Evinrude ®/Johnson ® Genuine
Parts or parts with equivalent characteristics, including type, strength and material?
8) Are you ready to follow the recommendations in this service manual before you ser-
vice any boat or outboard?
S–24
INDEX
INDEX
A Pinion Gear 301, 325
Abbreviations 6 Propeller Shaft 306, 331, 332
Accessories Wrist Pin 201, 209
Battery Cable, P/N 584348 68 Break-In
XD100 Outboard Oil Decal, P/N 352369 EMM Programming 169, 224
168 Gearcase 294, 313, 316, 338
Adjustments Oiling 169
Control Cable 23, 273, 283 Procedure 71
Shift Linkage 224
Shift Rod 11, 13, 15, 296, 319 C
Steering Friction 31 Capacitor Test 87
Throttle Friction 31 Clamp Screw 261
Tilt Limit Switch 32 Connecting Rods
Timing Pointer 117 Installation on Crankshaft 213
TPS Calibration 118 Installation on Piston 209
Trim Sending Unit 33, 34 Orientation 209, 213
Trim Tab 35 Removal from Crankshaft 200
Air Silencer 47 Removal from Piston 201
Air Temperature Sensor TIghtening 213
Connections 96 Control Cable
Description 61 Adjustments 23
Resistance Test 100 Installation 23
Alternator Circuit Test 103 Cooling System
AMP Connector Servicing 121 Adapter Housing 181
Anodes Components 180
Anti-Corrosion 48 Cylinder Block Venting 182
Continuity Check 48 EMM and Vapor Separator Cooling 183
Gearcase 297, 320 Engine Temperature Check 184
Propeller Shaft Bearing Housing 306, 331 Exhaust Housing 180
Stern Bracket 255, 257, 260 Flushing 39
Hose Routing and Water Flow 178
B Operating Temperatures 11, 13, 15, 38
Batteries Operation 183
Charging System Tests 102 Pressure Relief Valve 181, 187
Connections 28 Running on a hose 40
Maintenance 28 Thermostat 11, 13, 15, 181
Requirements 11, 13, 15 Thermostats 181, 186
Storage 50 Vapor Separator 137
Bearing Water Intake Screens 38, 301, 324, 334
Connecting Rod 213 Water Pump 180, 294, 316
Crankshaft 202, 203, 207, 208 Water Supply Tube 180, 251, 252
Driveshaft 305, 330 Corrosion
I–1
INDEX
Anodes 48, 255, 257, 260, 297, 306, 320, 331 Oiling Rate 70, 168
Cylinder walls 204 Reports 73
Long Term Storage 49 Sensor Monitoring 99
Metal components 48 Service Codes 69
Steering Cable 41 Static Ignition Test 85
Cover Service 54 Timing Verification 71, 118
Crankcase TPS Calibration 72, 118
Assembly 215 Driveshaft
Disassembly 199 Installation 310, 336
Crankshaft Removal 299, 321
Assembly 207, 212 Service 323
Disassembly 201 Shimming 308, 333
Inspection 205 Driveshaft Bearing Housing 305, 330
Crankshaft Position Sensor Dual-Outboard
Description 63 Alignment 36
Operation Test 84 I-Command settings 27
Resistance Test 99
Cylinder Bore E
Honing 204 Electrical Circuits
Inspection 205 EMM Pin Locations 96
Cylinder Head Fuse 98
Inspection 205 Ground Circuits 98
Installation 211 Key Switch 106
Removal 200 Start Circuit 104
SystemCheck 111
D Electrical Connectors
Deutsch Connector Servicing 120 AMP Connectors 121
Diagnostic Procedures Deutsch Connectors 120
Dynamic Tests 80 Packard Connectors 123
Fuel Delivery Tests 88 Electrical Harness
Ignition Tests 83 Connections 24, 25
LED Indicators 81 Emergency Stop Switch
Strategy 78 Operation Check 37
Diagnostic Software Test 109
Break-In Programming 169 Emissions Information 7
Communication With Outboard 67 EMM
Crankshaft Position Sensor 84 12 V Circuit Sensor 60
Cylinder Drop Tests 80 Connections 58, 59, 96
Diagnostic Procedures Overview 78 Diagnostics 67, 78
Fuel Injector Programming 72, 150 Functions 58, 64
Fuel Injector Tests 88 LED Indicators 81
Fuel Pump Test 88 Sensors 60, 61
I-Command settings 27 Service Codes 69
Idle Speed Control 72 Servicing 74
Oil Injector Test 171 Software Replacement 73
Oil Priming 174 Timing Verification 118
I–2
INDEX
I–3
INDEX
I–4
INDEX
Installation 210 S
Removal 201 S.A.F.E.
