V6 DPS Troubleshooting Guide Web

DPS Troubleshooting Guide
Evinrude® E-TEC® G2
Dynamic Power Steering (DPS)
*5011264* Version A
CALIFORNIA PROPOSITION 65 WARNING
WARNING
This product contains or emits chemicals know to the state of California to cause cancer and
birth defects or other reproductive harm.
All rights reserved. No parts of this Manual may be reproduced in any form without the prior written per-
mission of Bombardier Recreational Products Inc.
©Bombardier Recreational Products Inc. (BRP) 2019
™®Trademarks of BRP or its affiliates.

This document contains the trademarks of the following companies:
E-TEC® is a registered trademark of .
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G2® is a registered trademark of .
ICON™ is a trademark of .
TABLE OF CONTENTS
S E R V I C E P R O D U C T S I N D E X ................................................................................................................ 1
D P S S Y S T E M O V E R V I E W ...................................................................................................................... 1
M I D S E C T I O N I D E N T I F I C A T I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 2
D P S V E R S I O N I D E N T I F I C A T I O N .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 3
D Y N A M I C P O W E R S T E E R I N G ( D P S ) ................................................................................................... 5
D Y N A M I C P O W E R S T E E R I N G ( D P S ) - T H E O R Y O F O P E R A T I O N . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . . 5
DYNAMIC POWER STEERING (DPS-1) - “EARLY PRODUCTION” ..................................... 7
DYNAMIC POWER STEERING (DPS-2) - “CURRENT PRODUCTION” ............................... 9
D P S T R O U B L E S H O O T I N G C H A R T S .................................................................................................. 1 3
D P S - 1 T R O U B L E S H O O T I N G C H A R T . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 3
D P S - 2 T R O U B L E S H O O T I N G C H A R T . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 1 6
D P S W I R I N G D I A G R A M S ...................................................................................................................... 1 9
D P S 1 / D P S 2 W I R I N G . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 0
D P S 2 C O N T R O L M O D U L E .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 2
D P S M O D U L E .......................................................................................................................................... 2 3
D P S - 1 S Y S T E M T E S T S . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 3
D P S - 2 S Y S T E M T E S T S . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 4
L O A D S T E E R I N G F I R M W A R E . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 5
D P S S Y S T E M U P D A T E S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 6
E V D I A G 6 - D P S A S S I S T A D J U S T M E N T . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 7
C O L O R T O U C H S C R E E N - D P S A S S I S T A D J U S T M E N T .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 8
N A U T I L U S 3 . 5 C O L O R S C R E E N - D P S A S S I S T A D J U S T M E N T .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 2 9
D P S E L E C T R I C M O T O R ....................................................................................................................... 3 1
M O T O R D E R A T I N G .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 3 1
E L E C T R I C M O T O R . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 3 2
S T E R N / S W I V E L S Y S T E M O V E R V I E W .............................................................................................. 3 5
S T E E R I N G P R E S S U R E S E N S O R C A L I B R A T I O N ( A F A A N D N E W E R M O D E L S O N L Y ) . . .. . . .. . .. . . .. . .. . 3 5
S T E E R I N G P O S I T I O N S E N S O R C A L I B R A T I O N . . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 3 7
DUAL OUTBOARD INSTALLATIONS................................................................................... 37
CALIBRATE END POINTS ....................................................................................................... 37
CALIBRATE TURN LIMITS....................................................................................................... 38
F I L L I N G A N D B L E E D I N G T H E H Y D R A U L I C S T E E R I N G S Y S T E M . . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 3 9
HYDRAULIC STEERING FLUID ........................................................................................... 39
SINGLE STATION / DUAL ENGINE INSTALLATIONS ........................................................ 39
SINGLE STATION STEERING INSTALLATIONS ................................................................ 39
MANUAL METHOD................................................................................................................. 39
POWER PURGE METHOD ...................................................................................................... 43
STEERING SYSTEM CHECKS............................................................................................. 45
G2 66°V6 AND 74°V6 FULL FEATURED STERN/ SWIVEL STEERING SHAFT VERTICAL
M O V E M E N T . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . 4 7
III
TABLE OF CONTENTS
A C C E S S O R Y K I T S ................................................................................................................................. 4 9
H Y D R A U L I C T I E B A R K I T ( T W I N G 2 E N G I N E I N S T A L L A T I O N ) . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 4 9
MULTIPLE OUTBOARD TRANSOM..................................................................................... 50
D P S T R O U B L E S H O O T I N G ................................................................................................................... 5 3
D I A G N O S T I C S O F T W A R E I N S P E C T I O N S . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 3
D A T A L O G G I N G .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 5
D P S 2 - S T E E R I N G S Y S T E M T E S T ( A F A A N D N E W E R M O D E L S ) . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 6
D P S M O T O R D O E S N O T R U N / C O D E 2 1 1 .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 7
D P S M O T O R C O N T I N U E S T O R U N / R U N S C O N S T A N T L Y . . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 5 9
U N R E S P O N S I V E A N D / O R S L U G G I S H S T E E R I N G . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 1
O N L Y G E T S T E E R I N G A S S I S T I N O N E D I R E C T I O N , N O T T H E O T H E R . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 3
S T E E R I N G I S S T I F F I N O N E D I R E C T I O N O R T H E O T H E R .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 4
STEERING WHEEL KEEPS TURNING AND DOES NOT STOP / HELM “FREEWHEELS” IN ONE
D I R E C T I O N . . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 5
D P S 2 M O D U L E T R O U B L E S H O O T I N G .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 6 6
D P S - C O U P L E R . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 7 0
D P S S P E C I F I C F A U L T C O D E S ............................................................................................................ 7 1
D P S F A U L T C O D E C H A R T .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 7 1
F A U L T C O D E S E R V I C E A C T I O N S . . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. 7 5
FAULT CODE 211 ................................................................................................................. 75
FAULT CODE 212 ................................................................................................................. 75
FAULT CODE 213 ................................................................................................................. 75
FAULT CODE 214 ................................................................................................................. 75
FAULT CODE 215 ................................................................................................................. 76
FAULT CODE 216 ................................................................................................................. 76
FAULT CODE 217 ................................................................................................................. 76
FAULT CODE 218 ................................................................................................................. 76
FAULT CODE 219 ................................................................................................................. 76
FAULT CODE 220 ................................................................................................................. 77
FAULT CODE 221 ................................................................................................................. 77
IV
SERVICE PRODUCTS INDEX
Hydraulic Steering Fluid

P/N 770891
Page:39
1
DPS System Overview
DPS System Overview 1

The Dynamic Power Steering (DPS) system is in-
tegrated into the midsection of the specific Evin-
rude® E-TEC® G2® models. Boats that are
rigged with the DPS system deliver superior han-
dling and more control in tight turns and large
bodies of water.
Older designs of hydraulic steering used a sepa-
rate hydraulic cylinder mounted to the front of the
outboard.
The DPS system was developed from a ground up
initiative. It is it’s own unique design with 3 levels
of adjustment.
The DPS system simplifies rigging in the boat as
well as opens up space within the boat for the cus-
tomer’s unique needs.
It is the duty of the technician to identify a

DPS model prior to servicing. A DPS model
will have the DPS pump included in the stern
and swivel assembly as shown.
In the case of multiple outboard installations, be
sure to reference the I n s t a l l a t i o n P r e d e l i v e r y
G u i d e for your exact model outboards and
situation.
All Evinrude® E-TEC® G2® models have

fully Integrated Hydraulic Steering (IHS).
The DPS system is a model specific feature on G2
engines.
1
DPS System Overview
Midsection Identification
Midsection Identification
This is to identify what style midsection you are about to work on.
System Identification view of midsection
2
DPS System Overview
DPS Version Identification
DPS Version Identification

There are two ways to identify whether the DPS system is a DPS1 or a DPS2.
1
The easiest and quickest option is to visually inspect if the system is using a steering position sensor.
If the system is utilizing a steering position sensor then the system is a DPS2. DPS1 does NOT use a
steering position sensor.
1. Steering Position Sensor
The second option for checking the DPS version is to connect the engine to EvDiag6 and check for the
steering position sensor.
3
Notes
Notes Notes
Technician’s Notes Related Documents
Bulletins
Instruction Sheets
Other
4
Dynamic Power Steering (DPS) - Theory of Operation
Dynamic Power Steering (DPS) - Theory of 2

Operation
Description of how the Dynamic Power Steering (DPS) system operates.
The Dynamic Power Steering (DPS) system is an optionally ordered, integrated system within the stern
and swivel assembly. The system uses hydraulic pressure, a control module, a pump assembly, and sen-
sors to control the system. The system simplifies rigging (by allowing a single rigging entry-point), and al-
lows for better space allocation within the boat. The system can be tailored to individual needs with three
levels of adjustment. All power steering assist levels offer the same rate of assistance at engine speeds
below 4500 RPM. As the engine RPM increases above 4500 RPM, assist levels progressively decrease
according to the individuals setting. The factory default assist level is “Minimum”. The assist level can be
adjusted using the Evinrude® ICON-Touch or ICON CS digital display to change the power steering as-
sist level to “Medium” or “Maximum”.
WARNING
Selection of power steering assist level is a matter of operator preference.
Be aware that changing the power steering assist level can affect boat handling.
After changing the level of power steering assist, operate the boat with care to become familiar
with any changes in boat handling characteristics.
If your boat is not equipped with an ICON™ digital display, you must use EvDiag6 software to change
the power steering assist level.
Module Power and Ground
DPS module power