Pistons Description 66
Assembly 209 Low Oil 62
Inspection 206 No Oil 166
Installation 210 Temperature 60, 61
Removal 200 Safety 1
Powerhead Sensor Tests 99
Assembly 207 Sensors
Cleaning 204 Air Temperature Sensor 61, 100
Cylinder Compression Testing 194 Barometric Pressure Sensor 61
Disassembly 197 Crankshaft Position Sensor 63, 84, 99
Inspection 205 EMM 60
Installation 220 Engine Temperature Sensor 61, 100, 186
Removal 194 Throttle Position Sensor 63, 99
Predelivery Checks 37 Service Charts
Pre-Season Service 50 Electrical and Ignition 92
Pressure Relief Valve Fuel System 126
Assembly 188 Gearcase 286
Disassembly 187 Manual Starter 364
Inspection 188 Midsection 238
Priming Oiling System 158
Fuel System 140 Shift Cable Adjustment, Tiller 283
Propeller Shift Housing
Inspection 289 Assembly 303, 328
Installation 290 Installation 309, 334
Selection 289 Removal 300, 324
Propeller Shaft Shift Linkage
Installation 309, 334 Adjustment 224
Lubrication 43 Installation 216
Removal 300, 324 Lubrication 42
Propeller Shaft Bearing Housing Removal 198
Disassembly 306, 331 Shift Rod
Installation 312, 337 Housing Installation 335
Removal 298, 321 Shift Rod Adjustment 11, 13, 15, 296, 319
Shimming, Driveshaft 308, 333
R Shutdown 66
Relays No Oil 166
Trim and Tilt 110, 345 Spark Plugs
Remote Controls Gap 11, 13, 46
Cable Adjustment 23 Indexing 46
Rigging Maintenance Schedule 20
Outboard 21 Recommendation 11, 13, 15, 46
Rope Replacement 370 Removal 46
RPM Limit 11, 13, 15, 63, 64 Replacement 46
Service 46
I–5
INDEX
Specifications 10, 12 T
Starter Tachometer
Assembly 367 Pulse Setting 38
Circuit Description 104 Technical Data 10, 12
Current Draw Test 107 Temperature
Installation 119, 371 Operating 38, 184
Removal 119 Operation below freezing 164
Rope Replacement 370 Sensors 61
Solenoid Test 106 Temperature Sender
Voltage Drop Test 107 Service 186
Start-In-Gear Protection 37 Thermostat
Stator Assembly 187
Resistance Test 101 Description 181
Service 115 Disassembly 186
Voltage Output Test 101 Inspection 187
Steering Handle Temperature 11, 13, 15
Assembly 271, 278 Throttle Cable Adjustment, Tiller 273, 284
Disassembly 269, 275 Throttle Linkage
Inspection 271, 278 Installation 217
Installation 273, 282 Lubrication 42
Removal 268, 274 Removal 198
Steering System Throttle Position Sensor
Lubrication 41 Description 63
Steering Arm and Shaft 254, 256, 260, 262 Resistance Test 99
Steering Friction 31, 262 Tiller Adjustments
Steering Torque 35 Steering Friction Adjustment 31
Stern Bracket Tiller handle
Assembly 255, 259, 264 Lubrication 41
Disassembly 254, 256, 261 Tilt Limit Switch
Removal 255, 263 Adjustment 34
Stop Circuit 109 Cam Installation 244, 245
Storage 49 Tilt Support 342
Submerged Engines 51 Tilt Tube
Swivel Bracket Installation 245, 256
Installation 260 Lubrication 42
Lubrication 42 Removal 244, 255
Removal 257 Timing Adjustments
SystemCheck Timing Verification 118
Circuits 111 TPS Calibration 118
LOW OIL Warning Signal 166 Timing Pointer Adjustment 117