– The DPS module power is supplied by the power lead which fastens to the rear of the positive battery
stud in the top frame.
DPS module ground
– The DPS module ground is supplied by the individual lead which secures to the port side of the en-
gine block. All grounds should have good continuity to one another (less than 1 ohm resistance)
Turning the DPS module ON
– Upon EMM power up: The switched 12V supplied on the Purple/White wire in the DPS module to the
EMM connector.
– 5V is supplied to both the pressure sensors, and the steering position sensor on the Red wires.
5
DPS-2 Circuits
DPS Motor Power and Ground
– 12 volt (battery voltage) is supplied to module through the 3-pin (round black) DPS Motor connector
from the back of the positive battery cable stud at the front of the engine. DPS module controls the
output of this voltage to the DPS motor while also stepping up the current.
– DPS Motor ground is supplied from the module to the cylinder block.
DPS Motor Power and Ground
– Key on power is supplied to the DPS module via purple/white wire at pin # 3 of the flat 4-pin connector
at DPS module.
– DPS module ground is supplied via black wire at pin # 4 of the flat 4-pin connector at DPS module.
DPS Module Communication to EMM
– The module communicates faults and DPS data to the EMM via the two CAN wires (orange/black and
brown/orange) at pin #s 1 and 2 of the flat 4-pin connector at DPS module.
External DPS Sensors (PORT/STARBOARD Pressure and Steering Angle)
– Analog sensors use 5v power supplied by DPS Module (red wire)
– DPS Module also contains the ground circuit for these sensors (black wire)
– Signal wire color is unique to each sensor – green = starboard, white = port, blue = steering position.
The module reads and interprets the voltage returning on these signal wires as inputs.
6
Dynamic Power Steering (DPS-1) - “Early Production”

200 HO - 300 HP V6 74° “ABA Models”
The first DPS system was introduced with the 3.4L 74° V6 “ABA” models. The system is controlled by
helm pressure and helm pressure sensors. Hydraulic fluid supplied by the helm, shifts the shuttle in the
manifold. Once the helm supply pressure reaches 12psi (83 kPa), the motor/pump turns ON. The system 2
follows a “map” that relates the helm pressure and how much assist is provided by the DPS system
(Pulse-Width Modulation (PWM) control of the motor not just an on or off). At the end of the stroke, the
pressure in the steering cylinder rises very quickly. The pump pressure sensor detects the rise in pres-
sure and turns the pump OFF. The DPS-1 system uses one 500psi (3447 kPa) helm pressure sensor
and one 2000 psi (13790 kPa) pump pressure sensor.
1. DPS Pump Assembly

2. DPS Control Module
3. Pump Pressure Sensor
4. Helm Pressure Sensor
7
DPS1 is not compatible with Ultraflex SVS or SeaStar Pro Series helms
1. Pump PSI Sensor
2. Helm PSI Sensor
8
Dynamic Power Steering (DPS-2) - “Current Production”

150 HP - 200 HP V6 66° ALL / 200 HO - 300 HP V6 74° “AFA Models”
The current Dynamic Power Steering (DPS-2) system was introduced with the “AFA” models. The sys-
tem is controlled by port helm pressure, starboard helm pressure, and steering position. When the differ-
ence between the port and starboard helm pressure rises above 12psi (83 kPa), the DPS motor/pump 2
turns ON. The steering position sensor monitors the angular position of the steering actuator and shuts
OFF the assist when the system hits the end of its travel. The end points of travel are calibrated in the
factory and tell the DPS module when the steering is near the end of its stroke. This control strategy pre-
vents high torque, high pressure, and wasted energy at the end of the stroke. For multiple engine appli-
cations, turn limits are needed to be set to prevent the master motor from overpowering the slave motor.
The turn limits work like the individual engines’ endpoints and keep the DPS system from pushing on the
slave steering systems at the end of the stroke. The DPS-2 system uses 1500psi (10342 kPa) port and
starboard helm pressure sensors.
The DPS-2 system on AFA and newer engine models includes three external sensors - 1500 psi (10342
kPa) port and starboard helm pressure sensors, a steering position sensor; and two sensors internal in
the DPS module - a thermistor to monitor DPS motor circuit temperature, and a module temperature sen-
sor. As the steering wheel is turned, hydraulic fluid in the helm begins moving through the steering sys-
tem. The pressure sensor in the direction of the turn, signals the DPS module of an increase in hydraulic
pressure. The DPS module then gathers information from all the DPS sensors to determine whether to
activate the DPS motor or not.
DPS Motor Activation
– Pressure differential between pressure sensors is greater than 12 psi (83 kPa)
– Steering angle less than 2° of where the end points were set
– Thermistor temp is below 150°F (66°C) – see DPS Troubleshooting for limited assist symptoms.
– Module temp is below 216° F (80°C)
Mutli-Engine Applications
– Refer to the information from Multiple Outboard Transom in the Installation and Predelivery guide.
– Turn Limit calibration is necessary to prevent damage to the tie bar or transom of the boat due to
overloading pressure on the slave engine. Turn limits work like the individual engine’s end points.
– A “Pro Series Helm” CANNOT be used in multi-engine applications regardless of DPS/IHS model.
DPS Compatibility
– i-Dock/Jostick Controlled Applications
– Evinrude® i-Dock engines are model specific and NOT compatible with DPS model engines.
*Please see I-Dock Installation and User Guide for Evinrude i-Dock engines.
– SeaStar Optimus 360 “I-Dock” systems are NOT compatible with DPS model engines. A DPS
model must be converted to an IHS model before SeaStar Optimus 360 system installation.
*Please see 2016-03(W) Bulletin
9
1. DPS Pump Assembly

3. Steering Pressure Sensor
4. Port Pressure Sensor
5. Starboard Pressure Sensor
10
1. STARBOARD pressure sensor (psi)

2. PORT pressure sensor (psi)
11
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
12
DPS Troubleshooting Charts
DPS-1 Troubleshooting Chart

3
Start in this column to select Then Perform the checks or And Take the action in this column to resolve the
th e descri ption t hat best fits tests in this column to issue.
the symptom determine the issue.
Symptom Perfo rm this Check Take this Action
1. DPS-1 No assist YES Enough fluid in the helm? NO Fill Helm and check for leaks.
YES
Is this a DPS model? NO This is a manual hydraulic midsection, inspect

for kinked hose and/or teach driver to use trim.
YES
Use EvDiag6 to check: Is NO Follow directions to update software.

the correct DPS software
installed?
YES
Use EvDiag6 to check: Is YES Troubleshoot using the Fault Code Chart
there a Fault Code?
NO
Use EvDiag6 to check: Is NO Investigate 4 pin connector to DPS module

the “Power Steering” tab (supplies power and CAN)
visible in EvDiag6?
YES
Use EvDiag6 to check: Is NO Short in Module - Replace the Module

the DPS Thermistor
Temperature <66°C
(150.8°F)?
YES
Use EvDiag6 to check: NO Is helm pressure sensor functional (Use EVD6

Steer to center. Is helm to view helm pressure, should be less than 10
pressure below 10psi? psi)? Pro Helm? Kinked or Twisted hose
(check hoses for damage or kinks)? Auto Pilot?
SPA?
YES
13
the description that best fits tests in this column to issue.
Symptom Perform this Check Ta ke thi s Action
Use EvDiag6 to check: NO Check helm pressure sensor / wire / terminals /

Does helm pressure connection with DPS module
sensor rise when steering
to PORT and
STARBOARD?
YES
Use EvDiag6 to check: NO Check to see if DPS is turned off? (Engine

Steer from lock to lock in report?)
5 seconds. Do you see
duty cycle while turning?
YES
Use EvDiag6 to check: NO Fault Code 211 should be present. Use the
Do you see current while Fault Code Chart
turning?
YES
Can you hear the DPS NO Replace the electric motor

motor run?
YES
Use EvDiag6 to check: Is NO Replace the pump/motor coupler

pump pressure at least
100psi (689 kPa) above YES Internal leak, replace the stern and swivel
helm pressure while assembly
turning?
14
2. DPS-1 pump runs when not YES Is the boat rigged with a YES Switch to DPS-2 or replace Pro Series helm
steering Pro Series helm? with standard model. Use EVD6 to watch
sensor voltages before replacing sensors.
NO
3
Inspect the installation for YES Replace steering hoses.
a kink in the steering
lines. NO Inspect pressure sensor wires, terminals, and
connection with DPS module. Replace sensor
if necessary.
3. Significant initial resistance YES Steer PORT to YES Replace the DPS hydraulic manifold. (Spool in
felt when changing direction STARBOARD, then DPS manifold is sticking in the bore)
STARBOARD to PORT.
Is significant resistance
felt at initial change of
steering direction?
15

I M P O R T A N T : Before proceeding with any sort of troubleshooting, be sure to verify that the DPS firm-
ware is up to date.
Symptom Perform this Check Take this Action
1. DPS-2 No assist YES Enough fluid in the helm? NO Fill Helm and check for leaks.
YES
Is this a DPS model? NO This is a manual hydraulic midsection, inspect

(Remove PORT side for kinked hose and/or teach driver to use trim.
panel and locate DPS
module. No module =
non-DPS model)
YES
Use EvDiag6 to check: Is NO Follow directions to update software. Check for

the correct DPS software any known software issues. Verify that the
installed? latest firmware is installed, update and re-test
YES
Use EvDiag6 to check: Is YES Troubleshoot using the Fault Code Chart
there a Fault Code?
NO
Use EvDiag6 to check: Is NO Investigate 4 pin connector to DPS module

the “Power Steering” tab (supplies power and CAN)
visible in EvDiag6?
YES
Use EvDiag6 to check: Is NO Short in Module - Replace the Module

the DPS Thermistor
Temperature <66°C
(150.8°F)?
YES
Use EvDiag6 to check: NO Follow procedure to calibrate helm pressure

Steer to center. Are sensors. If offset is greater than 25 psi (172
PORT and STARBOARD kPa), replace the sensor.
Helm pressures within 13
psi (90 kPa) of each
other?
YES
16
Symptom Perform this Check Take this Action
Use EvDiag6 to check: NO Replace bad helm pressure sensor.

Does PORT sensor rise
when steering to PORT
and STARBOARD sensor 3
rise when steering
STARBOARD?
YES
Use EvDiag6 to check: Is NO Follow procedure to calibrate steering

steering position -32 endpoints (and turn limits, if applicable).
degree at PORT lock, Replace the sensor if steering position does not
and 32 degree at work after the calibration.
STARBOARD lock, and
changes smoothly
throughout the range?
YES
Use EvDiag6 to check: NO Check to see if DPS is turned off (Engine

Steer from lock to lock in report)
5 seconds. Do you see Engine report shows DPS voltage = 0 volts?
duty cycle while turning? Check wiring/connections for damage. Bad
module?
YES
Use EvDiag6 to check: NO Fault Code 211 should be present. Use the
Do you see current while Fault Code Chart
turning?
YES
Can you hear the DPS NO Replace the electric motor

motor run?
YES Broken pump/motor coupler or internal leak
2. Significant initial resistance YES Steer PORT to YES Replace the DPS hydraulic manifold. (Spool in
felt when changing direction STARBOARD, then DPS manifold is sticking in the bore)
STARBOARD to PORT.
Is significant resistance
felt at i n i t i a l change of
steering direction?
17
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
18
DPS Wiring Diagrams
DPS Wiring Diagrams
19
DPS Wiring Diagrams
DPS1 / DPS2 Wiring
DPS1 / DPS2 Wiring
1. EMM
3. DPS Control Module to EMM Connections
4. Steering Position Sensor (DPS 2 models only)
5. Battery Post (B+ supply to DPS Module
6. Port Steering Pressure Sensor (DPS 2 models only)
7. Starboard Steering Pressure Sensor (DPS 2 models only)
8. Helm Pressure Sensor (DPS 1 models only)
9. Pump Pressure Sensor (DPS 1 models only)
10. Ground (to port engine ground screw)
20
DPS Wiring Diagrams
DPS1 / DPS2 Wiring
Steering Position Sensor Revision
21
DPS Wiring Diagrams
DPS2 Control Module
DPS2 Control Module
22
DPS Module
DPS-1 System Tests
DPS Module
DPS-1 System Tests

Use the Power Steering screen of Evinrude® Diagnostics 6 software to observe DPS system reactions
while turning the steering wheel.
Pressure values should go up and down based on the helm’s turn.
The expected Pump Current range is >20 amps.
If less than 20 amps is seen, this could be an indicator of a failed DPS coupler as the motor is operating
with no load on it. If less than 20 amps with duty cycle at 100%, inspect the DPS coupler. 5
DPS1 Helm Pressure and Pump Pressure
23
DPS Module
DPS-2 System Tests
DPS-2 System Tests

Use the Power Steering screen of Evinrude® Diagnostics 6 software to observe DPS system reactions
while turning the steering wheel.
Pressure values should go up and down based on the helm’s turn.
DPS2 - Turn to Port Pressure
DPS2 - Turn to Starboard Pressure
24
DPS Module
Load Steering Firmware
Load Steering Firmware

DPS Module - Steering firmware load
Use the Evinrude® Diagnostics 6 software (v

6.4.10032.0 or higher) to update the firmware.
All replacement DPS modules are shipped from
the Parts and Accessories Catalog (PAC) without
firmware installed. Select the correct software for
the replacement DPS module.
NOTICE
Installing incorrect DPS software will cause:
– Fault codes 220 and 221 on ABA models
– DPS pump to run non-stop on AFA models
1. Engine controller
5
“ABA” models use a different firmware than the
“AFA” and newer models. Refer to the table below.
DPS firmware for “ABA” models is NOT compati-
ble with “AFA” models.
Engine Version Revision
Model
66° V6 2.7L 3030559 2024546 or
AAA and higher
newer
74° V6 3.4L 3030541 34025
G2 ABA (DPS1)
74° V6 3.4 L 3030559 2024546 or
AFA & Newer (DPS2) higher
Connect the MPI-2 and adapter cable to the laptop 1. Select Software
2. Next, Select Firmware for application
and to the NMEA 2000 network. Turn the key
switch to the ON position, then start the diagnostic
program.
After the program connects to the network, select
from the device list the Engine Controller (EMM).
NOTICE
This software updates the engine model
number stored in the EMM.Install this EMM
software in ALL outboards of multiple out-
board installations.Firmware of ABA and AFA
models is NOT compatible. Outboards which
are not updated will not run.
DPS Module
25
DPS Module
DPS System Updates
DPS System Updates

There have been instances in which extensive time was taken to troubleshoot a G2 outboard for a sus-
pected power steering issue only to find that the Dynamic Power Steering Control Module software was
incorrect. Check the Module software version.
If the unit is suspected of a power steering issue, use Evinrude® Diagnostics 6 to verify that the DPS
Control Module software version is correct.
Select “BRP engine controller (EMM)” in the Network Diagnostic box and then select “Identification”.
Verify that the engine controller is updated with the latest software revision for the application.
26
DPS Module
EvDiag6 - DPS Assist Adjustment
EvDiag6 - DPS Assist Adjustment

Use EvDiag6, Engine Option Configuration menu to change the level of DPS assistance from “Min”,
“Med”, and “Max” assistance to the operator.
27
DPS Module
Color Touch Screen - DPS Assist Adjustment
Color Touch Screen - DPS Assist Adjustment

Use the touchscreen and go to “Mode” to adjust and change the level of power steering assistance from
“Min Assist”, “Med Assist”, and “Max Assist” to the operator.
The higher the setting, the more responsive/effortless the steering is.
– “Min Assist” is minimal assistance from the DPS system to the operator.
– “Med Assist” is medium assistance from the DPS system to the operator.
– “Max Assist” is highest assistance from the DPS system to the operator.
All assist levels are the same below 4500 RPM
7.0 inch Gauge
28
DPS Module
Nautilus 3.5 Color Screen - DPS Assist Adjustment
Nautilus 3.5 Color Screen - DPS Assist Adjustment

Press the “Mode Select” button to access the Mode Select screen.
Use the up and down arrow buttons to select the Power Steering Assist option.
Press the right facing arrow button to toggle the selection between “Minimum”, “Medium”, or “Maximum”
assistance to the operator.
Use the gauge set to Port/Single to set the power steering assist for single engine configurations and
both port and starboard engines on twin engine applications.
N O T E : The DPS assistance is set to “Minimum” from the factory.
29
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
30
DPS Electric Motor
Motor Derating
DPS Electric Motor
Motor Derating
To prevent damage occurring due to overheating, the DPS electric motor is controlled by a thermistor
(thermal switch) which is located in the DPS Control Module.
The thermistor heats up as the electric current flows through the motor.
If an excessive amount of current flows through the thermistor in a short amount of time, the thermistor
opens the circuit and the motor will not operate until components cool down.
In the DPS system, the temperature of the thermistor is monitored, and in extreme applications, limits the
amount of the steering assist to prevent the thermistor from opening.
The limiting of the steering assistance is referred to as “Derating”.
The derating is accomplished by limiting the assist level gradually as the thermistor temperature goes 6
over 134°F (57°C).
If the temperature of the thermistor continues to rise, the assist continues to decrease until the DPS turns
off at 150°F (66°C).
This control strategy ensures that the steering effort does not change rapidly so the operator can feel the
gradual changes in the steering.
DPS Module
31
DPS Electric Motor
Electric Motor
Electric Motor
1. Use two scrap screws to secure the DPS Mani-
fold to a bench vise. 2 1
011013-4
Eps-0BDEBF2A
011013-2 1. O-ring
2. Coupler
Eps-0BDE0ABA
4. Clean and dry all parts thoroughly.
2. Remove the four screws and washers retaining 5. Align the slot in the coupler with the shaft on
the electric motor. Then remove the motor from the pump (shown) and with the shaft on the
the manifold housing. electric motor.
3
2 1 2
1
011013-3 011013-5
Eps-0BDE794B Eps-0BDEF323
1. Screws 1. Couplet
2. Washers 2. Shaft
3. Electric motor
6. Install the electric motor on the manifold as-
3. Remove the O-ring and coupler from the mani- sembly. Install four screws and washers.
fold housing, or electric motor. 7. Tighten screws to a torque of 60 to 84 In. lbs.(7
to 10 N·m).
32
DPS Electric Motor
Electric Motor
011013-6
Eps-0BE240F8
1. Screws
33
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
34
Stern/ Swivel System Overview
Steering Pressure Sensor Calibration (AFA and Newer Models Only)
Steering Pressure Sensor Calibration (AFA and

Newer Models Only)
I M P O R T A N T : Calibrate the pressure sensor 8. After the program connects to the network, se-
when: lect Engine Controller (EMM) from the device
– replacing a DPS module list.
– replacing a DPS manifold 9. Then select the Power Steering button.
– replacing a steering pressure sensor 10. Select Enable Calibration. The power steering
pump is disabled while in calibration mode.
1. Connect a piece of tubing to each bleed valve.
2. Insert the open end of the tubing into a contain-
er appropriate for collecting hydraulic steering
fluid. 1
2
7
009397-2
Eps-0B5428F4
1. Power Steering
2. Enable Calibration
11. Select Zero Pressure Sensors. The button will

1. Bleed valves
deactivate while setting the ZERO point. Wait
for the button to activate BEFORE continuing.
3. Open the both bleed valves at least one-half 12. Select Disable Calibration to save the setting
turn to relieve pressure on the hydraulic steer- and re-enable the power steering pump.
ing system.
4. Wipe up any spilled steering fluid with shop
towels.
ENVIRONMENTAL NOTE
Dispose of contaminated shop towels according
to local environmental regulations.
5. Use Evinrude Diagnostics software v 6.1 or

higher to calibrate steering pressure sensors.
6. Connect the MPI-2 and adapter cable to the
laptop and the NMEA 2000 network.
7. Turn the key switch to the ON position and
start the diagnostic program.
35
Steering Pressure Sensor Calibration (AFA and Newer Models Only)
13. Fill and bleed the steering system of air. Refer

to F i l l i n g a n d B l e e d i n g t h e H y d r a u l i c S t e e r -
ing System.
2
1
009398-1
_PSDiasble_CalEps-0B548863
1. Zero Pressure Sensors

2. Disable Calibration
36
Steering Position Sensor Calibration

I M P O R T A N T : Calibrate the steering position
sensor when:
– replacing a DPS module 1
– replacing a steering position sensor
2
Use Evinrude Diagnostics software v 6.4 or higher
to calibrate the steering position sensor.
Dual Outboard Installations