NO OIL Warning Signal 166 Tools
Outboard connections 24 Accessory Power Cable Kit, P/N 5008092
Tests 111, 112, 113 67, 73, 152
Winterization Procedure 49 Backing Plate, P/N 325867 300, 322
Ball Socket Installer tool, P/N 342225 273,
284
I–6
INDEX
Ball Socket Remover tool, P/N 342226 154, Injector Puller Kit, P/N 356461 150
268, 274 Injector Test Fitting Kit, P/N 5005844 142
Battery Cable, P/N 584348 68 Key Switch Assembly, P/N 176408 68
Bearing Installation Tool, P/N 326562 307, Large Puller Jaws, P/N 432129 203, 305,
332 306, 330, 331
Bearing Installation Tool, P/N 339750 332 Lifting Fixture, P/N 396748 195, 196, 220,
Bearing Puller, P/N 432130 306 222
Bootstrap Tool, P/N 586551 74 Lower Driveshaft Puller, P/N 342681 322
Collar, P/N 328363 308 Oetiker Pincers, P/N 787145 30
Collar, P/N 341440 333 Peak Reading Voltmeter, P/N 507972 102
Connector Service Tool, P/N 342667 120 Pinion Bearing Remover and Installer, P/N
Crankshaft Bearing/Sleeve Installer, P/N 5005927 301
338647 207 Pinion Bearing Remover/Installer, P/N
Crimp Tool, AMP 121 5005927 301, 325
Crimping Pliers, P/N 322696 120 Pinion Nut Holder, P/N 334455 321, 337
Diagnostic Interface Cable, P/N 437955 67 Pinion Nut Starting Tool, P/N 320675 311
Diagnostic Power Supply, P/N 587005 67, Pinion Nut Starting Tool, P/N 342216 336
73, 84, 152 Piston Spanner Wrench, P/N T-553 355,
Driveshaft Holding Socket, P/N 311875 356
321, 337 Piston Stop Tool, P/N 342679 117
Driveshaft Holding Socket, P/N 334995 Primary Lock Tool, P/N 777077 121
299, 312 Puller Bridge, P/N 432127 305, 306, 330,
Driveshaft Puller, P/N 390706 322 331
Driveshaft Seal Protector, P/N 312403 308, Puller, P/N 387206 300
309, 311 Retaining Ring Pliers, P/N 331045 298, 312
Driveshaft Seal Protector, P/N 318674 333, Rod Cap Alignment Fixture, P/N 396749
334, 336 213
Driveshaft Shimming Tool, P/N 5005925 Seal Installation Tool, P/N 326551 307, 332
308, 333 Seal Installation Tool, P/N 330268 330
Electrical Test Probe Kit, P/N 342677 103 Seal Installation Tool, P/N 336311 332
End Cap Spanner Wrench, P/N 352932 Seal Installer, P/N 342665 305
354, 359 Secondary Lock Installer, P/N 777079 121
Flywheel Holder, P/N 771311 115 Secondary Lock Tool, P/N 777078 121
Fuel Pressure Gauge, P/N 5006397 143 Shim Gauge Bar, P/N 328366 308
Fuel Pressure Gauge, P/N 5007100 141, Shim Gauge Bar, P/N 328367 333
146 Slide Hammer Adapter, P/N 340624 348
Gauging Head, P/N 352879 324 Slide Hammer, P/N 391008 207, 322, 348
Gearcase Alignment Gauge Kit, P/N Slide Hammer, P/N 432128 203, 245
5006349 324 Small Puller Jaws, P/N 432131 331
Gearcase Filler, P/N 501882 44 Spanner Wrench, P/N T-552 354
Gearcase Pressure Tester, P/N 507977 Starter Rope Threading Tool, P/N 378774
291 370
Gearcase Vacuum Tester, P/N 507982 291 Starter Winder/Installer Kit, P/N 392093
Guide Pins, P/N 383175 313 367
Hydraulic Cylinder Rod Holder Set, P/N Stator Test Adaptor, P/N 5005799 101, 102
983213 354 Syringe, P/N 346936 172
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.