NOTICE
Failure to complete steering sensor calibra-
tion on dual engine applications can result in
damage to the tie bar(s) and/or the transom 009397-2
of the boat due to overloading.
Eps-0B5428F41
– The power steering pump must NOT run
during the calibration procedure. 1. Power Steering
2. Enable Calibration
– The diagnostics software will disable the
pump for outboard being calibrated. 2. Press Reset Limits. Then be SURE to select
End Points.
I M P O R T A N T : Calibrate the steering position
sensors on dual outboard installations when: 7
– installing outboards for the first time
– replacing a DPS module
– replacing a steering position sensor
Dual outboard installations REQUIRE calibration

of the DPS equipped outboard. Calibrate the E n d 2
1
P o i n t of the DPS outboard FIRST. Then calibrate
the T u r n L i m i t .
Calibrate End Points
NOTICE
Calibrating end points requires disconnecting 009399-1
the tie bar. During this procedure outboards Eps-0B5781E2
could contact, resulting in damage to the en-
1. Reset Limits
gine covers. Have an assistant manually 2. End Points
move outboards to prevent damage.
3. Slowly turn the steering wheel until the out-
Before calibrating End Points: board is turned fully to PORT.
– disconnect the tie bar from the outboards I M P O R T A N T : Make sure outboards do not con-
tact. Slowly turn the steering wheel, while an as-
After the program connects to the network, select sistant manually moves the disconnected
the Engine Controller (EMM) from the device list outboards.
for the DPS outboard. Then select the Power
Steering button. 4. Then press the Set Port button. The button will
1. Select Enable Calibration. The power steering deactivate while saving the PORT end point.
pump is disabled while in calibration mode. Wait for the button to activate BEFORE
continuing.
5. Slowly turn the steering wheel until the out-
board is turned fully to STARBOARD.
37
I M P O R T A N T : Make sure outboards do not con-

tact. Slowly turn the steering wheel, while an as-
sistant manually moves the disconnected
outboards.
6. Then press the Set Starboard button. The but-
ton will deactivate while saving the STAR-
BOARD end point. Wait for the button to 1
activate BEFORE continuing.
7. Select Disable Calibration to save the setting
and re-enable the power steering pump.
009399-3
Eps-0B581936
1. Turn limits
3
3. Turn the steering wheel until the outboards are
1 turned fully to PORT. Then press the Set Port
button. The button will deactivate while setting
2 the PORT turn limit. Wait for the button to acti-
vate BEFORE continuing.
4. Turn the steering wheel until the outboards are
turned fully to STARBOARD. Then press the
009399-2
Set Starboard button. The button will deacti-
vate while setting the STARBOARD turn limit.
Eps-0B579F85
Wait for the button to activate BEFORE
1. Set Port continuing.
2. Set Starboard
3. Disable Calibration
5. Select Disable Calibration to save the settings
and re-enable the power steering pump.
Before continuing:
– turn the key switch to the OFF position
– Turn the key switch to the ON position
8. After completing end points calibration, cali-
brate the turn limits. See C a l i b r a t e T u r n
Limits. 3
Calibrate Turn Limits
1
Before calibrating Turn Limits:
– connect tie bar to the outboards 2
– adjust outboard alignment
Turn the key switch to the ON position, then start
the diagnostic program.
009399-2
After the program connects to the network, select
Eps-0B579F851
from the device list for the Engine Controller
(EMM) the DPS outboard. Then select the Power 1. Set Port
2. Set Starboard
Steering button. 3. Disable Calibration
1. Select Enable Calibration. The power steering Before continuing:

pump is disabled while in calibration mode. – turn the key switch to the OFF position.
2. Then be SURE to select T u r n L i m i t s . – Turn the key switch to the ON position
6. Test the steering system. See S t e e r i n g S y s -
tem Test.
38
Filling and Bleeding the Hydraulic Steering System
SERVICE PRODUCTS
Description Part Number Page
HYDRAULIC STEERING FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 770891 . . . . . . . . . . . . . . . . . . . . . . . . 39
Hydraulic Steering Fluid Single Station Steering Installations

WARNING The following instructions describe the fill and
bleed procedure for a single and dual outboard
Use ONLY approved hydraulic fluids. installation.
Non-approved fluids can cause steering sys-
tem damage, or reduced steering control. Manual Method
This can result in loss of boat control and in- Also refer to the instructions provided with the hy-
jury to the occupants. draulic steering helm pump.
1. Use SeaStar Hydraulic fluid HA5430, P/N

I M P O R T A N T : Turn the key switch to the ON
position for models with DPS.
770891, or Hydraulic fluid meeting MIL SPEC:
Mil-H-5606. I M P O R T A N T : Make sure the outboard is
Required Product trimmed to the full DOWN position before begin-
ning this procedure. Air will NOT bleed completely
from the steering system if the engine is even 7
Hydraulic Steering Fluid slightly trimmed up.
P/N 770891
1. Remove the filler cap from the helm.
2. Install the threaded end of the filler tube (sup-
Single Station / Dual Engine plied with helm) into the helm.
Installations 3. Fill the helm with the recommended fluid. Fluid
Filling and bleeding dual engine installations is the should always be visible in the filler tube. Use
same as single engine installations. additional bottles of fluid as needed. Do NOT
proceed with the next step until the helm is full
Follow the instructions found in Manual Method or of fluid.
the Power Purge Method.
39
4. Turn the steering wheel clockwise until the out-

board is turned fully to STARBOARD and re-
sistance is felt. Be sure to maintain fluid level
at the helm/reservoir.
010832-3P
PEps-07CC3262
2 1. Turn the steering wheel counter-clockwise

2. Outboard turned to PORT
010832-3S
Have an assistant open and close the bleed
SEps-07CC142A valves and hold the outboard in position as
1. Turn the steering wheel clockwise directed:
2. Outboard turned to STARBOARD 6. Attach a length of clear hose to the UPPER
bleed valve. Use an appropriate container to
5. Turn the steering wheel counter-clockwise until
catch fluid flowing from the bleed valve.
the outboard is turned fully to PORT and resist-
7. Open the UPPER bleed valve o n e – h a l f turn.
ance is felt. Be sure to maintain fluid level at
8. H o l d the outboard in a PORT turn.
the helm/reservoir.
9. Then turn the steering wheel clockwise. Con-
tinue turning the steering wheel clockwise until
there are no air bubbles present in the flow of
fluid coming out of the bleed valve. Be sure to
maintain fluid level at the helm/reservoir.
40
2
1
010832-1A
2
File0000051215Eps-07C3D09D
010832-3P
1. UPPER bleed valve
2. Turn the steering wheel clockwise PEps-07C36610
1. Turn the steering wheel counter-clockwise

10. H o l d the outboard in a PORT turn. 2. Hold outboard in PORT turn
11. Then turn the steering wheel counter– clock-
wise. Continue turning the steering wheel 12. Have the assistant release the outboard. Close
counter– clockwise until there are no air bub- the UPPER bleed valve.
bles present in the flow of fluid coming out of 13. Turn the steering wheel clockwise until engine
the bleed valve. Be sure to maintain fluid level is turned fully to STARBOARD and resistance
at the helm/reservoir. is felt. Be sure to maintain fluid level at the
helm/reservoir.
41
2
1
2 010832-1B
BEps-D54CC543
010832-3S
1. LOWER bleed valve
SEps-07CF0412 2. Turn the steering wheel counter-clockwise
1. Turn the steering wheel clockwise
2. Outboard turned to STARBOARD
18. H o l d the outboard in a STARBOARD turn.
19. Then turn the steering wheel clockwise. Con-
14. Attach the length of clear hose to the LOWER tinue turning the steering wheel clockwise until
bleed valve. there are no air bubbles present in the flow of
15. Open the LOWER bleed valve o n e – h a l f turn. fluid coming out of the bleed valve. Be sure to
16. H o l d the outboard in a STARBOARD turn. maintain fluid level at the helm/reservoir.
17. Then turn the steering wheel counter– clock-
wise. Continue turning the steering wheel
counter– clockwise until there are no air bub-
bles present in the flow of fluid coming out of
the bleed valve. Be sure to maintain fluid level
at the helm/reservoir.
42
TELEFL EX POWER PURGE JR.
1. Remove the fill cap from the helm. Connect the

1 hydraulic fluid supply line of the purging unit to
the helm.
2. Connect the hydraulic fluid return lines of the
purging unit to the two bleed valves of the
steering system.
4 7
010832-3 2
1
Eps-07CF206F
20. Have the assistant release the outboard. Close

the LOWER bleed valve.
21. Tighten both bleed valves to a torque of 84 to
120 in.lb. (9.5 to 13.5 N·m).
22. Remove the filler tube from the helm. Install
the fill cap on the helm, tighten securely.
23. Proceed to S t e e r i n g S y s t e m C h e c k s .
Power Purge Method
A Teleflex Power Purge system, P/N 768014, can
be used to bleed the steering system. Make sure
the purging unit has the correct hydraulic fluid.
Purge the steering system manually if the fluid in 3 010840-1
the purging unit is a non-approved or unknown
type. Eps-D5516041
1. Power Purge unit

I M P O R T A N T : Turn the key switch to the ON 2. Hydraulic fluid supply lines
position for models with DPS. 3. Hydraulic fluid return lines
4. Bleed valves
3. Loosen both bleed valves o n e - h a l f turn. Then

turn the purge unit ON.
43
5. H o l d the outboard in a PORT turn.

6. Turn the steering wheel counter– clockwise.
Continue turning the steering wheel counter–
clockwise until there are no air bubbles present
in the flow of fluid coming out of the bleed
valve.
7. Next turn the steering wheel clockwise. – Con-
1 tinue turning the steering wheel clockwise until
there are no air bubbles present in the flow of
fluid coming out of the bleed valve.
2 8. Have the assistant release the outboard. Turn
the steering wheel clockwise until engine is
010838-1
turned fully to STARBOARD and resistance is
Eps-D551A0EE felt.
1. Upper bleed valve
2. Lower bleed valve
4. After air bubbles are no longer visible, turn the

steering wheel counterclockwise until engine is
turned fully to PORT and resistance is felt.
010839-1S
SEps-07CC8EEE

2 2. Outboard turned to STARBOARD
9. H o l d the outboard in a STARBOARD turn.

010839-1P
10. Turn the steering wheel clockwise. – Continue
PEps-07CC8458 turning the steering wheel clockwise until there
1. tTurn the steering wheel counterclockwise are no air bubbles present in the flow of fluid
2. Outboard turned to PORT coming out of the bleed valve.
Have an assistant hold the outboard in position 11. Next turn the steering wheel counter– clock-
as directed: wise. – Continue turning the steering wheel
44
counter– clockwise until there are no air bub- – Use two fingers to push the gearcase to port.
bles present in the flow of fluid coming out of – Measure and record the distance between the
the bleed valve. mark and the reference point.
12. Have the assistant release the outboard. Tight-
en both bleed valves to a torque of 84 to 120
in. lb. (9.5 to 13.5 N·m). Then turn the purge 3
unit OFF. 1
13. Disconnect the return lines of the power purge
from the two bleed valves of the steering
system.
14. Disconnect the hydraulic fluid supply line of the
power purge from the helm.
15. Install the covers on the bleed valves. Install 4
the fill cap on the helm, tighten securely. 2
16. Perform S t e e r i n g S y s t e m C h e c k s .
Steering System Checks

009427
1. Turn steering wheel to PORT. After engine is
turned fully to PORT, apply enough force to Eps-D553622C
the steering wheel to exceed the pressure re- MECHANICAL FREE PL AY MEASUREMENT
1. Mark
lief valve pressure of the helm. 2. Reference point object
2. While pressure is maintained on helm, check 3. Push against gearcase
all PORT lines and fittings for leaks. 4. Measurement
3. Turn steering wheel to STARBOARD. After en-
gine is turned fully to STARBOARD, apply
– Use two fingers to push the gearcase to 7
starboard.
enough force to the steering wheel to exceed
the pressure relief valve pressure of the helm.
4. While pressure is maintained on helm, check 1
all STARBOARD lines and fittings for leaks.
5. Repair all leaks. Repeat steps 1 through 4 be-
fore continuing.
6. Cycle the steering system from full PORT turn
to full STARBOARD turn several times. Defi-
nite resistance should be felt when the steering
wheel is turned full PORT or full STARBOARD. 2
I M P O R T A N T : If definite resistance is NOT felt,
or if steering feels loose or “soft” wait 15 minutes
and repeat the bleeding process.
7. Check the fluid level of the helm pump and fill 009428
per the manufacturers recommendation. Eps-D5537020

8. Check mechanical free play. MECHANICAL FREE PL AY MEASUREMENT
1. Push against gearcase
N O T E : Some free play movement of the steering 2. Measurement
system is normal.
– Measure and record the distance between the
Check mechanical free play: mark and the reference point.
– Make sure the anti-ventilation plate of the gear- Add the measurements. The result should not ex-
case is approximately level. ceed approximately 0.59 in. (15 mm).
– Make a mark in the center/rear of the anti-ven-
tilation plate of the gearcase. If the result exceeds this dimension, additional
– Center a stationary object, such as a length of bleeding may be required. Push the gearcase to
threaded rod attached to a plate, behind the port, until the steering mechanism bumps the me-
mark on the gearcase to serve as a reference chanical stop. Then push steadily with increasing
point. force. Repeat to starboard. Definite resistance
45
should be felt in both directions. If after bumping move in the direction it is being pushed, or it feels
the mechanical stop the gearcase continues to loose or “soft” repeat the bleeding process.
46
G2 66°V6 and 74°V6 Full Featured Stern/ Swivel Steering Shaft Vertical Movement
G2 66°V6 and 74°V6 Full Featured Stern/ Swivel

Steering Shaft Vertical Movement
N O T E : Steering shaft vertical movement in all stern/ swivel assemblies is normal. By design, when
steering from port lock to starboard lock, the steering shaft will move vertically .010” (.254mm) to .030”
(.762mm). If excessive vertical movement greater than .030” (.762mm) is suspected, a measurement of
the vertical shaft movement should be preformed.
Reference the TST (OE G2 66° and 74° Full Featured Stern/Swivel Steering Shaft Vertical Movement_
000134676_TST84Y018S00_en) for the below information.
1. Attach the lifting hook to the engine.
2. Remove the two upper stern/ swivel nuts.
3. Remove the four lower engine mount bolts.
4. Separate the stern/swivel from the engine midsection. Do not remove the steering hoses.
5. Attach a dial indicator assembly to the stern/ swivel, and secure dial indicator on the top of the swivel
cap.
6. Turn the stern/ swivel to the full port position. This will ensure the steering piston is at the bottom of its
travel.
7. Set the dial indicator to zero.
N O T E : Make sure that the dial indicator has a preload, zeroed, and in the center of the cap.
8. Steer to the full starboard position. This will ensure that the steering piston moves to the top of its trav-
el. Observe the movement of the dial indicator.
7
9. If the measurement is >.030” (.762 mm), replace the steering shaft top cap, P/N 5009971.
The new steering shaft top cap kit now utilizes washer under the retention bolts and an increased bolt
torque. This will reduce vertical play by .010 - .015” (.254 - .381 mm).
47
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
48
Accessory Kits
Hydraulic Tie Bar Kit (Twin G2 Engine Installation)
Accessory Kits

Installation of Hydraulic Tie Bar Kit, P/N 5009622, requires one DPS outboard and one non-DPS
outboard.
Follow to instruction sheet, P/N 358194, which is included in the kit.
1. Hoses labeled “1” are rated at 3000 psi minimum and must be supplied by BRP. See PAC catalog and instruction sheet, P/N 358194.
2. Hoses labeled “2” can be any hose approved by the helm manufacturer (1500 psi rating).
49
Accessory Kits
Multiple Outboard Transom

A three outboard installation REQUIRES 2 DPS outboard models.
Install the DPS outboards in the following transom positions:
– 1 and 2, or
– 2 and 3, or
– 1 and 3
Transom Positions - Three Outboards

A four outboard installation REQUIRES 2 DPS outboard models.
One DPS outboard MUST be mounted on the port side of the boat and the other mounted on the star-
board side of the boat.
Install the DPS outboards in the following transom positions:
– 1 and 3, or
– 2 and 3, or
– 2 and 4
Do NOT install the DPS outboards together in transom positions 1 and 2, or 3 and 4.
50
Accessory Kits
Transom Positions - Four Outboards
51
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
52
DPS Troubleshooting
Diagnostic Software Inspections
DPS Troubleshooting

Before running the outboard, use Evinrude Diag-
nostics software v 6.4 or higher to review informa-
tion saved in the EMM.
Correct any problems and clear any fault codes
before further troubleshooting.
1
Faults
Check the Faults Screen. Press the Active Faults

button to view existing faults.
2
The Active Faults screen displays fault codes that
currently exist. An active fault becomes an oc-
009282-1
curred fault only if the outboard is running.
Eps-D6DDB5B8
OCCURRED FAULTS SCREEN

1. Occurred Faults button
2. Detailed Information
Profiles
1 Review information about how the outboard has

been operated using the Profiles screens.
– Check the RPM Profile for long periods of low
speed operation or periods of over-revving 9
2 RPM.
009283-1
Eps-D6DDA081
ACTIVE FAULTS SCREEN

1. Active Faults button
2. Information
Press the Occurred Faults button to view detailed

information about the operating conditions of the
engine at the time the fault code was set.
009290-0
Eps-D6DDCEF2
RPM PROFILE
– Check the Engine Temperature Profile for evi-

dence of cold running or overheating.
53
DPS Troubleshooting
– The Last Two Minutes report is generated and

saved as part of the Engine Report. Engine
run-time values during the last two minutes of
operation above 1500 rpm is collected once
per second. The newest record is first on the
list. As each new record is added, the oldest
record is removed.
009291-0
Eps-D6DDE920
ENGINE TEMPERATURE PROFILE
History and Reports
View engine history and save reports from the His-

tory screen. Reports save a snapshot of current
009295-0
engine and sensor conditions.
Eps-D6DE5D14
From the History screen: LAST TWO MINUTES
– Press the Create EDF button to create an en-
gine data file. Engine data files are required
when replacing an EMM.
– Press the Running History button to view the
Last Two Minutes of engine run history.
– Press the Create Report button to create a
new report (must be connected to/communi-
cating with the engine EMM).
– Press Open Exports Folder to view saved
reports.
– Press Show Selected Report to view a report
selected from the Engine History Records List.
009292-0
Eps-D6DDFB7B
HISTORY SCREEN
54
DPS Troubleshooting
Data Logging
Data Logging
Run the outboard in the water at all speeds. Be
sure to run at any report problem engine speeds
to confirm actual symptoms. Inspection should in-
clude the following:
– Use the diagnostics software Logging function
to record engine data as a problem is
occurring.
N O T E : The engine should have sufficient cool-

ing water provided to keep the DPS Module cool
prior to proceeding with any logging.
I M P O R T A N T : The Data Log should be set to

300 ms and include the Port and Starboard Pres-
sures, Thermistor Temperature, DPS Duty Cycle,
DPS Module Temp, Pump Current, and Steering
Angle. This will give a complete and accurate data
log for further troubleshooting.
When initiating the data log, do not turn the engine

immediately. Allow the engine to sit static for a
couple seconds so that a baseline can be logged.
With a baseline log, it will allow the technician to
see any irregularities with any of the sensor read-
ings when compared to the baseline readings.
The engine should then be turned smoothly from
full lock port to full lock starboard a couple times
each way with the helm input to provide a good
data log.
9
LOGGING SCREEN
55
DPS Troubleshooting
DPS2 - Steering System Test (AFA and newer models)
DPS2 - Steering System Test (AFA and newer

models)
Steering System Test:
Turn the steering wheel fully to PORT. The power steering pump should run, and then shut OFF when
the engine is fully to PORT.
Turn the steering wheel fully to STARBOARD. The power steering pump should run, and then shut OFF
when the engine is fully to STARBOARD.
In some installations it may be difficult to hear the power steering pump cycle ON/OFF. Use the Power
Steering screen of EvDiag6 to monitor P u m p C u r r e n t and D u t y C y c l e .
1. Pump Current
2. Duty Cycle
56
DPS Troubleshooting
DPS motor does not run / Code 211

– Is this a DPS model engine?
– Remove the port side panel and locate a DPS module. No module = non-DPS model.
– Is the “Power Steering” icon visible at the top of EvDiag6?
-OR- Is there a “Steering Firmware” number in the software section at the bottom of the “Identification”
screen?
– NO
♦ Test the DPS module 4–pin CAN connector
♦
Scale Red Meter Lead Black Meter Lead Reading
Volts Purple/White (pin 1) Engine ground 12v (battery voltage)
Volts Orange/Black (pin 2) Engine ground 2.0v ± 0.1
Volts Brown/Orange (pin 3) Engine ground 3.0v ± 0.1
Ohms Black wire (pin 4) Engine ground <2Ω
◊ Unplug all three external DPS sensors (port, starboard, and steering angle sensor)
⇒ One of these sensors may be shorted internally or on their wire harness (red wire); plug
them in one by one until the symptom returns. Replace the failed sensor.
– Do the pressure sensor readings rise when turning to each respective side (Port rises when turning to
port, starboard rises when turning to starboard?
– NO
♦ Test DPS module pressure sensor circuits using “DPS Quick Test TST” to determine if prob-
lem is in the module – DPS monitor screen should read 0 psi with the sensor unplugged, and
1500psi when the red and green (or white) wires are momentarily jumped. 9
◊ If the module passes these tests, the sensor is causing the issue. Replace the pressure
sensor.
– Is the steering angle reading a constant -32°/+32°?
– YES
♦ Unplug the steering position sensor from the module, does it now read N/A?
◊ If yes, replace the steering position sensor.
– Does the steering angle sweep smoothly through the full range (-32° port / +32° starboard)?
– Test the DPS module steering position sensor circuits
♦ If the module passes these tests, replace the steering position sensor
Scale Red Meter Lead Black Meter Lead Reading

Volts Red wire Engine ground 5v
Volts Red wire Blue wire 1.5v ± 0.1
Ohms Black wire Engine ground <2Ω
57
DPS Troubleshooting
– Does Duty cycle / Pump Current rise when turning the engine?
– NO (only one, the other or neither rise)
♦ Check 12v supply to 3-pin DPS motor plug (battery voltage)
♦ Check DPS motor ground connection on cylinder block from module
♦ Check DPS Module output using 5010720 test lead, per 2018-05(S) Service Bulletin
♦ Test DPS motor resistance = around 5 Ω
58
DPS Troubleshooting
DPS Motor continues to run / runs constantly

Does the DPS motor run when the key is off?
– “Only when the trim or control head is activated or moved”
– The systems “wakes up” when the key is turned on or the trim switch or remote control are acti-
vated. Key on power is supplied from the helm to the EMM.
Unplug the 3-pin DPS motor plug to prevent the motor from constantly running.
– Verify that the two red wires on the DPS motor 3-pin connector have not been accidentally
switched in the plug. This would give the DPS motor a constant 12v from the battery cable stud.
See below image.
59
DPS Troubleshooting
– Open EvDiag6, Power Steering Monitor screen. Verify that the pressure sensors are reading zero
psi with the engine(s) and helm not turning.
♦ If either or both pressure sensors are reading pressure here, perform the pressure sensor /
module tests as outlined earlier. Replace the failed pressure sensor.
– If neither pressure sensor is reading pressure when the helm and engine are static, but the DPS
motor still runs, and the wires are in their correct pin locations, the issue may be internal in the
DPS module.
60
DPS Troubleshooting
Unresponsive and/or Sluggish Steering

Problem:
The DPS steering is sluggish, slow to respond, or the DPS motor is not running as the steering wheel is
turned.
Solution:
Use DPS Test Lead, P/N 5010720, with a Peak-Reading Voltmeter or Digital Multimeter and DVA adapt-
er to test the output of the DPS module.
9
1. DPS Test Lead, P/N 5010720
Test Procedure
The output of the DPS module is Pulse-width Modulation (PWM). Use the DPS Test Lead, P/N 5010720,
and a Peak Reading Voltmeter such as a Stevens CD-77, or a Digital Mutlimeter with a DVA adapter,
such as a Stevens PVA-1, to check the DPS module output.
1. Install the test adapter between the DPS module and the DPS motor cable.
2. Connect the meter leads to the DPS Test Lead, P/N 5010720. Connect the positive meter lead to the
red lead. Connect the negative meter lead to the black lead.
3. If using the Stevens CD-77, set to “POS” and “50”.
4. If using a digital multimeter, turn the multimeter on. Set as recommended by the instructions for the
DVA adapter. Select a voltage range that will read a minimum of 12 volts.
5. If using a Stevens PVA-1, set the multimeter to “DC Volts”. Select a voltage range that will read a min-
imum of 12 volts.
6. Turn the key switch to the ON position.
7. Turn the steering wheel in a smooth even motion and observe the voltage reading.
I M P O R T A N T : Turning the steering wheel erratically will result in erratic voltage readings. Any result
ABOVE 0.0 volts indicates output from the module.
61
DPS Troubleshooting
1. DPS Module Test Adapter, P/N 5010720

2. DPS motor cable
3. Digital Multimeter with DVA adapter
If the test results indicate output from the DPS module (12 volts approximately), the DPS module is good.
Check wiring and test the DPS steering motor.
If the test results indicate no output (0.0 volts) from the DPS module, additional troubleshooting is
required.
For DPS1 models, refer to the correct S e r v i c e M a n u a l .
For DPS2 models, continue to D P S 2 M o d u l e T r o u b l e s h o o t i n g .
62
DPS Troubleshooting
Only get steering assist in one direction, not the other
Only get steering assist in one direction, not the

other
Confirm that this is a DPS-2 system and DPS-2 firmware is installed in the module.
Proceed with the DPS pressure sensor monitoring to confirm that each pressure sensor rises in pressure
when turning to that respective side. (Port reading rises when turning to port, Starboard reading rises
when turning to starboard)
Verify that the steering position sensor is not reading erratically or flip flopping rapidly between positive
and negative readings.
– If the engine has the new digital style steering position sensor (P/N 5010945), please verify that the
latest DPS module, P/N 587430, is installed.
– This new style steering position sensor is not compatible with the P/N 587389 or earlier
DPS modules.
63
DPS Troubleshooting
Steering is stiff in one direction or the other
Steering is stiff in one direction or the other

Verify that the steering is still stiff even with the key in the OFF position and the DPS motor is not running.
This will isolate the DPS system from the hydraulic system. The steering should feel the same one way
or the other, even with the key OFF.
– If the steering is still stiff in one direction, isolate the boat hydraulic system from the engine. Remove
the hydraulic lines from the swivel and install a short length of hydraulic line from one fitting to the oth-
er as a bypass. Manually turn the engine from full lock to full lock in each direction. Should have
smooth operation.
– If the engine moves freely from one side to the other, the issue is in the boat hydraulic system.
64
DPS Troubleshooting
Steering wheel keeps turning and does not stop / helm “freewheels” in one direction
Steering wheel keeps turning and does not stop /

helm “freewheels” in one direction
Remove the hydraulic lines form the swivel. Install plugs into the fittings on the hydraulic lines, as well as
on the fittings on the swivel.
– With the fittings on the swivel, you should not be able to manually move the engine very much from
side to side along the steering axis.
– With the plug fittings on the hydraulic lines, you should not be able to turn the helm very much to ei-
ther side.
– If either system presents free movement, that is the culprit system and needs to be repaired /
replaced.
65
DPS Troubleshooting
DPS2 Module Troubleshooting

The output of the DPS module is Pulse Width Modulated (PWM). Use the DPS Test Lead, P/N 5010720,
and a Peak Reading Voltmeter such as a Stevens CD-77, or a Digital Multimeter with a DVA Adapter,
such as a Stevens PVA-1, to check the DPS module output.
Install the test lead between the DPS module and the DPS motor cable.
Connect the meter leads to the DPS Test Lead, P/N 5010720. Connect the positive meter lead to the red
lead. Connect the negative meter lead to the black lead. If using a Stevens CD-77, set to “POS” and “50”.
If using a digital multimeter, turn the multimeter on. Set as recommended by the instructions for the DVA
adapter. Select a voltage range that will read a minimum of 12 volts.
If using a Stevens PVA-1 set the multimeter to “DC Volts”. Select a voltage range that will read a mini-
mum of 12 volts.
DC V
Ω OFF AC V
~500
DC V
AUTO 200
20
DC
10A
HZ
PVA – 1
PEAK LOW
COM DVA V
3
1
5010720
Eps-22911F34
1. DPS Test Lead, P/N 5010720

2. DPS module
3. DPS motor cable
Turn the key switch to the ON position.

Turn the steering wheel in a smooth even motion and observe the voltage reading.
I M P O R T A N T : Turning the steering wheel erratically will result in erratic voltage readings. Any result
ABOVE 0.0 volts indicates output from the module.
Results
If test results indicate output from the DPS module (12V approximately), the DPS module is good. Check
wiring and test the DPS steering motor. If test results indicate no output (0.0 volts) from the DPS module,
additional troubleshooting is required.
If no voltage output is observed use the “Power Steering” tab of Evinrude® Diagnostics 6 software v 6.4
or higher, as follows:
Monitor the PORT and STARBOARD pressure while steering the outboard.
Confirm a 12psi (82.7 kPa) difference between PORT and STARBOARD pressures, which is required to
activate the DPS motor.
66
DPS Troubleshooting
1. PORT pressure
2. STARBOARD pressure
9
If a 12 psi (82.7 kPa) difference is present, observe the Pump Current and Duty Cycle.
Result
– If the Duty Cycle increases but the Pump Current remains at 0, replace the DPS Module.
67
DPS Troubleshooting
1. Pump Current
2. Duty Cycle
Confirm that the DPS Module Thermistor Temp is less than 150°F (66°C).
Result
– If the Thermistor Temp is greater than 150°F (66°C), the system has derated to the point which it will
no longer function.
– If the Thermistor Temp is greater than 150°F (66°C) immediately after powering up the system, re-
place the DPS Module.
68
DPS Troubleshooting
1. Thermistor Temp 9
69
DPS Troubleshooting
DPS - Coupler
DPS - Coupler
Problem: An updated version was made of Nylon (right-
Short term failures of the DPS motor coupler hand side).
caused by material. Loss of power steering. Steer-
ing still operates but requires additional effort on
the operator’s part.
A recent product improvement changed the mate-
rial on the Dynamic Power Steering (DPS) motor
coupler.
If the pump current is noticed to be <20 amps
when the commanded pump duty cycle is at
100%, it is most likely due to a failed DPS coupler.
The latest version is the powdered metal cou-

pling, P/N 359280, which was tooled and
tested to improve long-term durability.
The original coupler was black in color and 1. Verify that the DPS motor is operational. Use
made of Acetal plastic (left-hand side). the Power Steering screen of EvDiag6 to moni-
tor the P u m p C u r r e n t and the D u t y C y c l e
while steering the engine from side to side.
2. Inspect the motor (and coupler) if the P u m p
C u r r e n t and D u t y C y c l e do not increase dur-
ing the steering test.
Replace the DPS motor and coupler with MOTOR,
O-RING & COUPLER KIT, P/N 5009941.
The Coupler and O-ring are available to purchase
separately if the motor is in operational condition:
Coupler, P/N 359280 and O-ring, P/N 321163.
70
DPS Specific Fault Codes
DPS Fault Code Chart
DPS Fault Code Chart
10
71
Service Action
NOTE: Use BOSSWeb>Info Center>Case for
warranty authorization. Include the engine’s
Fault Evinrude® Digital Touch System Check model number and serial number, Remote
Possible Causes for the
Code EMM/Circuit Sensor Screen Display Display Time to Activate Fault Information Control’s serial number, accurate service
Fault
No. information, and current Engine Report files
(pdf) for the EMM, the Remote Control, and (if
equipped) iDock components.

1. The power steering
wiring is damaged or there
Power steering motor
Power steering motor is a faulty wire connection.
(DPS) current is LESS
211 has an OPEN circuit Engine Check Engine 1 second 2. The power steering Refer to Fault Code 211 in Service Actions.
than 0.5 amps with the
(DPS1/DPS2) motor is faulty
duty cycle over 25%.
3. The DPS module is
faulty
200 - 300 HP 3.4L ABA 200 - 300 HP 3.4L

Engine Models (DPS- ABA Engine Models
1 ) : DPS helm pressure Engine Check Engine ( D P S - 1 ) : Helm
sensor BELOW pressure sensor 1. The helm pressure
expected voltage range voltage is LESS than sensor has damaged wiring
0.12 Volts. (OPEN circuit) or a faulty
212 1 second connection. Refer to Fault Code 212 in Service Actions.
AFA and Newer Engine AFA and Newer
M o d e l s ( D P S - 2 ) : PORT E n g i n e M o d e l s ( D P S - 2. The helm pressure
2 ) : PORT helm sensor is damaged.
helm pressure sensor Engine Check Engine
BELOW expected pressure sensor
voltage range voltage is LESS than
0.12 Volts.
200 - 300 HP 3.4L ABA 200 - 300 HP 3.4L

1 ) : DPS helm pressure Engine Check Engine ( D P S - 1 ) : Helm
sensor ABOVE expected pressure sensor
1. The helm pressure
voltage range voltage is GREATER
sensor has damaged wiring
than 4.60 Volts.
213 1 second (SHORT circuit) or a faulty Refer to Fault Code 213 in Service Actions.
AFA and Newer connection.
AFA and Newer Engine
M o d e l s ( D P S - 2 ) : PORT E n g i n e M o d e l s ( D P S - 2. The helm pressure
2 ) : PORT helm sensor is damaged
helm pressure sensor Engine Check Engine
ABOVE expected pressure sensor
voltage range voltage is LESS than
4.60 Volts.
Service Action
Fault
200 - 300 HP 3.4L ABA 200 - 300 HP 3.4L

1 ) : DPS pump pressure Engine Check Engine ( D P S - 1 ) : DPS
BELOW expected pressure sensor 1. The helm/DPS pressure
voltage range voltage is LESS than sensor has damaged wiring
0.12 Volts (OPEN circuit) or a faulty
214 1 second connection. Refer to Fault Code 214 in Service Actions.
AFA and Newer Engine AFA and Newer
Models (DPS-2): E n g i n e M o d e l s ( D P S - 2. The helm pressure
STARBOARD helm Engine Check Engine 2 ) : STARBOARD helm sensor is damaged.
pressure BELOW pressure sensor
expected voltage range voltage is LESS than
0.12 Volts
ABA Engine Models ABA Engine Models

( D P S - 1 ) : DPS pump ( D P S - 1 ) : DPS
Engine Check Engine pressure sensor
pressure ABOVE
expected voltage range voltage is GREATER
than 4.60 volts. 1. The helm pressure
AFA and Newer sensor has damaged wiring
215 1 second E n g i n e M o d e l s ( D P S - (SHORT circuit) or a faulty Refer to Fault Code 215 in Service Actions.
AFA and Newer Engine 2 ) : STARBOARD helm connection.
Models (DPS-2): pressure sensor 2. The helm pressure
STARBOARD helm Engine Check Engine voltage is LESS than sensor is damaged.
pressure ABOVE 4.60 volts. (DPS-2)
expected voltage range If an i-Dock installation,
contact Technical
Service for assistance.
1. Wiring or electrical
Excessive current connections for the power
detected. Power supply of the power
DPS Motor over-current Engine Check Engine steering module are loose,
216 3 occurrences Steering (DPS) Motor Refer to Fault Code 216 in Service Actions.
shutdown damaged, or incorrect.
shutdown due to short
circuit condition. 2. Power steering motor is
faulty
1. Wiring or electrical
The power supply The power steering connections for the power
voltage to the power supply voltage for the supply of the power
217 steering (DPS) module is Engine Check Engine 10 seconds power steering (DPS) steering module are loose, Refer to Fault Code 217 in Service Actions.
BELOW the expected module is LESS than 5 damaged, or incorrect.
voltage range volts. 2. Power steering module
is faulty
Service Action
Fault
1. Cooling water flow to the

power steering module is
DPS module The power steering restricted.
218 temperature ABOVE Engine Check Engine 1 second module temperature is 2. Power steering module Refer to Fault Code 218 in Service Actions.
expected range GREATER than 176° is overheating due to an
(80°C). excessive duty cycle
3. Power steering module
is faulty
A power steering fault
1. There is an iDock Fault
Power steering fault detected by the iDock
Engine Check Engine Code that initiated the
219 detected by iDock 1 second Control Module that is Refer to Fault Code 219 in Service Actions.
engine to go into S.A.F.E.
Control Module not an EMM failure.
mode.
S.A.F.E. Mode
The steering position 1. The steering position
sensor voltage is The steering position sensor has damaged wiring
220 BELOW expected Engine Check Engine 1 second sensor is LESS than or has a faulty connection Refer to Fault Code 220 in Service Actions.
voltage range (DPS-2 0.12 volts 2. The steering position
only) sensor has an OPEN circuit
1. The power steering
The steering position position sensor has
The power steering
sensor voltage is damaged wiring or has a
Engine Check Engine position sensor is
221 ABOVE expected range 1 second faulty connection Refer to Fault Code 221 in Service Actions.
GREATER than 4.60
(DPS-2 only) 2. The power steering
volts.
position sensor has an
OPEN circuit
Fault Code Service Actions

Fault Code 211 Fault Code 213
1. Use EVD6 EvDIAG6 Software Manager screen 1. Use EVD6 Power Steering screen to observe
to review software updates. Tip: Go to HELP power steering (DPS) system reactions while
Menu in EVD6 and select “Check for program turning the steering wheel. Observe the Port
updates”. Select Contents to access User Help Pressure and the Starboard Pressure.
File and to learn about DPS System Software 2. Turn the steering wheel to PORT. While hold-
Updates. ing the steering wheel against the stop, ob-
2. Use EVD6 Power Steering screen to observe serve the PORT Pressure.
power steering system reactions while turning
the steering wheel. Watch the PUMP CUR- -Pressure should be approximately 1000 psi
RENT and the DUTY CYCLE fields. See the (6895 kPa) for a standard helm, or approxi-
DPS Troubleshooting Charts (DPS1/DPS2). mately 1500 psi (10342 kPa) for a Pro-Series
3. Locate the wiring and the connections for the or SVS-Series helm. Watch the PUMP CUR-
power steering motor (DPS). Repair damaged RENT and the DUTY CYCLE fields. See DPS
power steering wiring or faulty wire connection. Troubleshooting Charts (DPS1/DPS2).
4. Perform the Power Steering Motor tests. 3. Turn the steering wheel fully to STARBOARD.
(See BOSSWeb for the latest version of the While holding the steering wheel against the
service manual) stop, observe STARBOARD Pressure.
5. Perform the Power Steering Module test. -Pressure should be approximately 1000 psi
(6895 kPa) for a standard helm, or approxi-
Fault Code 212 mately 1500 psi (10342 kPa) for a Pro-Series
1. Use EVD6 Power Steering screen to observe or SVS-Series helm. Watch the PUMP CUR-
power steering (DPS) system reactions while RENT and the DUTY CYCLE fields. See DPS
turning the steering wheel. Observe the Port Troubleshooting Charts (DPS1/DPS2).
Pressure and the Starboard Pressure. 4. Check wiring and connections for the helm/
2. Turn the steering wheel to PORT. While hold- DPS pressure sensor and the DPS module.
ing the steering wheel against the stop, ob- 5. Perform the Steering Pressure Sensor Tests.
serve the PORT Pressure. (See BOSSWeb for the latest version of the
service manual) If the engine is part of an Evin-
-Pressure should be approximately 1000 psi rude® i-Dock installation, Use BOSSWeb>Info
(6895 kPa) for a standard helm, or approxi- Center>Case for technical or warranty support.
mately 1500 psi (10342 kPa) for a Pro-Series
or SVS-Series helm. Watch the PUMP CUR- Fault Code 214
RENT and the DUTY CYCLE fields. See DPS
1. Use EVD6 Power Steering screen to observe
10
Troubleshooting Charts (DPS1/DPS2).
3. Turn the steering wheel fully to STARBOARD. power steering (DPS) system reactions while
While holding the steering wheel against the turning the steering wheel. Observe the Port
stop, observe STARBOARD Pressure. Pressure and the Starboard Pressure.
2. Turn the steering wheel to PORT. While hold-
-Pressure should be approximately 1000 psi ing the steering wheel against the stop, ob-
(6895 kPa) for a standard helm, or approxi- serve the PORT Pressure.
mately 1500 psi (10342 kPa) for a Pro-Series
or SVS-Series helm. Watch the PUMP CUR- -Pressure should be approximately 1000 psi
RENT and the DUTY CYCLE fields. See DPS (6895 kPa) for a standard helm, or approxi-
Troubleshooting Charts (DPS1/DPS2). mately 1500 psi (10342 kPa) for a Pro-Series
4. Check wiring and connections for the helm/ or SVS-Series helm. Watch the PUMP CUR-
DPS pressure sensor and the DPS module. RENT and the DUTY CYCLE fields. See DPS
5. Perform the Steering Pressure Sensor Tests. Troubleshooting Charts (DPS1/DPS2).
(See BOSSWeb for the latest version of the 3. Turn the steering wheel fully to STARBOARD.
service manual) If the engine is part of an Evin- While holding the steering wheel against the
rude® i-Dock installation, Use BOSSWeb>Info stop, observe STARBOARD Pressure.
Center>Case for technical or warranty support. -Pressure should be approximately 1000 psi
(6895 kPa) for a standard helm, or
75
approximately 1500 psi (10342 kPa) for a Pro- wire connection at the starter solenoid and at
Series or SVS-Series helm. Watch the PUMP the RED (B+) battery stud at the top of the cen-
CURRENT and the DUTY CYCLE fields. See ter frame.
DPS Troubleshooting Charts (DPS1/DPS2). 3. Perform the power steering pump and control
4. Check wiring and connections for the helm/ circuit test BEFORE replacing the power steer-
DPS pressure sensor and the DPS module. ing motor.
5. Perform the Steering Pressure Sensor Tests. Use BOSSWeb>Info Center>Case for techni-
(See BOSSWeb for the latest version of the cal or warranty support.
service manual) If the engine is part of an Evin-
rude® i-Dock installation, Use BOSSWeb>Info Fault Code 217
Center>Case for technical or warranty support. 1. Use EVD6 Power Steering screen to observe
power steering (DPS) system reactions while
Fault Code 215 turning the steering wheel. Watch the PUMP
1. Use EVD6 Power Steering screen to observe CURRENT and the DUTY CYCLE fields. See
power steering (DPS) system reactions while DPS Troubleshooting Charts (DPS1/DPS2).
turning the steering wheel. Observe the Port 2. Locate the wiring and the connections for the
Pressure and the Starboard Pressure. power steering module. Check the BLACK
2. Turn the steering wheel to PORT. While hold- ground wire connection from the module to the
ing the steering wheel against the stop, ob- engine block. Check the RED (B +) wire con-
serve the PORT Pressure. nection to the module. Check the RED (B +)
wire connection at starter solenoid and at the
-Pressure should be approximately 1000 psi RED (B +) battery stud at top of the center
(6895 kPa) for a standard helm, or approxi- frame.
mately 1500 psi (10342 kPa) for a Pro-Series 3. Perform the power steering pump and control
or SVS-Series helm. Watch the PUMP CUR- circuit test BEFORE replacing the power steer-
RENT and the DUTY CYCLE fields. See DPS ing module.
Troubleshooting Charts (DPS1/DPS2). Use BOSSWeb>Info Center>Case for techni-
3. Turn the steering wheel fully to STARBOARD. cal or warranty support.
While holding the steering wheel against the
stop, observe STARBOARD Pressure. Fault Code 218
-Pressure should be approximately 1000 psi 1. Use EVD6 Power Steering screen to observe
(6895 kPa) for a standard helm, or approxi- the power steering (DPS) control module tem-
mately 1500 psi (10342 kPa) for a Pro-Series perature. Watch the PUMP CURRENT and the
or SVS-Series helm. Watch the PUMP CUR- DUTY CYCLE fields. See DPS Troubleshoot-
RENT and the DUTY CYCLE fields. See DPS ing Charts (DPS1/DPS2).
Troubleshooting Charts (DPS1/DPS2). 2. Verify if there are other fault codes related to
4. Check wiring and connections for the helm/ engine overheating and the engine's cooling
DPS pressure sensor and the DPS module. system. Repair any engine cooling system is-
5. Perform the Steering Pressure Sensor Tests. sues. Check the cooling water flow to and
(See BOSSWeb for the latest version of the through the power steering module. Retest
service manual) If the engine is part of an Evin- after the cooling issue is resolved.
rude® i-Dock installation, Use BOSSWeb>Info 3. Is there an excessive duty cycle related to over
Center>Case for technical or warranty support. active steering activity?
4. Perform power steering pump and control cir-
Fault Code 216 cuit test BEFORE replacing the power steering
1. Use EVD6 Power Steering screen to observe module.
power steering (DPS) system reactions while Use BOSSWeb>Info Center>Case for techni-
turning the steering wheel. Watch the PUMP cal or warranty support.
CURRENT and the DUTY CYCLE fields. See
DPS Troubleshooting Charts (DPS1/DPS2). Fault Code 219
2. Locate the wiring and the connections for the 1. Review the iDOCK Control Module Fault Co-
power steering module. Check the BLACK des chart.
ground wire connection from the module to the
engine block. Check the RED (B +) wire con-
nection to the module. Check the RED (B +)
76
Fault Code 220 (BLACK). Connect the negative meter lead to

1. Use EVD6 Power Steering screen to observe a clean engine ground.
the power steering (DPS) system reactions -Meter reading should be less than 5 ohms.
while turning the steering wheel, observe the
steering angle.
If an Evinrude® i-Dock installation, the Evin-
rude® i-Dock must be selected. This is a setup
requirement.
2. Check the DPS module connectors and wiring.
3. Perform the electrical circuit tests.
Fault Code 221

1. Use EVD6 Power Steering screen to observe
the power steering (DPS) system. Observe the
PORT and STARBOARD helm pressures and
the steering angle while turning the steering
wheel in a counter-clockwise directions and
then in a clockwise direction.
2. Perform a Steering Pressure Sensor Test.
Turn the steering wheel to PORT (counter-
clockwise). While holding the steering wheel
against the stop, observe the PORT pressure
reading. Then turn the steering wheel to
STARBOARD (clockwise). While holding the
steering wheel against the stop, observe the
STARBOARD pressure reading. The pressure
readings will vary depending upon the amount
of effort applied to the steering wheel. Look for
the helm pressure reading to change relative
to the applied steering effort.
-The typical steering pressure reading can vary
between approximately 25 - 1000 psi (6895
kPa) for a standard helm and at 1500 psi
(10342 kPa) for a Pro-Series or SVS-Series
helm. The steering helm’s pressure relief valve
10
limits the maximum system pressure at 1000
psi (6895 kPa) for a standard helm, and at
1500 psi (10342 kPa) for a Pro-Series or SVS-
Series helm.
3. Power Steering (DPS) Position Sensor circuit
voltage is too high. Check wiring and connec-
tors. Perform electrical circuit tests.
-Use the diode test function of a digital multi-
meter to check the signal circuit. Connect the
BLACK meter lead to PIN1 wire (BLUE), con-
nect the RED meter lead to the engine ground.
-Meter reading should be approximately 0.5
VDC.
4. Use a digital multimeter with appropriate test
probe leads to measure Power Steering (DPS)
Position Sensor ground circuit resistance. Con-
nect the RED meter lead to the PIN3 wire
77
Notes
Notes Notes
Bulletins
Instruction Sheets
Other
78
Index
Index
79
www.brp.com
SKI-DOO® SEA-DOO® CAN-AM®

LYNX® EVINRUDE® ROTAX®
MANITOU® ALUMACRAFT®

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DPS Troubleshooting Guide

Dynamic Power Steering (DPS)

™®Trademarks of BRP or its affiliates.

Hydraulic Steering Fluid

DPS System Overview 1

It is the duty of the technician to identify a

All Evinrude® E-TEC® G2® models have

System Identification view of midsection

DPS Version Identification

1. Steering Position Sensor

Dynamic Power Steering (DPS)

Dynamic Power Steering (DPS) - Theory of 2

Module Power and Ground

DPS module power

Dynamic Power Steering (DPS-1) - “Early Production”

1. DPS Pump Assembly

Dynamic Power Steering (DPS-2) - “Current Production”

1. DPS Pump Assembly

1. STARBOARD pressure sensor (psi)

DPS Troubleshooting Charts

DPS-1 Troubleshooting Chart

Symptom Perfo rm this Check Take this Action

Is this a DPS model? NO This is a manual hydraulic midsection, inspect

Use EvDiag6 to check: Is NO Follow directions to update software.

Use EvDiag6 to check: Is NO Investigate 4 pin connector to DPS module

Use EvDiag6 to check: Is NO Short in Module - Replace the Module

Use EvDiag6 to check: NO Is helm pressure sensor functional (Use EVD6

Symptom Perform this Check Ta ke thi s Action

Use EvDiag6 to check: NO Check helm pressure sensor / wire / terminals /

Use EvDiag6 to check: NO Check to see if DPS is turned off? (Engine

Can you hear the DPS NO Replace the electric motor

Use EvDiag6 to check: Is NO Replace the pump/motor coupler

Symptom Perfo rm this Check Take this Action

Symptom Perfo rm this Check Take this Action

DPS-2 Troubleshooting Chart

Symptom Perform this Check Take this Action

Is this a DPS model? NO This is a manual hydraulic midsection, inspect

Use EvDiag6 to check: Is NO Follow directions to update software. Check for

Use EvDiag6 to check: Is NO Investigate 4 pin connector to DPS module

Use EvDiag6 to check: Is NO Short in Module - Replace the Module

Use EvDiag6 to check: NO Follow procedure to calibrate helm pressure

Symptom Perform this Check Take this Action

Use EvDiag6 to check: NO Replace bad helm pressure sensor.

Use EvDiag6 to check: Is NO Follow procedure to calibrate steering

Use EvDiag6 to check: NO Check to see if DPS is turned off (Engine

Can you hear the DPS NO Replace the electric motor

DPS Wiring Diagrams

DPS1 / DPS2 Wiring

Steering Position Sensor Revision

DPS2 Control Module

DPS-1 System Tests

DPS1 Helm Pressure and Pump Pressure

DPS-2 System Tests

DPS2 - Turn to Port Pressure

DPS2 - Turn to Starboard Pressure

Load Steering Firmware

Use the Evinrude® Diagnostics 6 software (v

DPS System Updates

EvDiag6 - DPS Assist Adjustment

Color Touch Screen - DPS Assist Adjustment